Free Aerospace Sheet Metal Technician course (4months)

 Aerospace Sheet Metal Technician:

Brief Job Description: Aerospace Sheet Metal Technician is responsible for manufacturing sheet metal components through various processes as per requirements.

Personal Attributes: The individual should have basic communication ability and should be responsible in order to maintain procedures. He should have the ability to understand engineering drawings, do’s and don’ts of metal forming process defined in work instruction or by a shop supervisor.

sheet metal forming operations for aircraft applications:-

Perform sheet metal forming operations:

PC 1. issue required metal of required guage/specification from the stores for performing the forming operation

PC 2. carry out heat treatment operation, if necessary.

PC 3. interpret the component drawing and material specification as mentioned in the route card

PC 4. mark the dimensions required to be formed on the sheet metal as per loft / flat pattern wherever required

PC 5. select appropriate tool for performing the shearing of sheet metal operation such as punching, blanking, perforating, parting, notching and lancing

PC 6. identify the fixtures required to perform the required forming operation

PC 7. ensure the press, punch or ram and set of dies required for operation are in good condition

PC 8. identify the type of forming operations required to achieve the final output

PC 9. perfom the forming operation on a test piece, if necessary

PC 10.compare the output of the test piece with the requirements and note the findings, if any

PC 11. make necessary corrections in the tool or fixtures to remove the discrepancies observed, if any

PC 12. apply the stipulated load on the actual piece gradually till the part geometry is achieved

PC 13. carry out heat treatment operation, if necessary and perform dressing on the sheet metal, if required

PC 14. trim the part using trim and drill jig

PC 15. carry out the visual inspection and check the critical dimensions like contour as per fixture and sheet metal defects like cracks, orange peel and oil canning

PC 16. ensure sheet metal is appropriately stored after use and all the tools returned to stores.

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 sheet metal shop/ organisation

Technical Knowledge

KB1. aerospace manufacturing standard and procedures such as

ISO 9001, AS9100, etc

KB2. different types of sheet metal forming

KB3. forming tools, dies and fixture

KB4. basic fundamentals of machines used for sheet metal forming

KB5. knowledge of sheet metal and heat treatment processes

KB6. basic principles of 5S in manufacturing

KB7. application of coolant and lubricants

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

KB9. basic arithmetic and calculation methods for tolerance limits

KB10. safety guidelines related to different machines

KB11. basic understanding of the 3D models in CAD.

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. listen with full attention and comprehend the information given by the speaker. Professional Skills Problem Solving The user/individual on the job needs to know and understand how to: SB1. judge when to ask for help from a supervisor SB2. suggest options to operators in case any issue is observed during operations Plan and Organise The user/individual on the job needs to know and understand how to: SB3. plan work assigned on a daily basis and provide estimates of time required for each piece of work SB4. prioritise actions to achieve required outcomes   Analytical Skills   The user/individual on the job needs to know and understand how to: SB5. analyse the complexity of work to determine if it can be successfully carried out SB6. visualise the final product from the engineering drawing/ machine drawing, sketch provided by the supervisor SB7. analyse the cause of defects related to e.g. cutting tools, machine, fixtures etc. Desire to learn and take initiatives  The user/individual on the job needs to know and understand how to: SB8. learn from mistakes by analysing and discussing with peers/ seniors SB9. discuss new ideas and participate in new initiatives SB10. follow instructions and work on areas of improvement identified SB11. complete the assigned tasks with minimum supervision SB12. complete the job defined by the supervisor within the timelines and quality norms. 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 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. 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 chec k that thetools, fixtures & jigs that are lying on workstations are the ones in use and unnecessary 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 places and in the manner indicated in the 5S instructions   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 job needs to know and understand how to: SB3. persuade co team members to follow 5S 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 5 S 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 SB9. ensure self-cleanliness on a daily basis SB10. 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 appropri ate 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< br>  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 KA4. the reporting hierarchy and escalation matrix 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     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 .