mechanical automation and maintenance fitting · 2020. 9. 22. · mechanical automation and...

Mechanical Automation and Maintenance Fitting

Revision 2.1

SOLAS – © 2020 28 30/07/2020

ACKNOWLEDGEMENT

The Apprenticeship Programme for this craft occupation is founded on the results of industry-based surveys and research into the skills, knowledge and competence required by today’s craftspeople.

SOLAS acknowledges the support and participation of all the craftspeople, employer representatives, Institutes of Technology, SOLAS Curriculum Writers and worker representatives who contributed to the development of the curricula for this craft occupation.

Revision: 2.1

© SOLAS - 2020

Castleforbes House,Castleforbes Road,

Dublin 1

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying, recording

or otherwise, without prior written permission of the copyright owner.

Published by SOLAS – Further Education and Training Authority

SOLAS - © 2013 3 Rev 2.1 CADU - 31/07/09

Page No.

Apprenticeship Training Programmes 4

Apprenticeship Training Programme 6

Learning Outcomes 7

Training Approach 8

Assessment Model 9

Access, Transfer and Progression 11

Resources 13

Quality Assurance 14

Learner Information 15

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Contents

Mechanical Automation

and Maintenance FittingIntroduction

Code 60

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SOLAS, The Further Education and Training Authority, has statutory responsibility for theorganisation and control of designated apprenticeships through powers conferred on it bythe Industrial Training Act, 1967, and the Labour Services Act, 1987-2009 and the FurtherEducation & Training Act 2013. SOLAS is advised on the development of theapprenticeship system in Ireland by the National Apprenticeship Advisory Committee(NAAC), representing all the relevant social partners and stakeholders. SOLAS hasdeveloped the programmes in partnership with Employers, Trade Unions, the Departmentof Education and Skills and the Institutes of Technology.

The SOLAS Apprenticeship is a system of employment focused training and educationwhich enables a person to obtain the Skills, Knowledge and Competence required toperform effectively as a craftsperson in industry, to respond appropriately to technicalchange, and to seek progression through further education and training within the NationalFramework of Qualifications.

SOLAS has responsibility for promoting and overseeing the training and education of allapprentices in the following Crafts:

The quality of Irish apprenticeship programmes is recognised internationally. Apprenticesparticipate on a world stage through the World Skills Competition; young people from allover the world gather to compete in the skills of their chosen Craft. SOLAS apprenticeshave consistently attained high standards in this competition and in previous years haveachieved gold, silver and bronze medals as well as diplomas of excellence in their chosenfields.


Apprenticeship Training Programmes



Code 60

Construction

• Brick & Stonelaying• Cabinetmaking• Carpentry & Joinery• Environmental Stonecutting• Floor & Wall Tiling• Painting & Decorating• Plastering• Plumbing• Wood Manufacturing and Finishing

Electrical

• Aircraft Mechanics• Electrical• Electrical Instrumentation• Instrumentation• Refrigeration & Air Conditioning• Electronic Security Systems

Printing

• Print Media

Motor

• Agricultural Mechanics• Construction Plant Fitting• Heavy Vehicle Mechanics• Motor Mechanics• Vehicle Body Repairs

Engineering

• Mechanical Automationand Maintenance Fitting

• Metal Fabrication• Sheet Metalworking• Jewellery• Toolmaking• Industrial Insulation• Farriery

SOLAS - © 2013 5 Rev 2.1 CADU - 31/07/09

Structure and Apprenticeship programmes consist of alternating phases of On-the-Job Duration of and Off-the-Job training and education. This model of training Apprenticeship allows apprentices to integrate the knowledge and skills acquired during

Off-the-Job training and education with those gained in the On-the-Jobphases of training. The exposure to changing industrial contexts andthe opportunity to further practise and develop their knowledge andskills enables apprentices to achieve the high levels of competenceexpected of craftspeople in the contemporary workplace.

The structure of apprenticeship programmes ensures that the trainingand education delivered to apprentices are grounded in the needs ofthe workplace. The culture of apprenticeship learning and developmentprepares apprentices to be adaptable, flexible and to be self-motivated tomanage change. The programme also prepares the apprentice to meetthe challenge of future developments in their craft and the workplace byequipping them with the necessary skills, knowledge and competence.

The alternating phases of training generally consist of three Off-the-Jobphases and four On-the-Job phases, although differences do occur insome apprenticeships.

The duration of apprenticeship programmes is determined by thetraining, educational and development requirements of eachoccupation. However, the normal duration of Off-the-Job trainingphases is as follows:

Phase 2 - 20 weeks in a SOLAS Training Centre

Phase 4 - 10 weeks in an Institute of Technology

Phase 6 - 10 weeks in an Institute of Technology

The On-the-Job training takes place with the employer and normally lastsfor a minimum of the following periods:

Phase 1 - Minimum of 12 weeks with employer




The apprenticeship process is deemed to be complete when anapprentice has successfully achieved the required qualifying standard,completed all of the alternating On-the-Job and Off-the-Job phases oftheir apprenticeship, served the appropriate minimum time frame fromthe date of registration. On successful completion of theirapprenticeship, each apprentice will be awarded a Level 6 AdvancedCertificate by Quality and Qualifications Ireland (QQI)





Code 60

SOLAS - © 2013 6 Rev 2.1 CADU - 31/07/09

Revision of This curriculum is a revision of the original SOLAS standards-based Curricula apprenticeship programme. In 2003, the NAAC initiated a major review

of the apprenticeship programme and respective curricula. The aim of this review was to ensure that apprenticeship programmes remained up-to-date, relevant, and met the emerging needs of learners, the workplace and the economy.

Curricula for all apprenticeships have been revised within theparameters of the NAAC reports, pedagogical design needs, theNational Framework of Qualifications and the Awards Councils' (QQI)requirements.

Standards- Each apprenticeship programme is based on an occupational analysis Based of that Craft and reflects the results of a national survey carried out to

establish the current and emerging skills, knowledge and competencesrequired by craftspeople.

This curriculum is standards-based, written as learning outcomes andstructured in a modular format. All modular learning objectives, unitactivity statements and key learning points are based on the NationalOutcome Standards for the craft.

Aims The aims of the apprenticeship programmes are to provide:

• Learners with the knowledge, skill and competence required toperform effectively as craftspeople, i.e., highly skilled workers whoare able to work autonomously, contribute to a technical team, takepersonal responsibility for completing projects to relevant qualitystandards in a timely manner, and interact effectively with colleaguesand customers in an industrial setting which is experiencing constantand progressive change.

• Industry with craftspeople who have acquired mastery over theunderpinning knowledge, skills and competences relevant to theircraft. Mastery is demonstrated by the ability of the craftsperson toapply their skill and knowledge in different contexts; to exerciseinitiative and solve problems by determining possible solutions andjudging the appropriateness of different approaches.

• Apprentices with the skills, knowledge and competence to enablethem to perform as qualified and suitably motivated craftspeople withthe potential to progress into supervisory and/or management rolesand/or self-employment, both nationally and internationally.

• Apprentices with the ability to respond to changes in their craft andthe workplace by transferring their knowledge and skills, identifyinglimits in their knowledge and taking responsibility for addressing theiremerging learning requirements.

• Apprentices with the necessary knowledge, skills and competence tocontribute significantly to the development of the Irish economy andto respond to the emerging needs of the workplace and newtechniques and technologies employed in their craft.





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Objectives To provide apprentices with:

1. The theoretical underpinning and related knowledge necessary forthe effective exercise of their craft.

2. Essential knowledge relevant for each field of study and the skillsand competences required by the craft, underpinned by integratedand relevant maths, science and technology and appropriateverbal, written and graphic communication and personal skills.

3. A comprehensive range of core, specialist and personal skillsrequired by industry. Personal skills include:

• Customer relations• Adaptability• Teamwork• Initiative• Planning• Information gathering

4. Specialised knowledge of a broad range of areas and theoreticalconcepts relevant to their craft and the ability to apply theirknowledge, skills and competences to familiar and unfamiliarcontexts they encounter.

5. The ability to safely and effectively exercise their craft observingtechnical and environmental standards and regulations.

6. The ability to diagnose and resolve problems encountered in thecourse of their work.

7. The ability to take responsibility for planning their own work andensuring that it adheres to the quality standards of their craft.

8. The ability to communicate and interact effectively and exerciseappropriate leadership within the workplace environment.

9. A thorough knowledge of the structure and ethos of their chosencraft.

10. The ability to take responsibility for their own continuing learning inorder to keep up to date with new regulations, materials andtechniques relevant to their craft.

11. An opportunity to transfer or progress to other awards on theNational Framework of Qualifications once they have attained theLevel 6 Advanced Certificate Craft Qualification from QQI.


