Free Casting or Foundry Assistant Course(4Months)

Casting or Foundry Assistant:

Brief Job Description

Casting Helper will be involved in cleaning the slag, supporting in pre casting & post casting operations and storing the output at designated place.

Personal Attributes Reading, writing and communication skills, ability to plan and prioritize, quality consciousness, safety orientation, Dexterity, Ability to use fingers, hands and feet with ease to complete the assigned task (Dexterity), high precision and sensitivity to problem solving and sensitivity towards safety for self and equipment.

Maintain a safe and healthy working environment:

Elements and Performance Criteria

Identify and report the risks identified

To be competent, the user/individual on the job must be able to:

PC1..    Identify activities which can cause potential injury through sharp objects, burns, fall, electricity, gas leakages, radiation, poisonous fumes, chemicals ,loud noise

PC2.     Inform the concerned authorities about the potential risks identified in the processes, workplace area/ layout, materials used etc

PC3.     Inform the concerned authorities about machine breakdowns, damages which can potentially harm man/ machine during operations

PC4.     Create awareness amongst other by sharing information on the identified risks

Create and sustain a Safe, clean and environment friendly work place

To be competent, the user/individual on the job must be able to:

PC5..    Follow the instructions given on the equipment manual describing the operating process of the equipments

PC6..    Follow the Safety, Health and Environment related practices developed by the organization

PC7.     Operate the machine using the recommended Personal Protective Equipments (PPE)

PC8. . Maintain a clean and safe working environment near the work place and ensure there is no spillage of chemicals, production waste, oil, solvents etc

PC9.     Maintain high standards of personal hygiene at the work place

PC10. Ensure that the waste disposal is done in the designated area and manner as per organization SOP.

PC11. Inform appropriately the medical officer/ HR in case of self or an employees illness of contagious nature so that preventive actions can be planned for others

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1. relevant standards, procedures and policies related to Health, Safety and Environment followed in the company

KU2. basic knowledge of Safety procedures( fire fighting, first aid) within the organization

KU3. knowledge of various types of PPEs and their usage

KU4. basic knowledge of risks/hazards associated with each occupation in the organization

KU5. how to safely operate various tools and machines and risksassociated with the tools/ equipment

KU6. knowledge of personal hygiene and how an individual an contribute towards creating a highly safe and clean working environment

Generic Skills (GS)

User/individual on the job needs to know how to:

GS1.     write basic level notes and observations

GS2.     read safety instructions put up across the plant premises

GS3.     read safety precautions mentioned in equipment manuals and panels to understand the potential risks associated

GS4.     effectively communicate information to team members

GS5.     informemployees in the plant and concerned functions about events, incidents & potential risks observed related to Safety, Health and Environment.

GS6.     question operator/ supervisor in order to understand the safety related issues

GS7.     attentively listen with full attention and comprehend the information given by the speaker during safety drills and training programs

GS8.     use common sense and make judgments during day to day basis

GS9.             use reasoning skills to identify and resolve basic problems

GS10. use common sense and make judgments during day to day basis

GS11. use reasoning skills to identify and resolve basic problems

Maintain 5S at the work premises:

Elements and Performance Criteria

Ensure sorting

To be competent, the user/individual on the job must be able to:

PC1..     follow the sorting process and check that the tools, fixtures & jigs that are lying on workstations are the ones in use and unnecessary items are not cluttering the workbenches or work surfaces.

PC2..     ensure segregation of waste in hazardous/ non hazardous waste as per the sorting work instructions

PC3..     follow the technique of waste disposal and waste storage in the proper bins as per sop

PC4..     segregate the items which are labelled as red tag items for the process area and keep them in the correct places

PC5.      sort the tools/ equipment/ fasteners/ spare parts as per specifications/ utility into proper trays, cabinets, lockers as mentioned in the 5s guidelines/ work instructions

PC6. .    ensure that areas of material storage areas are not overflowing

PC7.      properly stack the various types of boxes and containers as per the size/ utility to avoid any fall of items/ breakage and also enable easy sorting when required

PC8.      return the extra material and tools to the designated sections and make sure that no additional material/ tool is lying near the work area

PC9.      follow the floor markings/ area markings used for demarcating the various sections in the plant as per the prescribed instructions and standards

PC10.    follow the proper labeling mechanism of instruments/ boxes/ containers and maintaining reference files/ documents with the codes and the lists

Ensure proper documentation and storage ( organizing , streamlining)

To be competent, the user/individual on the job must be able to:

PC11.    check that the items in the respective areas have been identified as broken or damaged

