Free Aerospace Lab Technician NDT course (4 months)

 Aerospace Lab Technician NDT:

Brief Job Description: Aerospace Lab Technician is responsible for understanding the

work instruction / laboratory test procedures, NDT requirements, technical support

to junior staff, control the work instruction, Laboratory Test Procedures (LTP),

Technique sheet required for carrying out the NDT inspection for metallic and composite strutcures.

Personal Attributes: Good eye sight, write basic level notes and observations,

read & comprehend Aerospace Lab Technician NDT documents and notes, process documentation & control plan,

interpret/ comprehend the information given in the document & notes and

read & interpret symbols given on equipment and work area.

Carry out pre-inspection activities as per aerospace standards:-

Performance Criteria:

Understanding of NDT requirements:

PC1. read the regulatory standard for the type of NDT test to be carried out

PC2. check the calibration certificate of NDT equipment

PC3. read the process layout and the drawings, and understand to find

out the NDT Aerospace Lab Technician NDT method and requirements

PC4. follow the meaning of terms in regulatory standard and develop ability

to translate the concepts in to practice Aerospace Lab Technician NDT

PC5. Understand the basic consumables which are used in NDT and their importance in Inspection process like

(i) Magnetic particle ink (fluorescent, visible)- with material certificate from

manufacturer and conform requirements of ASTM-1444, AMS2641 & AMS3044.

(ii) Penetrant system = dye penetrant ink (fluorescent), emulsifier, developer

(penetrant system as Aerospace Lab Technician NDT per listed in QPL-AMS-2644, also consist of a family,

furnished by one manufacturer only), pre cleaner and post cleaner

(iii) X-Ray – Industrial X-Ray film Fuji/ Kodak / Agfa makefilm; X-Ray

FilmFixture; X-Ray film developer, density film Aerospace Lab Technician NDT

PC6. Understand the supporting instruments used during testing of NDT Like

(i) Magnetic Particle Aerospace Lab Technician NDT Testing -Gauss Meter, Black Light Meter.

(ii)Penetrant Testing – Light Intensity Meter, Dry Developer fluorescent specks check block.

(iii) Eddy Current Testing – Probe safety tape Aerospace Lab Technician NDT

(iv) Radiography Testing – densitometer, radiation survey meter, illuminator.

Plan to observe/record the inspection results Aerospace Lab Technician NDT :

PC8. prepare a template to record the inspection results as per organisation procedure

PC9. assess possibility for type of results under supervision of NDT inspector

PC10. record the deviations from acceptance standard as mentioned in process layout/drawing/work instruction PC11. avail special tools and equipment from stores if required Aerospace Lab Technician NDT

Knowledge and Understanding:

Organisational  context

KA1. relevant standards and procedures followed in the company

KA2. different types of products manufactured by the company Aerospace Lab Technician NDT

KA3. different types of method/ equipment/ consumables/ standard block available

KA4. process flow in the organisation Aerospace Lab Technician NDT

Technical

Knowledge (Aerospace Lab Technician NDT )

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

KB2. different types of NDT method and process Aerospace Lab Technician NDT

KB3. different types of national/ international standard used in the process and their identification

KB4. basic fundamentals of NDT, Quality and Aerospace systems Aerospace Lab Technician NDT

KB5. how to read standards and specifications to create the system as designed in the documents. Knowledge in the interpretation of standards and guidelines Aerospace Lab Technician NDT

KB6. knowledge of all functions of NDT inspector Aerospace Lab Technician NDT

KB7. basic principle of NDT, material science, electronics & electrical and metallurgy Aerospace Lab Technician NDT

KB8. basic principle of 5S for maintaining hygiene at workplace Aerospace Lab Technician NDT