Learning Outcomes



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Training Apprenticeship programmes involve directed, work-based and self-Approach directed learning. All On-the-Job and Off-the-Job phases are

compulsory.

Off-the-Job The training during the Off-the-Job period is modular in nature.Training and Modular training is a system in which the training content is divided intoDevelopment independent units or modules of learning.

The curriculum is designed to be delivered in an integrated manner.This integration ensures that practical skills are developed inassociation with the required theory, maths, science, technical drawingand personal skills.

Apprentices are required to pass a series of Modular Assessments(tests) throughout their Off-the-Job training. These consist of practicaltests, written knowledge tests and coursework assessments. Theseassessments are distributed as separate documents.

Off-the-Job training takes place in Training Centres, Institutes ofTechnology and other approved Training Locations.

On-the-Job This form of training takes place with the employer and provides the Training and apprentice with training and practical experience in the working Development environment. In addition to further developing the skills and knowledge

gained during the Off-the-Job training phases, the apprentice developsthe competence and self-confidence to consistently perform toindustrial standards.

The competence of the apprentice is assessed in performing specifiedtasks against pre-set criteria laid out in the On-the-Job trainingdocumentation.

Assessment SOLAS is committed to the fair and consistent assessment of Model and apprentices and to the application of standards-based assessment Awards systems.

Throughout the period of apprenticeship, each apprentice undergoes a range of assessments to establish competence, monitor progress andidentify areas requiring additional skill development.

Two types of assessment are used to form the basis of certification:

• Off-the-Job Modular Assessment• On-the-Job Competence Assessment


Training Approach



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Assessment Off-the-Job Modular AssessmentModel and Modular Assessment is carried out during the Off-the-Job training Awards phases. It involves coursework assessment and standardised and cont’d supervised practical and written knowledge tests. Coursework

assessment consists of exercises and projects carried out with accessto all available resources.

The Assessment Programmes for each phase are implemented by theOff-the-Job training providers.

Under current legislation, an apprentice is allowed three attempts toreach the minimum qualifying standard in each Off-the-Jobassessment. If the apprentice fails to reach the minimum qualifyingstandard after three attempts, the apprentice’s apprenticeship will beterminated. (Rule 8, SI 168 of 1997, Labour Services Act, 1987-2009Apprentice Rules 1997). If an apprentice does not achieve the requiredstandard for a particular craft, SOLAS will not allow a furtherregistration application from the apprentice for the same craft.

On-the-Job Competence AssessmentCompetence Assessment is carried out during the On-the-Job trainingphases. Competence is defined as the application of skills, knowledgeand attitudes in order to perform tasks or combinations of tasks toindustrial and commercial standards under operational conditions.

The Workplace Assessment is carried out by the workplacesupervisor/assessor. An assessment specification and a detailedworkplace assessment checklist are provided in each of the On-the-Jobphases. As many attempts as is reasonable are allowed in order toachieve the required standard in each assessment.

Record SystemOff-the-JobThe Phase Summary Assessment documents for each Off-the-Jobphase are completed by the relevant Training Centre, Institute ofTechnology or approved training provider. The results for eachapprentice are recorded on the computerised assessment system. Both the employer and apprentice are notified by post of theapprentice's assessment results for each Off-the-Job training phase.

On-the-JobAt the end of On-the-Job phases 3, 5 and 7 the apprentice’s employersends the completed Phase Assessment Schedule sheet to the localServices to Business Office. The assessment results for eachapprentice are recorded on the apprenticeship computer managementsystem.


Assessment Model



Code 60

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Assessment Common ModulesModel The apprentice is required to complete a number of self-paced cont’d Common Modules during their training period. These modules are

made available to the apprentice through e-learning.During their Apprenticeship the apprentice will undertake self-directed

study in the following:

• Health and Safety

• Introduction to Learning to Learn

• Introduction to ICT

• Employment Legislation Awareness

• Environmental Awareness

The apprentice must have completed these Common Modules by theend of the Phase 3 On-the-Job training period. This requirement mustbe completed before commencement of Phase 4.

Craft AwardThis programme leads to a Level 6 Advanced Certificate from QQI.This award will be issued only to those who have passed all the modular assessments in the Off-the-Job training phases and therequired number of competence assessments in the On-the-Jobtraining phases.

Craft qualifications are graded as follows:• Pass • Pass with Merit

The overall grade appearing on the Level 6 Advanced Certificate fromQQI will be determined in accordance with results achieved in each ofthe three Off-the-Job training phases. These results are weightedaccording to agreed criteria.

Quality and Qualifications Ireland (QQI) has placed the AdvancedCertificate Craft at Level 6 on the National Framework of Qualifications.While the Advanced Certificate Craft Qualification has been placed asa set at Level 6, the QQI acknowledges that there are Level 7outcomes associated with awards in the set. This placement does notpreclude the possibility of existing Craft Qualification programmesbeing validated at Level 7.


Assessment Model



Code 60

SOLAS - © 2013 11 Rev 2.1 CADU - 31/07/09

Statement Requests for Recognition of Prior Learning for entry to the of Entry programme Requirements An applicant who wishes to have their other certified or non-certifiedcont’d learning considered for recognition for entry to apprenticeship should

initially apply to their local office.

Requests for exemption from part of the programmeAn apprentice who wishes to have their other certified or non-certifiedlearning considered for an exemption from part of their apprenticeshipprogramme should initially apply to their local Office.

An applicant will be required to support their application with relevant documentation in the form of a portfolio of evidence:• The portfolio of evidence will normally contain a description of the

content of the training or education course(s) previously undertaken• A certificate of evidence will contain a description of the content

(course syllabus) of the training or education course(s) previouslyundertaken

• A certificate confirming the applicant’s successful completion of thecourse should be included

• Evidence of work experience should also be included where relevant• In cases where it is not possible for SOLAS to make a clear

determination of the applicant’s skills, knowledge and competenceagainst the known standard, the applicant will be invited to sitcomposite practical and theoretical assessments.

The purpose of the portfolio is to allow the learning which has takenplace previously to be mapped against the entry requirements or thelearning outcomes of the phase of the programme for which anexemption is being sought.

The responsibility for the compilation and submission of the portfoliorests with the applicant. Local Offices provide guidance to applicantson the appropriate documentation required.

Foreign QualificationsIn the case of applicants with foreign qualifications, entry into theApprenticeship Programme will be determined by SOLAS upon receiptof a ‘statement of comparability’ of the applicants’ awards provided byQQI. In cases where it is not possible for SOLAS to make a cleardetermination of the applicants’ skills, knowledge and competenceagainst the known standard, applicants will be invited to sit compositepractical and theoretical assessments.


Access, Transfer and Progression



Code 60

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SOLAS is committed to the provision of training programmes that meet the needs of all currentand prospective learners. SOLAS recognises that National Policies on Lifelong Learningpromote and facilitate open and flexible access, transfer and progression pathways for itsapprenticeship programme.

Statement Learner Profileof Entry The minimum age at which the employment of an apprentice mayRequirements commence is 16 years of age.

The minimum educational requirements are:

1. Grade D in five subjects in the Department of Education & ScienceJunior Certificate Examination or approved equivalent,

or

2. The successful completion of an approved Pre-apprenticeshipcourse (4 modules - including 3 core modules in Maths, Science,Technical Drawing - Junior Certificate Level)

In certain crafts, apprenticeship applicants must pass the Ishiara colourvision test.

SOLAS recognises that people may seek to commence apprenticeshipholding qualifications other than those detailed above and equivalenceswith the Junior Certificate requirements are published in its booklet,Table of Equivalence of Qualifications for Entry to the Standards-basedApprenticeship in Ireland 1.

These equivalences include:

Award Title RequirementsLeaving Certificate (Applied) 50 credits

NCVA Foundation Programme 8 modules (Full Certificate)

NCVA Level 1 5 modules

NCVA Level 2 5 modules

GNVQ Foundation 8 modules

GNVQ Foundation 5 modules

NVQ Level 1 5 modules

NVQ Level 2 5 modules

Introductory Skills Certificate 2 8 technical modules

Note: Certificate titles may change. Please see the current Directoryof QQI Awards

1. These equivalences are under review2. Former awarding bodies SOLAS, CERT and TEAGASC


Access, Transfer and Progression



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Statement Transfer and Progression Pathwaysof Entry In the context of further development of the National Framework ofRequirements Qualifications, routes of transfer and progression will be established forcont’d all awards including the Level 6 Advanced Certificate from QQI.

Transfer and progression details will be published as they become available.

