Free Aerospace Conventional Machinist course (6 months)

 Aerospace Conventional Machinist:

Brief Job Description: This role primarily involves precision machining activities on various conventional machines such as carrying out all pre & post machining operations including self inspection and gauging as per work instructions / standard operating procedures.

Personal Attributes: The individual should have basic communication ability and should be responsible in order to maintain procedures. He should possess numerical and computational abilities. Openness to learning, ability to plan and organise own work and identify and solve problems in the course of working. Understanding the need to take initiative and manage self and work to improve efficiency and effectiveness.

Perform pre-machining activities (conventional) of parts used on an aircraft:-

Performance Criteria

Understanding the component requirements

PC1. obtain permission from the shop supervisor for using specific machine before starting the machining operations

PC2. follow the instructions related to specific machine for performing the operations

PC3. check the calibration certificate of the machine to be used

PC4. understand the output product requirement by reading the engineering drawing specified in the work instructions/ work order

PC5. reading the control panel instructions/ job orders to determine the correct output product specifications

PC6. understanding the tooling instructions (fixtures, cutting tools, jigs etc.) as specified in the Operating Manual (OM)/ Work Instructions (WI) or Standard Operating Procedures (SOP)

PC7. selection of proper coolant and lubricant required for machining the required component

PC8. set up, adjust, or operate basic or specialised machine tools used to perform precision machining operations.

PC9. operate equipment to verify operational efficiency

Checking the dimensions for the component

PC10. set the machine stops or guides or programmes as per the specified lengths indicated through scales or work instructions

PC11. measure and mark reference points/ cutting lines on the work parts, using compasses, callipers, rulers and other measuring tools

PC12. understand acceptance requirements/ limits of machining e.g. surface finish, specific orientation, gauge inspection etc.

PC13. understand any other specific requirement for machining

PC14. measure and hold the job with proper jigs and fixtures to a particular machine as the machining bed

Knowledge and Understanding

Organisational Context

KA1. relevant standards and procedures followed in the company

KA2. different types of products manufactured by the company

KA3. different types of machining processes/ tools available

Technical Knowledge

KB1. aerospace manufacturing standard and procedures such as ISO 9001, AS9100, etc

KB2. aerospace manufacturing standard and procedure

KB3. different types of machining processes

KB4. basic fundamentals of machines and mechanics

KB5. different types of tools used in the machining process with respect to type of process to be conducted

KB6. basic principles of 5S in manufacturing

KB7. the application of coolant and lubricants

KB8. impact of various machining processes on the final product outcome

KB9. basic arithmetic and calculation methods for tolerance limits

KB10. safety guidelines related to different machines.

Skills

Core Skills/ Generic Skills

Writing skills

The user/ individual on the job needs to know and understand how to: SA1. write basic level notes and observations SA2. draw basic level geometrical/ mechanical drawings and charts

Reading skills

The user/individual on the job needs to know and understand how to: SA3. read and interpret workplace related documentation SA4. read and interpret engineering drawings and sketches to understand the dimension of the output product

Oral Communication (Listening and Speaking skills)