PC12.    follow the given instructions and check for labelling of fluids, oils. lubricants, solvents, chemicals etc. and proper storage of the same to avoid spillage, leakage, fire etc

PC13.    make sure that all material and tools are stored in the designated places and in the manner indicated in the 5s instructions

Ensure cleaning of self and the work place

To be competent, the user/individual on the job must be able to:

PC14.    check whether safety glasses are clean and in good condition

PC15.    keep all outside surfaces of recycling containers are clean

PC16.. ensure that the area has floors swept, machinery clean and generally clean. in case of cleaning, ensure that proper displays are maintained on the floor which indicate potential safety hazards

PC17.. check whether all hoses, cabling & wires are clean, in goodcondition and clamped to avoid any mishap or mix up

PC18.. ensure workbenches and work surfaces are clean and in good condition

PC19.    follow the cleaning schedule for the lighting system to ensure proper illumination

PC20.    store the cleaning material and equipment in the correct location and in good condition

PC21.    ensure self-cleanliness – clean uniform, clean shoes, clean gloves, clean helmets, personal hygiene

Ensure sustenance

To be competent, the user/individual on the job must be able to:

PC22.    follow the daily cleaning standards and schedules to create a clean working environment

PC23.    attend all training programs for employees on 5 s

PC24.    support the team during the audit of 5 s

PC25.    participate actively in employee work groups on 5s and encourage team members for active participation

PC26.    follow the guidelines for what to do and what not to do to build sustainability in 5s as mentioned in the 5s check lists/ work instructions

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.     relevant standards, procedures and policies related to 5S followed in the company

KU2.     have basic knowledge of 5S procedures

KU3.     know various types 5s practices followed in various areas

KU4.     understand the 5S checklists provided in the department/ team

KU5.     have skills to identify useful & non useful items

KU6.     have knowledge of labels , signs & colours used as indicators

KU7.     knowledge on how to sort and store various types of tools, equipment, material etc.

KU8.     know , how to identify various types of waste products

KU9.     understand the impact of waste/ dirt/ dust/unwanted substances on the process/ environment/ machinery/ human body

KU10. have knowledge of best ways of cleaning & waste disposal

KU11. understand the importance of standardization in processes

KU12. understand the importance of sustainability in 5S

KU13. have knowledge of TQM process

KU14. have knowledge of various materials and storage norms

KU15. understand visual controls, symbols, graphs etc.

Generic Skills (GS)

User/individual on the job needs to know how to:

GS1.     write basic level notes and observations

GS2.     note down observations (if any) related to the process

GS3.     read 5S instructions put up across the plant premises

GS4.     effectively communicate information to team members inform employees in the plant and concerned functions about 5S

GS5.     question the process head in order to understand the 5S related issues

GS6.     attentively listen with full attention and comprehend the information given by the speaker during 5S training programs

GS7.     use common sense and make judgments during day to day basis

GS8.             use reasoning skills to identify and resolve basic problems using 5S

GS9.             persuade co team members to follow 5 S

GS10. ensure that the co team members understand the importance of using 5 S tool

GS11. use innovative skills to perform and manage 5 S activities at the work desk and the shop floor

GS12. exhibit inquisitive behaviour to seek feedback and question on the existing set patterns of work

GS13. do what is right, not what is a popular practices

GS14. follow shop floor rules& regulations and avoid deviations; make 5S an integral way of life

GS15. ensure self-cleanliness on a daily basis

GS16. demonstrate the will to keep the work area in a clean and orderly manner

Support in cleaning the slag from the furnace:

Elements and Performance Criteria

Clean and Lubricate the Die

To be competent, the user/individual on the job must be able to:

PC1..    inspect the die after casting operations for left over metal or other impurities

PC2..    load the die into cleaning tank with chemicals or manually spray the cleaning agents like caustic solution etc; use chippers or spatulas to remove spatters etc. from die (if required)

PC3. . lubricate the dies with oil/ grease in order to prepare it for the next cycle of casting operations

PC4. . in case of automatic cleaning, adjustable cleaning times are preset and dies are left to be cleaned and lubricated automatically

PC5. . examine dies to ensure they are clean, smooth, and coated as per the specification/ visual sample to be used for next set of operations

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.     relevant standards and procedures followed in the company

KU2.     different types of products manufactured by the company

KU3.     functional processes like Procurement, Store management, inventory management, quality management and key contact points for query resolution

KU4.     quality norms prescribed by the organization for casting jobs

KU5.     latest cleaning and lubricating agents and chemicals

KU6.     different types of casting processes and associated equipment

KU7.     different parameters pertinent to casting process like Temperature etc.