QQI will facilitate the development of a national approach to creditaccumulation and transfer, based on units of learning. Creditarrangements, when they have been developed will be made availableto holders of the Level 6 Advanced Certificate Craft from QQI.

Resources Programme Staff ProfileInstructors in SOLAS Training Centres who deliver Off-the-Job Phase 2training are required to have qualified as craftspeople and have aminimum of five years post-apprenticeship experience. Each instructorundergoes further development in training techniques. Relevant in-service technical training is provided as required.

Teaching staff in the Institutes of Technology who deliver Phases 4 and6 training are required to:

1. Hold a degree or its equivalent in the subject area orHave qualified as a craftsperson

2. Have three years relevant post graduate experience. In additionrelevant in-service technical training is undertaken as required

Support ServicesA range of services are provided by SOLAS including:

• Mandatory Apprenticeship Induction Presentation • Apprentice Training Information Pack

This includes curricula, quality assurance and validation requirement• Training and development for the apprentice, in-company

manager/verifier and assessors where required• Learning supports in accordance with SOLAS procedures• Advice and assistance to employers on all aspects of apprenticeship

including their capacity to undertake apprentice training• Preparatory training courses for educationally disadvantaged persons


Resources



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Quality The SOLAS approach to quality assurance is set out in the SOLASNational Assurance Quality Assurance Policy. The national quality assurance procedures

covering apprenticeship is set out by SOLAS Apprenticeship ServicesUnit.

As first provider SOLAS is responsible for the monitoring andevaluation of the training programme.

Quality Assurance within SOLAS and within educational providers iscarried out by their own respective quality assurance systems. QualityAssurance requirements, including agreed monitoring arrangements, aredocumented in a memorandum of understanding between SOLAS andeducational providers.

As part of arrangements outlined at the time of apprentice registrationan employer can expect to receive monitoring visits by SOLAS. Theobject of in-company monitoring is to verify that the training andassessment practices in the enterprises meet the standards requiredfor each On-the-Job phase of the apprenticeship. Monitoring withinSOLAS and the educational establishments takes place to assess theeffectiveness of the education and training curriculum.

Feedback forms are provided with all On-the-Job trainingdocumentation. In this way, employers can provide feedback andevaluation of the Off-the-Job training programme.


Quality Assurance



Code 60

SOLAS - © 2013 15 Rev 2.1 CADU - 31/07/09

Learner The Duties and Responsibilities of ApprenticesInformation Apprentices must comply with the statutory obligations under the

Industrial Training Act, 1967, the Labour Services Act, 1987-2009 andany Apprenticeship Rules (which may apply from time to time) inrelation to apprenticeship. Apprentices are required to attend theApprenticeship Induction Presentation and to attend, punctually, allscheduled classes and training sessions of all Off-the-Job trainingphases.

In addition, apprentices are required to take responsibility for their owncontinuing learning throughout the apprenticeship; be diligent andcommitted to all aspects of work, training and education throughout theapprenticeship; seek the advice of employer and/or workplaceassessor, where difficulties arise, while undergoing On-the-Job phasesof training and to attend any Off-the-Job training location for the Off-the-Job training phases.

Apprentices are expected to be responsible for attendance, timekeeping and behave in a responsible and mature manner in bothemployment and during Off-the-Job training phases. Apprentices arerequired to undertake all scheduled modular and competencyassessments including re-sit assessments.

It is imperative for apprentices to operate with due care and diligenceand observe all safety regulations as specified on both On-the-Job andOff-theJob training as stated in the apprenticeship programmespecification. Each apprentice will carry out all reasonable instructionsfrom the person or persons to whom they are assigned, during bothOn-the-Job and Off-the-Job phases of their apprenticeship.

Apprentices should be aware that the Off-the-Job phases of theapprenticeship do not alter their status as an employee of theiremployer, nor does it imply a contract of employment between SOLASand the apprentice. Apprentices remain, at all times during theapprenticeship, in the employment of the employer.

The Duties and Responsibilities of EmployersEmployers must comply with the statutory obligations under theIndustrial Training Act, 1967 the Labour Services Act, 1987-2009 andany Apprenticeship Rules (which may apply from time to time) inrelation to Apprenticeship and understand that they are required toimplement the approved curriculum appropriate to the craft.

Employers are expected to train the apprentice in the required On-the-Job aspects of apprenticeship and to provide the apprentice with theopportunities to practise new skills under supervised conditions whiletaking cognisance of the apprentice’s skill level at the time the task isbeing undertaken.

Consequently, employers are required to directly employ a suitablyqualified and craft specific craftsperson who can, or has been approvedby SOLAS, to act as the workplace assessor with responsibility fortraining, marking assessments, recording and processing assessmentchecklists and On-the-Job schedules as specified in the SOLASWorkplace Assessment Book for the On-the-Job phases of the


Learner Information



Code 60

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Learner Employers are expected to ensure that all the On-the-Job assessmentsInformation are conducted in a fair and consistent manner and to submit all the On-cont’d the-Job training assessment results to the assigned Local Office on

schedule. Employers are also required to maintain On-the-Job trainingassessment records for each apprentice and to ensure that SOLASpersonnel have access to these records when required.

Employers are expected to release the apprentice(s) for the Phase 1Apprenticeship Induction Presentation and Off-the-Job training phaseson the dates and to the location as specified by SOLAS.

Employers are expected to comply with all statutory health and safety,employment, apprenticeship legislative requirements in relation to theirapprentice(s).

RedundancyEmployers are required to contact the appropriate Local Office in theevent of terminating the employment contract with an apprentice, priorto doing so. Employers must also take all reasonable steps to havetheir obligations under the contract of apprenticeship transferred toanother employer.

In the event of redundancy employers are required to give written priornotice of the intended redundancy to thei appropriate Local Office andto take all reasonable steps to have their obligations under the contractof apprenticeship transferred to another employer.

Apprentices need to contact the appropriate Local Office in the eventthat the employer terminates the apprenticeship or the apprenticeterminates the employment contract.

Recruitment of ApprenticesProspective apprentices can obtain information on entry requirementsand craft occupations by accessing the adult career guidance serviceprovided through the Local Office located nationwide. Similarly, anyemployer wishing to recruit an apprentice should contact their LocalOffice for further information.

To register as an apprentice, the prospective apprentice must firstobtain employment with a SOLAS approved employer in their chosenoccupation. Under the statutory rules of apprenticeship all employersare required to register their apprentices with SOLAS within two weeksof commencing employment.

Furthermore, any employer wishing to register an apprentice must beable to satisfy SOLAS that the employer is capable of providing accessto the range of work specified in the apprenticeship curriculum. Theemployer must employ a suitably qualified and experiencedcraftsperson to oversee the training and work of the apprentice as wellas a suitable person approved by SOLAS to carry out the specifiedassessments required to establish an apprentice's competence.


Learner Information



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Learner Funding ArrangementsInformation While attending Off-the-Job phases of training the apprentice is paid a cont’d training allowance by SOLAS from an apprenticeship fund. Throughout

the On-the-Job training phases apprentices are paid the normalapprentice wage rate by the employer. In most cases such rates havebeen agreed between employer and trade union representatives andvary according to the year of apprenticeship.

Learners with Special NeedsPeople with a disability who meet the entry requirements areencouraged to apply directly to employers for apprenticeship places.

If you have any special requirements and need support with e.g.dyslexia, numeracy, literacy, physical disabilities or medical conditions itis your responsibility to inform your Training Advisor at the time ofregistration.You also need to bring this to the attention of your TrainingProvider and provide any necessary evidence before thecommencement of Training on Phase 2/4/6/ so that needs that theseneeds can be catered for when you attend Off-the-job training.

If you require additional learning supports in learning techniques,maths/science/drawing, practical work you should log on towww.solas.ie and go to eCollege or contact a Training Centre, anInstitute of Technology, local ETB or seek private tuition.

Equal OpportunitiesSOLAS apprenticeships are open to men and women equally. SOLASprovides a financial bursary to encourage employers to hire femaleapprentices. Application forms are available from all local TrainingCentres.

For further information please contact:SOLAS Apprenticeship Services

P.O. Box 45627 - 33 Upper Baggot St.

Dublin 4Tel: +353 1 607 0500

Fax: +353 1 607 0600e-mail: [email protected]

Web: http://www.solas.ie


Learner Information



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NOTES

MECHANICALAUTOMATION AND

MAINTENANCE

FITTING

INTRODUCTION TO

PHASES 1/3/5/7ON-THE-JOB

SOLAS - © 2013 2 Rev 2.1 CADU- 31/07/09

ACKNOWLEDGEMENT

The Statutory Apprenticeship Programme for this craft occupation is founded on the results of industry-based surveys and research into the skills, knowledge and competence required by today’s craftspeople.