The user/individual on the job needs to know and understand how to: SA5. discuss task lists and job requirements with co-workers SA6. effectively communicate information to team members SA7. discuss with supervisor in order to understand the nature of the problem SA8. attentively listen with full attention and comprehend the information given by the speaker Professional Skills Plan and Organise The user/individual on the job needs to know and understand how to: SB1. persuade team members to wear the personal protective equipment as per the requirement SB2. ensure that the team understands the importance of using various machines/equipment without creating any risk to human/machine   Critical thinking The user/individual on the job needs to know and understand how to: SB3. analyse, evaluate and apply information gathered from observation, experience, reasoning or communication to act efficiently   Problem Solving The user/individual on the job needs to know and understand how to: SB4. recognise a work place problem or a potential problem and take action SB5. determine problems needing priority action SB6. gather information and provide assistance as required to solve problems SB7. refer problems outside area of responsibility to approach person SB8. make decisions in emergency conditions in case of supervisor are not available. Analytical Skills The user/individual on the job needs to know and understand how to: SB9. analyse best possible solutions (cost, time, effort, etc.) suited for operations   Critical Thinking Skills The user/individual on the job needs to know and understand how to: SB10. concentrate on task at hand and complete it without errors SB11. apply balanced judgments to different situa   Perform various conventional machining operations of parts used on an aircraft Performance Criteria   Setting up machine as per work instructions   PC1. check the drawing issue (in route/ book card) and ensure that the latest issue/ version is being used PC2. check the calibration certificate of machines before using the same PC3. study the set-up sheet , drawing, route-card of the component to be machined. PC4. obtain the relevant cutting tools from the tool crib and verify the same. PC5. check the coolant and oil levels and inform maintenance department to replenish, if required PC6. check the centring and orientation of the work parts and check for alignment of the work parts as per instructions PC7. collect the checking gauges and measuring instruments as per drawing and check calibration certificate of the same PC8. ensure all covers and safety guards of machine are in position PC9. select the right cutting tool as per tooling instructions and as per work/ supervisor’s instruction PC10. check regularly for the tool bluntness, edge built up and chip off of tool cutting edges PC11. clearly understand the dos and don’ts of the manufacturing process as defined in SOP/ work instructions or defined by supervisors   Perform machining on the component   PC12. Study the drawing , read and interpret the instructions at the start of the machine, and accordingly establish the datum by using dial indicator/ slip gauges etc. PC13. check centre height of all the cutting tools/holder corresponding to the tool mentioned in the process sheet PC14. select the right cutting tool as per tooling instructions and as per work/ supervisor’s instruction PC15. carry out the machining operation as per the theoretical speeds and feeds, coolant on/ off commands etc. depending upon the cutting action noticed, use speed and feed override switch to fine tune the speed and feed, coolant on/ off switch to get smooth cutting and good finish PC16. ensure all the measurable dimensions before offloading the part from fixture PC17. offload the machined part from the work table by using proper material handing device or by hand for small parts   Observe/ Record the machining operations   PC18. observe machine operations to detect defects in the component manufactured PC19. observe the machine operations for any malfunctions and immediately inform the supervisor/ maintenance team of any malfunction observed to prevent damage to the machine or component PC20. ensure tool replacement as per recommended tool life or as and when cutting edges become dull PC21. ensure reading of key dimensions; provide tool offsetting with the help of supervisor   Knowledge and Understanding   Organisational Context KA1. relevant standards and procedures followed in the company KA2. different types of products manufactured by the company KA3. different types of machining processes/ tools available KA4. process flow/ routing of various components in the machine shop/ organisation   Technical Knowledge KB1. aerospace manufacturing standard and procedures such as ISO 9001, AS9100, etc KB2. different types of machining processes KB3. different types of tools used in the machining process and their identification KB4. basic fundamentals of machines and mechanics KB5. how to read machine drawing and machining the part to create the output as defined in the machine drawing KB6. knowledge of metal properties/ metallurgy KB7. knowledge of minor maintenance as per checklist KB8. basic principles of 5S in manufacturing KB9. the application of coolants and lubricants KB10. basic arithmetic and calculation methods for tolerance limits. KB11. basic knowledge on six sigma tools   Skills   Core Skills/ Generic Skills Writing skills The user/ individual on the job needs to know and understand how to: SA1. write basic level notes and observations SA2. draw basic level drawings and charts Reading skills The user/individual on the job needs to know and understand how to: SA3. read & comprehend documents and notes, process documentation & Control Plan SA4. interpret/ comprehend the information given in the documents and notes SA5. read and interpret symbols given on equipment and work area SA6. read machine drawings/ engineering drawings, sketches Oral Communication (Listening and Speaking skills) The user/individual on the job needs to know and understand how to: SA7. discuss task lists and job requirements with co-workers SA8. effectively communicate information to team members SA9. question supervisor in order to understand the nature of the problem SA10. attentively listen with full attention and comprehend the information given