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 Aerospace Lab Technician NDT Reading Skills The user/individual on the job needs to know and understand how to: SA3. read and comprehend documents and notes, process documentation & control plan SA4. interpret/ comprehend the information given in the document & notes SA5. read & interpret symbols given on equipment and work area SA6. read machine drawings/ engineering drawings, sketches etc.   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 Aerospace Lab Technician NDT SA9. discuss with 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 Decision Making The user/individual on the job needs to know and understand how to: SB1. judge when to ask help from supervisor SB2. suggest options to operators in case of any issue are observed during operation   Plan and Organise The user/individual on the job needs to know and understand: SB3. plan work assigned on a daily basis and provides estimates of time required for each piece of work   Customer centricity The user/individual on the job needs to know and understand: SB4. ensure that customer need are assessed and every effort is made to provide satisfactory service   Problem Solving The user/individual on the job needs to know and understand: SB5. recognise a work place problem or a potential problem and take action SB6. determine problems needing priority action Aerospace Lab Technician NDT SB7. gather information and provide assistance as required to solve problems SB8. refer problems outside area of responsibility to approach person 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 The user/individual on the job needs to know and understand how to: SB10. analyse, evaluate and apply information gathered from observation, experience, reasoning or communication to act efficiently Aerospace Lab Technician NDT     Carry out Non Destructive Testing as per aerospace standards Performance Criteria   Perform NDT Inspection   PC1. adhere to processes and procedures related to health and safety laid out by organisation PC2. interpret the NDT method mentioned in drawing, process layout and identify the respective work instruction/ LTP/ Technique Sheet PC3. review test orders to determine the type of requested tests, procedures to be followed and Aerospace Lab Technician NDT criteria for part acceptability. PC4. ensure power cables, tools and equipment are in usable condition PC5. ensure all test and measuring equipment are within the caliberated date and approved for usage PC6. carry out the control checks (under the supervision of NDT inspector) with standard block (in case of Liquid Penetrant Test (LPT) and Magnetic Particle Test (MPT)) and perform machine calibration of UT and ET with respective standard block and/or in case of RT or UT calculate the current, time, exposure, kW before to carry out inspection PC7. use proper safety items as required by respective test method like gloves, mask, googles etc. PC8. ensure and confirm the satisfactory system/machine performance under supervision of NDT inspector PC9. record the system/machine performance as per organisation standards PC10. perform pre-cleaning of the job with respective consumables PC11. perform visual inspection of each job after pre-cleaning to confirm the job is free from any damage or external crack Aerospace Lab Technician NDT PC12. carry out inspection process on each NDT method as per LTP/ Work Instruction under the supervision of NDT inspector Aerospace Lab Technician NDT   Observe/record the inspection results   PC13. record and document all the inspection results as per organisation procedure PC14. undertake assessment of results under supervision of NDT inspector PC15. record the deviations from the standards accepted PC16. interpret the severity and consequence of deviations (if occur/exist) from acceptance standard as mentioned in process layout/ drawing/ work instruction/ LTP PC17. record and document the Aerospace Lab Technician NDT deviations as per organisation procedures PC18. maintain tools and Aerospace Lab Technician NDT equipment are in safe condition for next test   Knowledge and Understanding     Organisational context   KA5. relevant standards Aerospace Lab Technician NDT and procedures followed in the company KA6. different types of products manufactured by the company KA7. different types of method/ equipment/ consumables/ standard block available KA8. process flow in the organisatio   Technical Knowledge   KB9. different types of NDT methods Aerospace Lab Technician NDT and process like acoustic emission, electromagnetic, leak, liquid penetrant, magnetic particle, neutron radiographic, radiographic, thermal or infrared, ultrasonic, vibration analysis and visual testing KB10. different types of national/ international standard used in the process and their identification KB11. basic fundamentals of NDT, Quality and Aerospace systems KB12. how to read standards and specifications to create the system as designed in the documents. Knowledge in the interpretation of standards and guidelines KB13. knowledge of all Aerospace Lab Technician NDT functions of NDT inspector KB14. documentation of non-destructive testing (NDT) methods and processes or results. KB15. six sigma tools and quality measurement metrics. KB16. basic principle of 5S for maintaining hygiene at workplace.     Core Skills/ Generic Skills   Writing Skills The user/ individual on the job needs to know and understand how to: SA3. write basic level notes and observations SA4. draw basic level geometrical/ mechanical drawings and charts Reading Skills The user/individual on the job needs to know and understand how to: SA7. read and comprehend documents and notes, process documentation & control plan SA8. interpret/ comprehend the information given in the document & notes SA9. read & interpret symbols given on equipment and work area SA10. read machine drawings/ engineering drawings, sketches etc.   Oral Communication (Listening and Speaking skills) The user/individual on the job needs to know and understand how to: SA11. discuss task lists and job requirements with co-workers SA12. effectively communicate information to team members SA13. discuss with supervisor in order to understand the nature of the problem SA14. attentively listen with full attention and comprehend the information given by the speaker     Professional Skills Decision Making The user/individual on the job needs to know and understand how to: SB11. judge when to ask help from supervisor SB12. suggest options to operators in case of any issue are observed during operation   Plan and Organise The user/individual on the job needs to know and understand: SB13. plan work assigned on a daily basis and provides estimates of time required for each piece of work   Customer centricity The user/individual on the job needs to know and understand: SB14. ensure that customer need are assessed and every effort is made to provide satisfactory service   Problem Solving The user/individual on the job needs to know and understand: SB15. recognise a work place problem or a potential problem and take action SB16. determine problems needing priority action SB17. gather information and provide assistance as required to solve problems SB18. refer problems outside area of responsibility to approach person Analytical Skills The user/individual on the job needs to know and understand how to: SB19. 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: SB20. analyse, evaluate and apply information gathered from observation, experience, reasoning or communication to act efficiently     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 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 dealing 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   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 areaPC9. follow the floor markings/ area markings used for demarcating the various sections in the plan t as per the prescribed instructions and standards   Ensure proper documentation and storage (organising, streamlining)     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   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. seek 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   Core Skills/ Generic Skills   Writing Skills On the job the individual needs to be able to: SA1. complete documentati on 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       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.