SOLAS acknowledges the support and participation of all the craftspeople, employer representatives,Institutes of Technology, SOLAS Curriculum Writers and worker representatives who contributed to thedevelopment of the curricula for this craft occupation.

Revision: 2.1

P.O. Box 45627-33 Upper Baggot Street

Dublin 4Ireland

© SOLAS - 2013

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmittedin any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without prior

written permission of the copyright owner.

Published by the Curriculum and Assessment Development UnitSOLAS - The Further Education and Training Authority

SOLAS - © 2013 3 Rev 2.1 CADU- 31/07/09

Page No.

SOLAS Policy Statement 4

Introduction to Phase 1 5

Introduction to Phases 3, 5 & 7 7

Phase 1 On-the-Job Competence AssessmentInduction, Training SpecificationsOn-the-Job Phase 1 Record of Training

Phase 3 Assessments Schedule 3On-the-Job Assessment Schedule (11 core assessments)

Phase 5 Assessments Schedule 5On-the-Job Assessment Schedule (9 core assessments)

Phase 7 Assessments Schedule 7On-the-Job Assessment Schedule(10 core assessments)


Contents


and Maintenance FittingOn-the-Job Phases

Code 60

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SOLAS - Policy StatementSOLAS is committed to a standards-based assessment system for all craft programmes.As part of this process, a series of assessment programmes has been produced toenable SOLAS to assess attainment for certification purposes. The design anddevelopment of these assessments is co-ordinated by the Curriculum and AssessmentDevelopment Unit in conjunction with Subject Matter Experts representing employer,trade union, educational and training interests, and reflects National Framework ofQualifications requirements for awards at Level 6.

AcknowledgementThe SOLAS Curriculum and Assessment Development Unit would like to acknowledgethe support and participation of social partners and training and educational providers inthe development of the occupational standards and curriculum for this craft.

AssessmentThere are two types of assessment for apprenticeship - assessment in Off-the-Job andworkplace competence assessment On-the-Job. This document refers to workplacecompetence assessment which is used to obtain evidence of performance under workplaceconditions. This evidence is collected by assessors using standardised checklists, whichensures that evidence of performance is available for verification purposes.

Certification

On successful completion of the required assessments, each apprentice will be awarded aLevel 6 Advanced Certificate from QQI.

Assessment SecurityThe workplace assessor will hold the original copy of the Workplace Assessment Book forthe relevant craft for each apprentice. The Assessment Book provides evidence of theapprentice’s workplace competence in the required assessments. It is essential that theassessor maintains the original copy in safekeeping for verification. Each WorkplaceAssessment has been validated and assessors must not adjust or alter in any way theAssessment Programme content.

Administration InformationSpecific administration details are included in each assessment. It is important thatassessors are familiar with the Workplace Competence Assessment Guidelines, whichprovide an overview of Workplace Assessment for Apprenticeship, and with the trainingand assessment requirements for their crafts.

Review and DevelopmentSOLAS Curriculum and Assessment Development Unit invites constructive feedback oneach assessment to ensure its continued conformance to the industrial and commercialstandards required by industry. All comments regarding assessments should be insertedin the standard Feedback Sheet, which is on the last page of this document, and thenforwarded to Apprenticeship Feedback, SOLAS, Curriculum and AssessmentDevelopment Unit, 27-33 Upper Baggot Street, Dublin 4.


Introduction


and Maintenance FittingOff-the-Job Phases

Code 60

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Purpose The purpose of the On-the-Job Phase 1 of the apprenticeship trainingand development programme is to provide the apprentice withintroductory training. This training provides apprentices with theopportunity to learn and practice basic skills in the workplace which aredeveloped further throughout their apprenticeship.

Content During Phase 1 the apprentice is introduced to basic skills in theworkplace environment which they will develop to the requiredstandards of accuracy, speed and quality. The apprentice works withexperienced craftspersons and is supervised in the acquisition andpractice of these skills. These skills are specified in the objectives foreach section of the Phase 1 On-the-Job training specification.

Assessment Each section of the Phase 1 training specification contains a list oftasks which must be checked off and signed by the employer andapprentice when the apprentice has completed them successfully. Oncompletion of Phase 1, an On-the-Job Record of Training will also becompleted by the employer and submitted to SOLAS as proof of theapprentice having completed this training.


Introduction to Phase 1



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SOLAS - © 2013 6 Rev 2.1 CADU- 31/07/09

Purpose The purpose of the On-the-Job Phases 3, 5 and 7 of apprenticeshiptraining and development programmes is to provide all apprentices withthe opportunity to practise the skills acquired in the Off-the-Job Phases2, 4 and 6 and to develop new skills and competences. It is the mainfunction of the On-the-Job phases to transfer Off-the-Job skillacquisition into workplace competence. This requires effectiveintegration of knowledge, practical and personal skills in the workplace.

Content During each phase the apprentice needs to practise in the workplaceenvironment the newly learned skills to the required standards ofaccuracy, speed and quality, and with the confidence whichcharacterises competence. These skills are stated in the moduleobjectives for each Off-the-Job phase and are further specified in detailin the competencies provided for each workplace assessment withinthis document. The apprentice works with experienced craftspersonsand is supervised in the practice and acquisition of the skills.

Assessment Workplace Competence Assessment is carried out during the On-the-Job Phases. Assessment in the workplace provides evidence ofcompetence. Workplace Competence is defined as the application ofskills, knowledge and competence to perform tasks or combinations oftasks to industrial and commercial standards under operationalconditions. Assessment schedules detailing requirements for each ofPhases 3, 5 and 7 are provided in this document. A checklist ofassessment points for each assessment is also included. Assessmentchecklists must be retained by the employer for the duration of theapprenticeship period.

Common Modules:The apprentice is required to complete a number of self paced

Common Modules during their training period. These modules are

made available to the apprentice through e-learning.

During their Apprenticeship the apprentice will undertake self study in

the following:

• Health & Safety

• Introduction to Learning to Learn

• Introduction to ICT

• Employment Legislation Awareness

• Environmental Awareness

The apprentice must have completed these Common Modules by the

end of the Phase 3 ‘on the job training’ period.


Introduction to Phases 3, 5 & 7



Code 60

Documenting Assessment of Workplace CompetenceTo assist assessors to plan and conduct assessment in a range of practical tasks, two documents are provided for each task:

1. Assessment Specification

2. Assessment Checklist

1. Assessment SpecificationThe Assessment Specification contains the information under the following headings which describes the assessment in detail:

Activity: Project requiring cognitive, practical and personal skills

Conditions: Range statement (type of environment, tools, equipment,resources and any constraints)

Standards: Safety, accuracy, speed, finish and quality

Preparation: Assessor’s role; location and timing of the assessment

Practical Skills The practical skills to be assessed

Related Knowledge: Science, maths, drawing and underpinning knowledge

Personal Skills The personal skills to be assessed

Assessment Method: Observation during task performance, examination ofwork piece or finished product, oral questions

2. Assessment Checklist This contains the following:

a) List of assessment points

b) Six columns to facilitate recording of assessmentresults for each task specified. To demonstrateworkplace competence, the apprentice must achieve allassessment points on one occasion for any one task.

c) Apprentice and assessor sign-off and date columnswhen assessment is successfully completed i.e. taskhas been achieved

SOLAS - © 2013 7 Rev 2.1 CADU- 31/07/09

Note: On successful completion of the On-the-Job Assessment Schedule of

Workplace Assessments in each Phase

1. Send the original copy to:

Local Training Centre

2. Retain a workplace copy and records for duration of apprenticeship


Introduction to Phases 3, 5 & 7



Code 60

SOLAS - © 2013 8 Rev 2.1 CADU- 31/07/09

This form provides the opportunity for Workplace Assessors to feed back any difficulties orsuggestions for improvement in the Workplace Assessments carried out in Phases 1/3/5/7of the Standards Based Apprenticeship.

Please complete the form below and return to: Apprenticeship Feedback,SOLAS, Curriculum and Assessment Development Unit, 27/33 Upper Baggot Street,Dublin 4.

We welcome your observations.

ASSESSMENT NO.

1. Please specify any craft skills important in your firm which areomitted from the Assessment Schedules in 1/3/5/7.

2. Indicate any instance where instructions are unclear.

3. Indicate if any assessment points are unclear.

4. State if competencies are unclear in any assessment.

5. Please describe any other difficulties or suggestions here regarding Workplace Assessment.

6. Do assessment criteria meet industrial standards for this phase?If NO, please specify the instance.

Name _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

Phone: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Mobile:_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

Address: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _


Workplace Assessment Feedback Sheet



Code 60

MECHANICALAUTOMATION AND

MAINTENANCE

FITTING

INTRODUCTION TO

PHASES 2/4/6OFF-THE-JOB

SOLAS - © 2013 2 Rev 2.1 CADU - 31/07/09

ACKNOWLEDGEMENT

The Statutory Apprenticeship Programme for this craft occupation is founded on the results of industry-

based surveys and research into the skills, knowledge and competence required by today’s craftspeople.