by the speaker   Professional Skills   Plan and Organise     The user/individual on the jo b needs to know and understand how to: SB1. persuade team members to wear the personal protective equipment as per the requirement SB2. ensure that the team understands the importance of using various machines/equipment without creating any risk to human/machine     Critical Thinking The user/individual on the job needs to know and understand: SB3. analyse, evaluate and apply information gathered from observation, experience, reasoning or communication to act efficiently   Problem solving The user/individual on the job needs to know and understand how to: SB4. recognise a work place problem or a potential problem and take action SB5. determine problems needing priority action SB6. gather information and provide assistance as required to solve problems SB7. refer problems outside area of responsibility to approach person SB8. make decisions in emergency conditions in case of supervisor are not available.   Analytical Skills The user/individual on the job needs to know and understand how to: SB9. analyse best possible solutions (cost, time, effort, etc.) suited for operations   Critical Thinking Skills The user/individual on the job needs to know and understand how to: SB10. concentrate on task at hand and complete it without errors SB11. apply balanced judgments to different situations   Conduct all post machining operations (conventional) of parts used on an aircraft   Performance Criteria   check quality of machined component   PC1. support the supervisor/ quality officer in measuring the specifications of the finished component and verify conformance as per work order/ instructions and drawing. PC2. use devices like micrometers, vernier calipers, gauges, rulers and any other inspection equipment for measuring specifications with valid calibration status. PC3. support the supervisor/ quality officer in noting down the observations of the basic inspection process and identify parts which comply with the specified standards PC4. separate the defective parts into two categories – parts which can be repaired/ modified and parts which are beyond repair and maintain records of each category. In case of rejection, it must be informed to the supervisor / quality officer. PC5. dispose of scrap or waste material in accordance with company policies and environmental regulations.   Knowledge and Understanding Organisational Context   KA1. relevant standards and procedures followed in the company KA2. different types of products manufactured by the company   Technical Knowledge   KB1. aerospace manufacturing standard and procedures KB2. different types of machining processes KB3. basic fundamentals of machines and mechanics KB4. different types of tools used in the machining process with respect to type of process to be conducted KB5. basic principles of 5S in manufacturing KB6. application of coolant and lubricants KB7. Impact of various machining processes on the final product outcome KB8. basic arithmetic and calculation methods for tolerance limits KB9. safety guidelines related to different machines   Skills     Core Skills/ Generic Writing skills The user/ individual on the job needs to know and understand how to: SA1. write basic level notes and observations SA2. draw basic level drawings and charts Reading skills The user/individual on the job needs to know and understand how to: SA3. read documents and notes SA4. interpret/ comprehend the information given in the documents and notes SA5. read and interpret symbols given on equipment and work area Oral Communication (Listening and Speaking skills) The user/individual on the job needs to know and understand how to: SA6. discuss task lists and job requirements with co-workers SA7. effectively communicate information to team members SA8. question operator/ supervisor in order to understand the nature of the problem SA9. attentively listen with full attention and comprehend the information given by the speaker     Professional Skills   Plan and Organise   The user/individual on the job needs to know and understand how to: SB1. persuade team members to wear the personal protective equipment as per the requirement SB2. ensure that the team understands the importance of using various machines/ equipment without creating any risk to human/ machine     Critical Thinking   The user/individual on the job needs to know and understand: SB3. analyse, evaluate and apply information gathered from observation, experience, reasoning or communication to act efficiently     Problem Solving   SB4. recognise a work place problem or a potential problem and take action SB5. determine problems needing priority action SB6. gather information and provide assistance as required to solve problems SB7. refer problems outside area of responsibility to approach person SB8. make decisions in emergency conditions in case of supervisor are not available     Analytical Skills   The user/individual on the job needs to know and understand how to: SB9. analyse best possible solutions (cost, time, effort, etc.) suited for operations     Critical Thinking Skills   The user/individual on the job needs to know and understand how to: SB10.concentrate on task at hand and complete it without errors SB11. apply balanced judgments to different situations       organisation safety and security procedures   Performance Criteria   Comprehending the safety and security procedures   PC1. comply with the organisation’s safety and security policies and procedures PC2. comply with the regulatory guidelines on safe conduct of operations and maintenance of conditions to thwart any acts of unlawful interference PC3. report any identified breaches of safety and security policies and procedures to the designated person PC4. report any theft of organisation property according to the organisation policy PC5. coordinate with other resources at the workplace (within and outside the organisation) to achieve a safe and secure environment PC6. identify and mitigate any safety and security hazards like illness, accidents, fires or acts of unlawful interference if it falls within the limits of the individual’s authority PC7. report any hazards outside the individual’s authority to the relevant person in line with organisational procedures and regulatory guidelines PC8. follow the