KU8.     measuring instruments like verniercaliper, micrometer

KU9.     geometry and dimensions

KU10. sketches and engineering drawings

KU11. safety precautions to be taken for all types of casting activities especially while handling hot

, caustic solutions etc.

KU12. mechanical/ heat laws and working of casting machines etc.

Generic Skills (GS)

User/individual on the job needs to know how to:

GS1.     document information from the sketches and engineering drawings

GS2.     write drawings to internal customers on the requirement of cleaning and lubricating agents, etc.

GS3.     note measurements, equipment panel readings for various process parameters in the required reporting formats

GS4.     read and interpret engineering drawing and sketches

GS5.     read equipment manuals and process documents to understand the equipment and processes better

GS6.     read instructions (e.g. safety instructions) with symbols while using the equipment in the plant area

GS7.     read internal drawings sent by internal customers ( other functions within the organization)

GS8.     discuss task lists, schedules, and work-loads with co-workers

GS9.     question internal customers/ Casting shop supervisor appropriately in order to understand the nature of the problem and make a diagnosis

GS10. plan and organize the work order and jobs received from the internal customers

GS11. plan and organize the design documents received from internal customers

GS12. organize all process/ equipment manuals so that sorting out information is without much time delay

GS13. organize apparatus etc. in an orderly manner at designated areas

GS14. understand the requirement of different types of cleaning and lubricating agents for different types of dies

GS15. finalize the optimum levels of physical parameters so that the job output meets the prescribed job standards, visual samples

GS16. think through the problem, evaluate the possible solution and suggest the best possible solution to the problem

GS17. identify immediate or temporary solutions to resolve delays

Clean and lubricating the dies:

Elements and Performance Criteria

Pour the metal

To be competent, the user/individual on the job must be able to:

PC1. . pull the molten metal from holding furnace with the use of tools like spatulas etc.

PC2..    pour the metal into casting while adhering to the standards pertinent tovarious parameters like speed, angle, temperature etc

PC3. . hand over the cast to the operator for performing casting operations

Conduct the actual casting process

To be competent, the user/individual on the job must be able to:

PC4. . unload the cast from die

PC5..    stamp the cast with the identifying information (wherever required) and send the same for further processing

PC6..    clearly understanding the does and donts of the manufacturing process as defined in SOPs/ work instructions or defined by supervisors

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.     relevant standards and procedures followed in the company

KU2.     different types of products manufactured by the company

KU3.     functional processes like Procurement, Store management, inventory management, quality management and key contact points for query resolution

KU4.     quality norms prescribed by the organization for casting jobs

KU5.     different types of casting processes and associated equipment

KU6.     different parameters pertinent to casting process like Temperature, etc.

KU7.     measuring instruments like verniercalipers, micrometer and other measurement systems

KU8.     geometry and dimensions

KU9.     sketches and engineering drawings

KU10. safety precautions to be taken for all types of casting activities

KU11. mechanical, heat laws and working of casting machines etc.

Generic Skills (GS)

User/individual on the job needs to know how to:

GS1.     document, interpret information from the sketches and engineering drawings

GS2.     note measurements, equipment panel readings for various process parameters in the required reporting formats

GS3.     read and interpret engineering drawing and sketches

GS4.     read equipment manuals and process documents to understand theequipment and processes better

GS5.     read safety instructions especially symbols while using the equipment in the plant area

GS6.     discuss task lists, schedules, and work-loads with co-workers

GS7.     question internal customers/ Casting shop supervisor in order to understand the nature of the problem and make a diagnosis

GS8.     organize all process/ equipment manuals so that sorting out information is fast

GS9.             organize apparatus etc in an orderly manner at proper designated areas

GS10. visualize the final job product after understanding the given drawing/ sketches

GS11. think through the problem, evaluate the possible solution and suggest the best possible solution to the problem

Assessment Guidelines:

1. Criteria for assessment for each Qualification Pack will be created by the Sector Skill Council. Each Element/ Performance Criteria (PC) will be assigned marks proportional to its importance in NOS. SSC will also lay down proportion of marks for Theory and Skills Practical for each Element/ PC.

• The assessment for the theory part will be based on knowledge bank of questions created by the SSC.

• Assessment will be conducted for all compulsory NOS, and where applicable, on the selected elective/option NOS/set of NOS.

• Individual assessment agencies will create unique question papers for theory part for each candidate at each examination/training center (as per assessment criteria below).

• Individual assessment agencies will create unique evaluations for skill practical for every student at each examination/ training center based on these criteria.

• To pass the Qualification Pack assessment, every trainee should score the Recommended Pass % aggregate for the QP.

In case of unsuccessful completion, the trainee may seek reassessment on the Qualification Pack