SOLAS acknowledges the support and participation of all the craftspeople, employer representatives,

Institutes of Technology, SOLAS Curriculum Writers and worker representatives who contributed to the

development of the curricula for this craft occupation.

Revision: 2.1

P.O. Box 456

27-33 Upper Baggot Street

Dublin 4

Ireland

© SOLAS - 2013

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted

in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without prior

written permission of the copyright owner.

Published by the Curriculum and Assessment Development Unit

SOLAS - The Further Education and Training Authority

SOLAS - © 2013 3 Rev 2.1 CADU - 31/07/09

Page No.

Introduction 4

Occupational Profile 5

Modular Plan 7

Personal Protection Equipment 13

Capital Equipment for Phase 2 14

Equipment and Tools for Phase 2 15

Training Aids and Resourced for Phase 2 25

Consumables for Phase 2 29

Apprentice Toolbox 31


Contents



Code 60

SOLAS - © 2013 4 Rev 2.1 CADU - 31/07/09

Purpose The purpose of Phases 2, 4 and 6 of apprenticeship training andeducation programmes is to provide all apprentices with theopportunity to learn, practise and develop the skills of their craft, tofamiliarise them with the terminology, tools, materials, equipmentand working practices which will form the foundation for their furtherdevelopment and progression.

Content During each phase the apprentice will undergo a series of integratedlearning experiences to develop the skills, knowledge andcompetence prescribed for each phase. The content is structured todevelop the apprentice in the range of skills which they will berequired to perform to agreed industry standards.

Assessment Throughout each phase, the apprentice will undertake a number ofassessments e.g. Theory, Practical, Drawing, Course Work, whichare an essential part of the certification and award of a Level 6Advanced Certificate from QQI.


Introduction



Code 60

SOLAS - © 2013 5 Rev 2.1 CADU - 31/07/09

Craft Occupation Engineering Trades: includes Toolmaker, Construction Plant Fitter,Metal Fabricator, Sheet Metal Worker

Industry Served Engineering, manufacturing, pharmaceutical, quarries and mines,food processing, local authorities, petrochemical, armed forces.

Profile of Craft The Fitter‘s job concerns plant and machinery installation,maintenance and repairs, replacement of broken or work parts,adjustment, servicing and checking components, machinery andequipment, component replacement. Parts may have to befabricated using machine tools i.e. lathes, milling machines, grindersetc., components may have to be repaired or fabricated usingwelding, brazing, rivetting, soldering etc. Increasingly machines andprocesses involve integration with computer and electronic operatingand control systems with mechanic/hydraulic and pneumatic devicesi.e.PLCs, CNC, CAD, CIM and CAM.

Core Skills Installation, service, maintenance, fault rectification of process plant,machine tools, power and production equipmentComponent fabrication byTurning, Milling, Welding,Cutting, Machining, Drilling,Reaming and Pipe Fabrication

Machine setting/adjustment ofcontrol system elements, including computerisation and systemprogramming

Specialist Skills Precision turningAdvanced millingCoded weldingCNC machining/programmingCAM, CADHydraulicsPneumaticsElectronics


Occupational Profile



Code 60

SOLAS - © 2013 6 Rev 2.1 CADU - 31/07/09

Common Skills Workshop practice including: safe use and maintenance of tools andequipment, marking out, drilling, tapping, reaming, rivetting, fasteners,technical drawings and interpretation of 1st and 3rd angle, isometric,oblique and freehand drawings/symbols.Safety - hazard avoidance,good workshop practices, basic first aid, fire extinguishers, electricalshocks, lifting, evacuation, basic thermal processes, patterndevelopment, materials, mechanical,handling light fabrication,environmental protection and rational use of energy

Personal Skills Initiative/adaptabilityVerbal communicationProblem solvingTeamworkPlanningReport writingNOTE: Integrated curriculum includes maths, science and theory


Occupational Profile



Code 60

Mo

du

le1

Mo

du

le 2

Mo

du

le 3

Mo

du

le 4

Intr

od

ucti

on

an

d

Tu

rnin

gM

illin

gT

herm

al

Pro

cesses

Ge

nera

l W

ork

sh

op

Skills

Mech

an

ical A

uto

mati

on

an

d M

ain

ten

an

ce F

itti

ng

Off

-th

e-J

ob

Ph

ases

Co

de 6

0

MO

DU

LA

R P

LA

N P

HA

SE

2

Tra

inin

g t

ime

586

hours

Assessm

en

t ti

me

39 h

ours

To

tal

625

hours

SOLAS - © 2013 7 Rev 2.1 CADU - 31/07/09

NO

TE

:

Dura

tions g

iven o

n a

ll are

guid

elin

e o

nly

Un

its

1.

Induction a

nd M

anual

Handlin

g

2.

Mark

Out, C

ut, F

ile

3.

Drill

and R

eam

4.

Thre

adin

g,

Counte

rsin

kin

gand C

ounte

rboring

5.

Sold

ering

6.

Riv

eting

7.

Drill

Sharp

enin

g

8.

Poly

mer

Mate

rials

9.

Assem

bly

Du

rati

on

113

hours

Units

1.

Intr

oduction:

Machin

eC

ontr

ols

, A

ttachm

ents

and

Opera

tions

2.

Facin

g,

Para

llel and

Ste

pped T

urn

ing

3.

Drilli

ng,

Ream

ing a

nd

Tappin

g

4.

Taper

Turn

ing a

nd

Knurlin

g

5.

Tool G

rindin

g a

nd

Form

ing

6.

Boring/S

tep B

oring

7.

Slid

ing (

Runnin

g)

Fits

Du

rati

on

110 h

ours

Units

1.

Machin

e C

ontr

ols

and

Opera

tions

2.

Face a

nd E

nd M

illin

g

3.

Ste

p a

nd A

ngle

Mill

ing

4.

Alig

nm

ent

of

the M

achin

eH

ead,

Table

and V

ice

5.

Mill

ing a

nd D

rilli

ng

6.

Slid

ing F

it /

Assem

bly

7.

Exte

rnal K

eyw

ay C

uttin

gand S

lottin

g

Du

rati

on

113

hours

Units

1.

Intr

oduction t

o M

anual

Meta

l A

rc W

eld

ing

2.

Lap/T

ee -

Fill

et

Weld

3.

Intr

oduction t

o O

xy-

Acety

lene W

eld

ing

4.

Oxy-A

cety

lene,

Outs

ide

Corn

er

Join

t

5.

Intr

oduction t

o O

xy-F

uel

Cuttin

g

6.

Intr

oduction t

o H

eat

Tre

atm

ent

Du

rati

on

64

hours

Mo

du

le 5

Mo

du

le 6

Mo

du

le 7

Mo

du

le 8

Pla

nt

an

d M

ach

ine

Flu

id P

ow

er

Syste

ms

Intr

od

ucti

on

to

CN

CIn

tro

du

cti

on

to

Ab

rasiv

e W

heels

Ma

inte

nan

ce

Mech

an

ical A

uto

mati

on

an

d M

ain

ten

an

ce F

itti

ng

Off

-th

e-J

ob

Ph

ases

Co

de 6

0

MO

DU

LA

R P

LA

N P

HA

SE

2

Tra

inin

g t

ime

586

hours

Assessm

en

t ti

me

39 h

ours

To

tal

625

hours

SOLAS - © 2013 8 Rev 2.1 CADU - 31/07/09

NO

TE

:

Dura

tions g

iven o

n a

ll are

guid

elin

e o

nly

Un

its

1.

Pip

ew

ork

and P

um

pin

gS

yste

ms

2.

Pla

nt

Serv

icin

g

3.

Drives a

nd T

ransm

issio

nS

yste

ms

4.

Machin

e I

nsta

llation a

nd

Main

tenance

Du

rati

on

78

hours

Units

1.

Opera

ting P

rincip

les

2.

Dis

trib

ution S

yste

ms

3.

Com

pre

ssed A

irP

repara

tion a

nd

Dis

trib

ution

4.

Pneum

atic A

ctu

ato

rs

5.

Pneum

atic V

alv

es

6.

Circuit D

esig

n a

nd

Constr

uction

7.

Hydra

ulic

Princip

les

8.

Hydra

ulic

Pow

er

Unit

9.

Hydra

ulic

Flu

ids

10.