organisation’s emergency procedures for accidents, fires or acts of unlawful interference PC9. identify and recommend opportunities for improving health, safety, and security to the designated person PC10. ensure that all health and safety records are updated and procedures are well defined   Knowledge and Understanding   Organisational   Context   KA1. hazard identification and risk management as defined within the organisational policy and procedures KA2. legislative requirements and organisation’s procedures for maintenance of safety and security standards and individual’s role and responsibilities in relation to this KA3. how and when to report hazards KA4. the limits of responsibility for dealin g with hazards KA5. the organisation’s emergency procedures for different emergency situations and the importance of following these KA6. the importance of maintaining high standards of safety and security KA7. implications that any non-compliance with safety and security may have on individuals and the organisation   Technical Knowledge   KB1. different types of breaches of safety and security and how and when to report these KB2. evacuation procedures for workers KB3. how to summon medical assistance and the emergency services, where necessary KB4. how to use the health, safety and accident reporting procedures and the importance of these KB5. regulatory guidelines on dealing with safety and security emergencies     Skills   Core Skills/ Generic Skills Writing Skills The user/ individual on the job needs to know and understand how to: SA1. complete accurate, well written report in English language detailing the situations of emergency with attention to detail   Reading Skills The user/individual on the job needs to know and understand how to: SA2. read instructions, guidelines/procedures/rules   Oral Communication (Listening and Speaking skills) The user/individual on the job needs to know and understand how to: SA3. listen to and orally communicate information with all concerned     Professional Skills Decision Making The user/individual on the job needs to know and understand how to: SB1. make decisions on a suitable course of action or response if permitted by the authority matrix   Plan and Organise The user/individual on the job needs to know and understand how to: SB2. monitor efficient functioning of all activities SB3. plan and organise work to achieve targets and deadlines   Customer Centricity The user/individual on the job needs to know and understand how to: SB4 . communicate with customers in a courteous manner SB5. maintain effective relationship with the customers   Problem Solving The user/individual on the job needs to know and understand how to: SB6. identify trends/common causes for errors and suggest possible solutions to the supervisor / management SB7. identify and correct errors Analytical Thinking The user/individual on the job needs to know and understand how to: SB8. analyse best possible solutions (cost, time, effort, etc) suited for operations   Critical Thinking The user/individual on the job needs to know and understand how to: SB9. concentrate on task at hand and complete it without errors SB10. apply balanced judgments to different situations     Maintain 5S at the work premises   Performance Criteria   Ensure sorting PC1. follow the sorting process and check that thetools, fixtures & jigs that are lying on workstations are the ones in use and un- necessary itemsare 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 labeled 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   Ensure proper documentation and storage PC10. Follow the proper labeling mechanism of instruments/ boxes/ containers and maintaining reference files/ documents with the codes and the lists PC11. Check that the items in the respective areas have been identified as broken or damaged PC12. follow the given instructions and check for labeling 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   Ensure cleaning of self and the work place 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 good condition 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 PC22. follow the daily cleaning standards and schedules to create a clean working environment PC23. attend all training programs for employees on 5S PC24. support the team during the audit of 5S 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   Organisational Context KA1. relevant standards, procedures and policies related to 5S followed in the company   Technical Knowledge KB1. have basic knowledge of 5S procedures KB2. know various types 5s practices followed in various areas KB3. understand the 5S checklists provided in the department/ team KB4. have skills to identify useful & non useful items KB5. have knowledge of labels , signs & colours used as indicators KB6. Have knowledge on how to sort and store various types of tools, equipment, material etc. KB7. know , how to identify various types of waste products KB8. understand the impact of waste/ dirt/ dust/unwanted substances on the process/ environment/ machinery/ human body KB9. have knowledge of best ways of cleaning & waste disposal KB10. understand the importance of standardisation in processes KB11. understand the importance of sustainability in 5S KB12. have knowledge of TQM process KB13. have knowledge of various materials and storage norms KB14. understand visual controls, symbols, graphs etc.   