Hydra

ulic

Actu

ato

rs a

nd

Valv

es

11.

Hydra

ulic

Circuit B

uild

ing

12.

Hydra

ulic

Fault F

indin

g

Du

rati

on

68

hours

Units

1.

CN

C M

achin

e T

ools

2.

Part

Pro

gra

mm

ing

3.

Data

Input/S

tora

ge P

art

Pro

gra

mm

ing

4.

CN

C S

ettin

g a

nd

Opera

tion

Du

rati

on

30

hours

Units

1.

Basic

Safe

ty R

ule

s

2.

Wheel F

langes a

nd

Assem

blie

s

3.

Abra

siv

e W

heel Types

and M

ounting

4.

Sta

ndard

Mark

ing S

yste

mfo

r A

bra

siv

e W

heels

Du

rati

on

10 h

ours

Mo

du

le 1

Mo

du

le 2

Mo

du

le 3

Mo

du

le 4

Be

nch

Fit

tin

gTu

rnin

gM

illin

gT

herm

al

Pro

cesses

Mech

an

ical A

uto

mati

on

an

d M

ain

ten

an

ce F

itti

ng

Off

-th

e-J

ob

Ph

ases

Co

de 6

0

MO

DU

LA

R P

LA

N P

HA

SE

4

Tra

inin

g t

ime

359

hours

Assessm

en

t ti

me

26 h

ours

To

tal

385

hours

SOLAS - © 2013 9 Rev 2.1 CADU - 31/07/09

NO

TE

:

Dura

tions g

iven o

n a

ll are

guid

elin

e o

nly

Un

its

1.

Lim

its a

nd F

its

2.

Com

ponent

Fabrication

3.

Pre

cis

ion A

ssem

bly

Du

rati

on

36

hours

Units

1.

Taper

Turn

ing

2.

Toolin

g,

Work

hold

ing a

nd

Support

ing D

evic

es

3.

Scre

wcuttin

g

4.

Eccentr

ic T

urn

ing

Du

rati

on

66 h

ours

Units

1.

Tee S

lot

and D

oveta

ilM

illin

g

2.

Boring a

nd C

ounte

r-B

oring

Du

rati

on

32

hours

Units

1.

Oxy-A

cety

lene W

eld

ing:

Butt J

oin

t

2.

Oxy-A

cety

lene W

eld

ing:

Open B

utt J

oin

t, P

ipe

Rota

ted

3.

Oxy-A

cety

lene B

ronze

Weld

ing:

Open C

orn

er,

Fill

et

Fla

t P

ositio

n

4.

Manual M

eta

l A

rcW

eld

ing:

Open C

orn

er,

Horizonta

l/V

ert

ical

5.

Manual M

eta

l A

rcW

eld

ing:

Tee F

illet,

Vert

ical

6.

Intr

oduction t

o M

AG

Sw

eld

ing

Du

rati

on

36

hours

Mo

du

le 5

Mo

du

le 6

Mo

du

le 7

Pla

nt,

Mach

ine M

ain

ten

an

ce

Au

tom

ati

on

an

d C

on

tro

lC

NC

Pro

gra

mm

ing

, O

pera

tio

ns

an

d E

lectr

ical

an

d C

om

mu

nic

ati

on

s

Mech

an

ical A

uto

mati

on

an

d M

ain

ten

an

ce F

itti

ng

Off

-th

e-J

ob

Ph

ases

Co

de 6

0

MO

DU

LA

R P

LA

N P

HA

SE

4

Tra

inin

g t

ime

359

hours

Assessm

en

t ti

me

26 h

ours

To

tal

385

hours

SOLAS - © 2013 10 Rev 2.1 CADU - 31/07/09

NO

TE

:

Dura

tions g

iven o

n a

ll are

guid

elin

e o

nly

Un

its

1.

Pla

nt

and M

achin

eM

ain

tenance S

yste

ms

2.

Bearing a

nd S

eals

3.

Pow

er

Tra

nsm

issio

n

4.

Ele

ctr

ical C

ircuits

5.

Ele

ctr

ical M

agnetic

Syste

ms,

Testing a

nd

Safe

ty

Du

rati

on

70

hours

Units

1.

Cascade C

ircuit D

esig

n

2.

Ele

ctr

o-P

neum

atics

3.

Sensors

and S

ensin

gS

yste

ms

4.

Logic

Syste

ms

Du

rati

on

66 h

ours

Units

1.

Tra

nsducers

2.

Tool C

hangin

g a

nd

Work

hold

ing

3.

CN

CC

om

mun

ication

4.

Manual P

art

Pro

gra

mm

ing

5.

Sub-R

outines a

nd L

oops

in C

NC

Pro

gra

mm

es

6.

Opera

tions a

nd S

ettin

g

7.

Com

munic

ations

Du

rati

on

53

hours

SOLAS - © 2013 11 Rev 2.1 CADU - 31/07/09

Mo

du

le 1

M

od

ule

2M

od

ule

3

Mo

du

le 4

Ma

nu

factu

rin

g P

rocesses

Inte

gra

ted

Au

tom

ati

on

C

AM

, C

AD

an

d C

om

pu

tin

gP

lan

t an

d M

ach

ine D

iag

no

sti

cs

an

d C

on

tro

l

Mech

an

ical A

uto

mati

on

an

d M

ain

ten

an

ce F

itti

ng

Off

-th

e-J

ob

Ph

ases

Co

de 6

0

MO

DU

LA

R P

LA

N P

HA

SE

6

Tra

inin

g t

ime

366

hours

Assessm

en

t ti

me

19 h

ours

To

tal

385 h

ours

SOLAS - © 2013 11 Rev 2.1 CADU - 31/07/09

NO

TE

:

Dura

tions g

iven o

n a

ll are

guid

elin

e o

nly

Un

its

1.

Pre

cis

ion S

urf

ace

Grindin

g

2.

Indexin

g/D

ivid

ing H

ead

3.

Work

hold

ing

Devic

es:

Jig

sand F

ixtu

res

4.

Manufa

ctu

ring

Pro

cesses/M

ate

rial

Manip

ula

tion

5.

Poly

mer

Mate

rials

and

Form

ing T

echniq

ues

6.

Pro

pert

ies a

nd H

eat

Tre

atm

ent

of

Ferr

ous

Mate

rials

7.

Pro

ject A

naly

sis

, P

lannin

gand P

roduction

8.

Pre

cis

ion A

ssem

bly

Techniq

ues

Du

rati

on

97

hours

Un

its

1.

Auto

mate

d C

ontr

ol

Syste

ms

2.

Auto

mate

d S

yste

ms

Layout

3.

Em

erg

ency S

top a

nd F

ail-

Safe

Syste

ms

4.

Syste

m D

esig

n

5.

PLC

Pro

gra

mm

ing a

nd

Circuit B

uild

ing

6.

Modula

r C

om

ponents

and

Sta

ndard

Part

s

7.

Modula

r D

evic

eC

onstr

uction a

nd

Assem

bly

Techniq

ues

8.

Com

mis

sio

nin

g,

Testing

and D

ebuggin

gTechniq

ues

9.

Intr

oduction t

o R

obotics

10.

Robot

Tasks a

nd

Pro

gra

mm

ing M

eth

ods

Du

rati

on

75

hours

Un

its

1.

CA

D S

yste

m/O

pera

ting

Syste

m

2.

Com

pute

r A

ided D

raw

ing

Pro

duction

3.

CA

D/C

AM

Mill

ing

4.

CA

D/C

AM

Turn

ing

5.

Dem

onstr

ation o

fIn

tera

ction o

f S

olid

-M

odelli

ng w

ith C

AD

/CA

M

6.

Com

puting

Du

rati

on

62

hours

Un

its

1.

Machin

e D

iagnostics

2.

Mechanic

al P

ow

er

Syste

ms

3.

Dis

mantlin

g,

Repair a

nd

Reassem

bly

4.

Ele

ctr

ical T

hre

e P

hase

and T

ransfo

rmers

5.

Ele

ctr

ical M

oto

rs

6.

Variable

Speed a

nd S

erv

oC

ontr

olle

d M

oto

rs

7.

Princip

les o

f B

asic

Refr

igera

tion

Du

rati

on

86

hours

SOLAS - © 2013 12 Rev 2.1 CADU - 31/07/09

Mo

du

le 5

Th

erm

al

Pro

ces

ses

Mech

an

ical A

uto

mati

on

an

d M

ain

ten

an

ce F

itti

ng

Off

-th

e-J

ob

Ph

ases

Co

de 6

0

MO

DU

LA

R P

LA

N P

HA

SE

6

Tra

inin

g t

ime

366 h

ours

Assessm

en

t ti

me

19 h

ours

To

tal

385 h

ours

NO

TE

:

Dura

tions g

iven o

n a

ll are

guid

elin

e o

nly

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SOLAS - © 2013 13 Rev 2.1 CADU - 31/07/09

General P.P.E.

Fire Retardant Coverall EN470-1EN531EN533

Head Protection EN397 (Safety Helmet)EN812: 2002 (Bump Cap)

Safety Boots/Shoes EN345 S3

Ear Defenders EN352-1

Ear Plugs EN352-2

Latex Gloves (Box) CE (General)

Industrial Gloves EN420(General)

Barrier Cream EN1500

Eye and Face Protection EN166 1B/1F (Goggles, Spectacles and Visors)

Dust Masks EN149:2001 FFP1 or FFP2 or FFP3 (Disposable/Shortlife)EN136 Class1 (Full Face Mask)EN140 (Half Face Mask)

N.B. Filters may be interchanged on half masks and full masks. It is important to seek advice from supplier when ordering filters. It is necessaryto advise supplier about any chemicals, etc. for which protection is sought.

Specific P.P.E.

Welding Gloves EN388EN407

Welding Aprons CE

Arc Welding Shield EN12941

Gas Welding Goggles EN175 1FT


Personal Protection Equipment List


and Maintenance FittingPPE list

Code 60

SOLAS - © 2013 14 Rev 2.1 CADU - 31/07/09

Based on group of 14

Power Supply Requirements: 380V 50Hz 3 Phase220V 50Hz Single Phase

Item Description Quantity

1. Centre Lathe 7Height of centres over bed 190mmSpindle bore (maximum bar diameter) 54mmDistance between centres 750mmCamlock type spindle noseSpindle speed range 25-2000RPM

2. Vertical Milling Machine 7Size of table 1065 x 230mmPower feed longitudinal traverse 675mmCross traverse 305mmVertical traverse 405mmSpindle speed range 50-3750RPMSpindle taper R8

3. Pedestal Grinder (double ended) 2Power of motor 0.75KWSpindle speed 2820RPMWheel size 203x25x19mmDistance between wheels 264mm

4. Electric Arc Welding Plant 7Mains input 380V ACAmperage output rating 25-220 ampsVoltage output (open circuit facility) 50-100 voltsSize 500x375x450mmElectrode leadElectrode holderEarth lead


Capital Equipment for Phase 2



Code 60

SOLAS - © 2013 15 Rev 2.1 CADU - 31/07/09

Based on a group of 14


1. Oxy-Acetylene Welding Plant 7Acetylene two stage regulator Range 0-103KN/m2Oxygen two stage regulator Range 0-482KN/m2Acetylene hose complete with nutsnipples, hose protectors, clips andclamps 5mm bore x 5m lengthOxygen hose complete with nuts,nipples, hose protectors, clips andclamps 5m bore x 5m lengthWelding torchCutting attachmentWelding nozzles Nos. 1,2,4,6 and 9Cutting nozzles Nos. 13 and 15Spark lighterNozzle cleaning setRubber wheeled welding trolley suitablefor two cylinders

2. Drilling Machine-Pedestal 4Power of motor 1KWSpindle speed 100-2900RPMDrilling capacity 25mmSpindle travel 125mmTable size 500 x 400mm

3. Marking Out Table 2Grade A type cast iron construction fittedwith 4 support legs 1m x 1m

4. Mandrel Press 1Maximum arbor diameter 50mmMaximum arbor length 381mmMaximum work diameter 381mm

5. Hydraulic Tube Bending Machine - Hand Operated 2Maximum capacity 50mmFormer sizes 1/2" 3/4" 1"End rollers

6. Shearing Machine - Hand Operated Type 1Capacity 3mm mild steelBlade length 350mm

7. Pipe Vices - Self Locking Hinged Type 1Capacity 3-50mm Diameter 12


Equipment & Tools for Phase 2



Code 60



8. Engineers Bench Vices 14Capacity 125mmSteel jaws 112mmCast iron body fitted with unbreakable nutand facility for withdrawing slide from bodyor cleaning and oiling

9. Hand operated water pressure test pump 1

10. CNC Milling Machine or CNC Training Unit 1or CNC Retrofitted Milling Machine.Control Unit to be compatible withISO Programming Codes

11. Oil Fired Boiler (max 25 kw output) 1Piped up to radiators and indirect cylinder. System to be fittedwith programmer, cylinder stat. zone valves and room stat(see Appendix for detail)

12. Separate Oil-fired Burners similar to typefitted to boiler

713. Fire-brick Containment Area for firing burners

C/W extraction system

14. Boiler Efficiency Testing Kit 1

15. Isolator Switch 1

16. Room Stat 1

17. Programmer 1

18. Cylinder Stat 1

19. Neon Indicators 2

20. Junction Boxes 1

Note: Items 15-16 are components for simulation of Boiler Control System.Module 5 Unit 2 Board Exercise.See appendix for wiring diagram and board layout.

SOLAS - © 2013 16 Rev 2.1 CADU - 31/07/09





Code 60

SOLAS - © 2013 17 Rev 2.1 CADU - 31/07/09



21. Tool Cabinets 1800x906x450mm 3

22. Machine cabinets 906x906x450mm 14

23. Portable Drill - side handle type 13mm capacity 1

24. Anvil and Stand 25.2kg 1

25. Machine Accessories and Tooling for Centre LatheDual inch/metric dials 7

Rotating centre 7

3 jaw self centering chuck with

set reversible jaws 7

4-way tool post 7

Drill chuck, arbor and chuck key 7

Two no. 4 Morse taper centres 7

High speed steel turning tool holders 7 of each

straight type 19x22x212mm 7

right hand type 19x22x212mm 7

left hand type 19x22x212mm 7

High speed steel parting-off tool holders 7 of each

Straight type 7 x 23mm 7

12 x 30mm 7

High speed steel parting-off blades 2x12x112mm

3x19x150mm 7 of each

Tungsten carbide tool Holders 7 of each

Right hand type 16x16x11mm

20x20x12mm

Double ended boring bars and holders 14mm Dia. x 169mm

19mm Dia. x 225mm

Tungsten carbide boring bars 7 of each

9x10x6mm

9x16x11mm

Knurling tool holders pivoted head

type with medium knurls 3x18x105mm 7

High speed steel tool bits 100 of each

6x50mm

8x56mm

10x69mm

13x100mm

Oil cans pressure type 1/4 litre capacity 7





Code 60



26. Milling Machine AccessoriesMachine vice swivel base type smooth jaws 125mm 7Set of holding down bolts, clampsand tee nuts Collets 1.5-20mm 7 setsLarge type autolock chuckSmall type autolock chuckShell and mill arbors 7 setsMorse taper adaptorJacobs chuck and key

3mm capacity19mm capacity 1

27. Milling CuttersEnd mills 2.5-25mm 14Slot drills 2.5-25mm 14Counter bores 4-16mm diameter 14Tungsten carbide face millsDrill sets. In steps of 0.5mm 1.5 -13mm 7 setsPlastic face hammers 38mm diameter 7Jacobs chuck and key 19mm capacity 2 of each13mm capacity

Oil cans pressure type 1/4 litre capacity 7

28. Welding EquipmentWelding curtains 1 per bayChipping hammers 1 per bayWire brushes 1 per bayWelding shields Welding goggles 7 pairsWelding aprons 7Welding gloves 7 pairsWelding caps 7Tongs 7

SOLAS - © 2013 18 Rev 2.1 CADU - 31/07/09





Code 60

SOLAS - © 2013 19 Rev 2.1 CADU - 31/07/09



29. Vernier height gauges 0.-300mm 2

30. Hardened and ground steel parallels 6x13x100mm 10 pairs6x25x150mm of each13x25x150mm20x38x200mm25x25x200mm25x50x250mm38x75x300mm

31. Universal type surface gauge 75x63 mmbase x 225mm column 3

32. Jacobs chuck and key 12mm capacity 4

33. Jacobs chuck and key 19mm capacity 2

34. Morse taper drill sleeves Inside-Outside No. 1 - No. 2

No. 1 - No. 3No. 1 - No. 4No. 2 - No. 3 7 of each

35. Drill drifts, No. 1, 2 and 3 morse taper 2 of each

36. Angle plate 100x75x75mm 2

37. Angle plate 225x225x225mm 2

38. Vee blocks complete with clamps 50x40mm40x25mm capacity 4 pairs

39. Surface plate Grade A 350x250mm complete with protective cover 2

40. Three wheel pipe cutter 6-50mm capacity 7

41. Tinmans snips 200 and 250mm 2 of each

42. Screwdrivers - blade size 100x4mm 1 of each

100x6mm250x10mm150x4mm150x8mm250x10mm





Code 60



The following hand tools should be kept in the Work Area

43. Pin punches 1.5-10mm 2 sets

44. Number stamps 6mm character 2 sets

45. Letter stamps 6mm character 2 sets

46. Beam trammel 2 sets

47. Centre squares: maximum work dia. 75mm 3

48. High speed steel counterbores 6-19mm 2 sets

49. High speed steel countersinks 13mm diameter 7

50. High speed steel drills straightshank imperial sizes in steps of 1/16" 1/16"-1/2" 4 sets

51. High speed steel drills straight shank metric sizes in steps of

0.5mm 1.5-13mm 4 sets52. High speed steel drills taper shank

Imperial sizes in steps of 1/8" 1/2"-1 1/8"