Skills   Core Skills/ Generic Skills Writing Skills The user/ individual on the job needs to know and understand how to: SA1. write basic level notes and observations SA2. note down observations (if any) related to the process SA3. write information documents to internal departments/ internal teams Reading Skills The user/individual on the job needs to know and understand how to: SA4. read 5S instructions put up across the plant premises Oral Communication (Listening and Speaking skills) The user/individual on the job needs to know and understand how to: SA5. effectively communicate information to team members inform employees in the plant and concerned functions about 5S SA6. question the process head in order to understand the 5S related issues SA7. attentively listen with full attention and comprehend the information given by the speaker during 5S training programs   Professional Skills Judgmental Thinking The user/individual on the job needs to know and understand how to: SB1. use common sense and make judgments during day to day basis SB2. use reasoning skills to identify and resolve basic problems using 5S Persuasion The user/ individual on the jobs needs to know and understand how to: SB3. persuade co team members to follow 5 S SB4. ensure that the co team members understand the importance of using 5S tool Creativity The user/individual on the job needs to know and understand how to : SB5. use innovative skills to perform and manage 5S activities at the work desk and the shop floor SB6. exhibit inquisitive behaviour to seek feedback and question on the existing set patterns of work Self –Discipline The user/individual on the job needs to know and understand how to: SB7. do what is right, not what is a popular practices SB8. follow shop floor rules & regulations and avoid deviations; make 5S an integral way of life SB11. ensure self-cleanliness on a daily basis SB12. demonstrate the will to keep the work area in a clean and orderly manner     Work effectively in a team Performance Criteria   Support the work team PC1. display courteous and helpful behaviour at all times PC2. take opportunities to enhance the level of assistance offered to colleagues PC3. meet all reasonable requests for assistance within acceptable workplace timeframes PC4. complete allocated tasks as assigned PC5. see k assistance when difficulties arise PC6. use questioning techniques to clarify instructions or responsibilities, PC7. identify and display a non-discriminatory attitude in all contacts with customers and other staff members   Maintain personal presentation PC8. observe appropriate dress code and presentation as required by the workplace, job role and level of customer contact PC9. follow personal hygiene procedures according to organisational policy   Develop effective work habits PC10. interpret, confirm and act on workplace information, instructions and procedures relevant to the particular task PC11. interpret, confirm and act on legal requirements with regards to anti- discrimination, sexual harassment and bullying PC12. ask questions to seek and clarify workplace information PC13. plan and organise daily work routine within the scope of the job role PC14. prioritise and complete tasks according to required timeframes PC15. identify work and personal priorities and achieve a balance between competing priorities   Knowledge and Understanding   Organisational Context KA1. policies and procedures relating to the job role KA2. the value system of the organisation KA3. employee rights and obligations   Technical Knowledge KB1. ask questions to identify and confirm requirements KB2. follow routine instructions through clear and direct communication KB3. use language and concepts appropriate to cultural differences KB4. use and interpret non-verbal communication KB5. the scope of information or materials required within the parameters of the job role KB6. consequences of poor team participation on job outcomes KB7. work health and safety requirements   Skills   Core Skills/ Generic Skills Writing Skills On the job the individual needs to be able to: SA1. complete documentation accurately SA2. write simple reports when required Reading Skills On the job the individual needs to be able to: SA3. read information accurately SA4. read and interpret data sheets Oral Communication (Listening and Speaking skills) The user/individual on the job needs to know and understand how to: SA5. listen to and orally communicate information with all concerned   Professional Skills   Decision Making   On the job the individual needs to be able to: SB1. make appropriate decisions regarding the responsibilities of the job role   Plan and Organise   The user/individual on the job needs to know and understand how to: SB2. monitor efficient functioning of all activities SB3. plan and organise work to achieve targets and deadlines   Customer Centricity   The user/individual on the job needs to know and understand how to: SB4. communicate with customers and other stakeholders in a courteous manner SB5. maintain effective work relationship Problem Solving   The user/individual on the job needs to know and understand how to: SB6. identify trends/common causes for errors and suggest possible solutions to the supervisor / management SB7. identify and correct errors   Analytical Thinking   The user/individual on the job needs to know and understand how to: SB8. analyse best possible solutions (cost, time, effort, etc.) suited for operations   Critical Thinking   The user/individual on the job needs to know and understand how to: SB9. concentrate on task at hand and complete it without errors SB10. apply balanced judgments to different situations   Problem Solving   The user/individual on the job needs to know and understand how to: SB6. identify trends/common causes for errors and suggest possible solutions to the supervisor / management SB7. identify and correct errors   Analytical Thinking   The user/individual on the job needs to know and understand how to: SB8. analyse best possible solutions (cost, time, effort, etc.) suited for operations   Critical Thinking   The user/individual on the job needs to know and understand how to: SB9. concentrate on task at hand and complete it without errors SB10. apply balanced judgments to different situations     Guidelines for Assessment 1. Criteria for assessment for each Qualification Pack will be created by the Sector Skill Council. Each 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 PC. 2. The assessment for the theory part will be based on knowledge bank of questions created by the SSC. 3. Assessment will be conducted for all compulsory NOS, and where applicable, on the selected elective/option NOS/set of NOS. 4. Individual assessment agencies will create unique question papers for theory part for each candidate at each examination/training center (as per assessment criteria below). 5. Individual assessment agencies will create unique evaluations for skill practical for every student at each examination/training center based on this criterion. 6. To pass the Qualification Pack, every trainee should score a minimum of 60% of aggregate marks to successfully clear the assessment. 7. In case of unsuccessful completion, the trainee may seek reassessment on the Qualification Pack.