53. High speed steel drills taper shank metric size in steps of 3mm ` 13-21mm 2 of each

54. Centre drills BSI-4 10 of each

55. High speed steel reamers hand typespiral flute imperial size in steps of 1/16" 3/16"-3/4" 3 of each

56. High speed steel reamers hand type spiral flute metric size in steps of 1mm 4-19mm 3 of each

57. High speed steel reamers machine type spiral flute imperial size in steps of 1/16" 3/16"-3/4" 3 of each

58. High speed steel reamers machinetype spiral flute metric size in steps of 1mm 4-25mm 3 of each

59. Drill drifts - hammer type morse taper 1-2 2

SOLAS - © 2013 20 Rev 2.1 CADU - 31/07/09





Code 60

SOLAS - © 2013 21 Rev 2.1 CADU - 31/07/09



60. Hand taps metric M4 x 0.70 3 of eachM5 x 0.80M6 x 1.00M8 x 1.25M10 x 1.50M12 x 1.75M14 x 2.00M16 x 2.00M18 x 2.50M20 x 2.50

61. Tapping wrenches (Adjustable) 1.5-6mm 6mm-19mm 7 of each

62. Dies - circular split type metric 7 of eachand die stocks M5 x 0.80

M6 x 1.00M8 x 1.25M10 x 1.50M12 x 1.75M14 x 2.00M16 x 2.00M18 x 2.50M20 x 2.501/2" U.N.C.1/2" U.N.F.

63. BSP stocks and dies 1/2" 3/4" and 1" 7 of each

64. Plastic faced hammers 2 lb 4

65. Combination sets 2

66. Vernier bevel protractorsaccurate to within 5 minutes. 4

67. Micrometers imperial size 1" - 2" 7 of each2" - 3" 3 off

68. Micrometers metric size 25 - 50mm 7 off50 - 75mm 7 off75 - 100mm 4 off

69. Screw extractors 1, 2, 3, 4, 5 and 6 2 sets

70. Spanners open ended 6 - 32mm 1 set





Code 60



71. Spanners ring 6 - 30mm 1 set

72. Socket set with the following accessories: Reversible ratchet

Sliding T barJointed nut spinnerSpeed braceTorque spanner 4 sets

73. Radius gauges Radii from 0.75 to 5mm by 0.25mm 2 of each

Radii from 5.5 to 13mm by 0.5mm 2 of each

74. Screw pitch gauges metric and imperial 6

75. Feeler gauges Blade thickness x 0.01mm 3

76. Depth micrometer 0 - 150mm 2 sets0 - 6" of each

77. Inside micrometers 25 - 50mm 2 of each50 - 100mm 2 off1" - 2" 2 off2" - 4" 2 off

78. Dial indicators with 100mm travel 0.01mm graduation 4

79. Dial indicator with 1" travel 0.001" graduations 4

80. Magnetic stands on/off control 63 x 63 x 76mm 4base size overall height 237mm

81. Telescoping gauges 12.7 - 19mm 1 set 19.0 - 31.7mm of each31.7 - 53.9mm53.9 - 88.9mm88.9 - 152.4mm

82. Engineer's square 300mm 1

83. Strip heater for polycarbonate 1

84. Angle grinder 5" 4

85. Angle grinder 9" 1

SOLAS - © 2013 22 Rev 2.1 CADU - 31/07/09





Code 60

SOLAS - © 2013 23 Rev 2.1 CADU - 31/07/09



86. Allen keys imperial 1/16" - 3/8" 3 sets

87. Allen keys metric 1.5 - 10mm 3 sets

88. Tool maker's clamps 75 x 11 x 38mm 14

89. File card 100 x 50mm 14

90. Vice grips 250mm 4

91. Rivetting tools to include snap, 3mm capacity 3 setsset and bolster

92. Rivetting tools to include snap, 5mm capacity 3 setsset and bolster

93. Pop Rivet Gun 3

94. Stillson 350mm 3

95. Stillson 450mm 3

96. Hand files 50mm bastard 14

97. Hand files 250mm smooth 14

98. Hand files 150mm bastard 14

99. Hand files 150mm smooth 14

100. Half round files 250mm bastard 14

101. Half round files 250mm smooth 14

102. Half round files 150mm bastard 14

103. Half round files 150mm smooth 14

104. Round files 250mm bastard 14

105. Round files 250mm smooth 14

106. Round files 50mm bastard 14

107. Round files 150mm smooth 14





Code 60



108. Square files 250mm bastard 14

109. Square files 250mm smooth 14

110. Square files 150mm bastard 28

111. Square files 150mm smooth 28

112. Flat files 200mm bastard 28

113. Flat files 200mm smooth 28

114. Three square 200mm bastard 28

115. Three square 200mm smooth 14

116. File handles to suit 250mm files 14



119. Engineer's scribes double ended 1 75mm 7

120. Engineer's Jenny callipers 125mm 7

121. Copper and hide faced hammer 38mm diameter 2

122. ‘G’ cramps 0-150mm capacity 7

123. Electric soldering irons 7 offSoft solderSoldering flux

124. 3 Leg Pulley Drawer 200mm capacity 4 off

125. Chain Breaker 1/2"pitch 4 off

126. Set of screw extractors 7 off

127. Drawing boards A2 or A3 Size 14 off

128. Drawing Instruments 14 sets

126. 45o and 60o set squares 14 sets

SOLAS - © 2013 24 Rev 2.1 CADU - 31/07/09





Code 60

SOLAS - © 2013 25 Rev 2.1 CADU - 31/07/09



1. Valves1" gate valve (GB) 7 off1" foot valve (GB) 7 off1" non-return valve (GB) 7 off3/4" gate valve instantor 14 off1/2" pressure relief valve 0.50 PSI range 14 off

2. Pump Exercise Unit 1 Module 5Pressure gauge 0 - 100 PSI 7 offCentrifugal pump 8 off(Pedrollo CPM 158 Single phase or equivalent)10 gal polypropylene 7 offFeed and expansion water tank

3. Direct DriveTransmission assembly unit 4 off

4. Conveyor Belt Unit 2 off

5. *Piston air compressor c/w receiver(single or two stage capacity 14 - 20 CFM) 1 off

6. Pillow block bearings for 30mm (11/4")shaft 28 off

7. Rigid coupling bored for 30mm shaft 7 off

8. Mild steel angle 2" x 2" x 1/4" 7 lengths

9. Selection of anti-friction and plain bearings for demonstration of bearing fitting/removal

Notes

*These items need not be new, but they should be operational. In addition to thelisted pump, centres should also obtain a larger second-hand unit. This could be used for demonstration of gland packing, bearing fitting and gasket making.


Training Aids & Resources for Phase 2



Code 60

SOLAS - © 2013 26 Rev 2.1 CADU - 31/07/09



11. Pneumatic Training Board with the following equipment

* NOTE: For a class of 14 a minimum of 7 boards is recommended

Double acting cylinders with adjustable cushions32 mm or 25 mm bore x 100 mm stroke approximately 2 off

Double acting cylinder non-cushioned32 mm or 25 mm bore x 100 stroke 1 off

Single acting cylinder25 mm bore x 100 mm stroke 1 off

5/2 double air valves — 1/8 ports 3 off

3/2 roller operated valves — spring return 6 off

3/2 one way trip valves — one off for each direction 2 off

Time delay unit normally closed 1 off

Impulse generator or normally open time delay 1 off

3/2 valve push button operated spring return 1 off

3/2 valve lever operated 1 off

3/2 diaphragm valve or pressure decay sensor 1 off

5/2 differential valve or multifunctional 5/2 valve 1 off

OR valve 1 off

AND valve 1 off

Quick exhaust valve 1 off

Uni-directional flow control valve (in line type) 4 off

Silencers for valve ports

Coils of 6 mm O.D. or 4 mm O.D. plastic tubing to suit ` 1 coil per boardthe fittings on valves and cylinders 8 per board

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