Free Airline Ground Support Equipment Mechanic course (6months)

 Airline Ground Support Equipment Mechanic:

Airline Ground Support Equipment Mechanic is responsible for maintaining the ground handling systems.

Brief Job Description: Individuals at this job are responsible for maintaining the mechanical systems of equipment and machinery. They use laid down procedures, and knowledge of the equipment to conduct routine maintenance and organize repairs. They are also involved in control and monitoring devices and occasionally in the manufacture of items that will help in maintenance.

Personal Attributes: This job requires the individual to work independently and be judicious in making decisions pertaining to one’s area of work. The individual must be physically fit to be able to maintain unusual working hours.

Safety and security procedures:

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. coordinate with other resources at the workplace (within and outside the organization) to achieve safe and secure environment

PC5. identify and mitigate any safety and security hazards like illness, accidents, fires or acts of unlawful interference if it falls within the limits of individual’s authority

PC6. report any hazards outside the individual’s authority to the relevant person in line with organisational procedures and regulatory guidelines

PC7. follow organisation’s emergency procedures for accidents, fires or acts of unlawful interference

PC8. identify and recommend opportunities for improving health, safety, and security to the designated person

PC9. ensure all health and safety records are updated and procedures well defined

Knowledge and Understanding

Organizational Context

KA1. hazard identification and risk management as defined within the organizational policy and procedures

KA2. regulatory 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. 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 organization

Technical Knowledge

KB1. different types of breaches of safety and security and how and when to report these

KB2. evacuation procedures for workers and passengers

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 accurately 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
Best Ground Handling Equipment Required for Aircraft Usage? | by Aeromax  GSE | Medium
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 Organize
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 passengers and other stakeholders in a courteous manner
SB5. maintain cordial 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
 
 

Airline Ground Support Equipment Mechanic





Cleaning of vehicles
 
Performance Criteria
 
Washing of vehicle
PC 1. start the water pump and check for water supply in the pipe
PC 2. thoroughly wash the external structure of the vehicle like the body, tyres, windshield, rear view mirrors etc. from the running water in pipe in order to clean the settled loose dust and dirt
PC 3. while washing the vehicle with running water, to ensure that water does not enter into components like starter motor, alternator and horn
 
Cleaning of vehicle
PC 4. rub the surfactant on the previously washed external structure properly using a spongy cloth in order to clean the hard-to-remove stains
PC 5. ensure that the stains are not visible on the vehicle after rubbing PC 6. while cleaning the vehicle, to observe and report any loose/
broken/ missing parts like mountings, seals, chassis fasteners
 
Re-washing and wiping
PC 7. after cleaning the vehicle, spray a jet of running water on the surfactant applied parts of vehicle in order to completely wash out the residue deposited on the vehicle
PC 8. while re-washing the vehicle with running water, to ensure that water does not enter into components like starter motor, alternator and horn
PC 9. take a clean wiping cloth and thoroughly wipe the whole vehicle including parts like dashboard, instrument panel, seats, steering wheel, driver console that cannot be surfactant cleaned as it would lead to malfunctioning
 
Knowledge and Understanding
 
Organizational Context
KA1 . point of contact in case of unavailability of surfactant/cloth
KA2 . any applicab le rules and employee code of conduct stated by the organization
Technical Knowledge
KB1. vehicle model and its appearance features which will aid him in cleaning
KB2. type of surfactant and cloth to be used for the cleaning process
Core Skills/ Generic Skills
Communication Skills
The user/ individual on the job needs to know and understand how to:
SA1. execute task of cleaning and escalate and convey areas of concern to driver/supervisor
Teamwork and multitasking
The user/individual on the job needs to know and understand how to:
SA2. clean the various vehicle models in coordination with respective drivers
SA3. share requisite knowledge with newly joined cleaners
 
Professional Skills
Plan and Organize
The user/individual on the job needs to know and understand how to: SB1. plan the cleaning activity so as to complete it in schedule time
 
 
Perform a routine check of basic functioning of vehicle and
 provide assistance to driver in servicing or minor repairs:

Basic technical check before the trip
PC 1. before start of the trip, refer a standard check list available and ensure correct levels of engine oil, coolant, clutch, brake oil, water in wiper washer
PC 2. check all the tyres including spare tyre for inflation with a pressure gauge and ensure correct levels by deflating or inflating suitably
PC 3. check that all lights, wiper and horn are working and report to the Driver/supervisor in case of any malfunctioning
PC 4. check the tool box and ensure availability of all the hand tools including jack, props, wheel choke etc
PC 5. observe all exterior and interior parts of the vehicle for any damages to body panels, lights and wind shield , other glass parts and mirrors.
 


Airline Ground Support Equipment Mechanic




Escalation and assistance in case of technical problem
PC 6. in case of any problem observed in any of the checkpoints, immediately inform the driver/ supervisor


Performance Criteria
 
Basic technical check before the trip
PC 1. before start of the trip, refer a standard check list available and ensure correct levels of engine oil, coolant, clutch, brake oil, water in wiper washer
PC 2. check all the tyres including spare tyre for inflation with a pressure gauge and ensure correct levels by deflating or inflating suitably
PC 3. check that all lights, wiper and horn are working and report to the Driver/supervisor in case of any malfunctioning
PC 4. check the tool box and ensure availability of all the hand tools including jack, props, wheel choke etc
PC 5. observe all exterior and interior parts of the vehicle for any damages to body panels, lights and wind shield , other glass parts and mirrors.
 
Escalation and assistance in case of technical problem
PC 6. in case of any problem observed in any of the checkpoints, immediately inform the driver/ supervisor
PC 7. assist the driver in resolution of problem by providing him the required tools and equipment on the spot and physically lend him a helping hand in doing the strenuous jobs like lifting of vehicle by jack in case of punctured tyre replacement , opening of screws and fixtures for lights , wiper, tyres etc. while repairing and filling the engine /brake/coolant oil and other fluids to ensure optimum levels
 
Knowledge and Understanding
 
Organizational Context
KA1. point of contact to inform in case of any technical deficiencies KA2. documents required for inspection as per government regulations
 
Technical Knowledge
KB1. vehicle model and its various technical features
KB2. operating criteria for all the points mentioned in the checklist
 
Core Skills/ Generic Skills
 
Basic reading and writing Skills
The user/ individual on the job needs to know and understand how to:
SA1. technical standards of vehicle operation in terms of level of engine oil, illumination of various lights, air pressure in tyres etc.
Communication skills
The user/individual on the job needs to know and understand how to:
SA2. follow driver instruction about the rectification guidelines
 
Professional Skills
Reflective Thinking
The user/individual on the job needs to know and understand how to: SB1. how to learn from past mistakes and identify potential problems
 
Assist in the repair and replacement of vehicle body and chassis components
 
Performance Criteria
 
Assist in repair & replacement of vehicle body and chassis components
PC1. assist the senior body technician to assess the overall damage to vehicle body and chassis components
PC2. follow supervisor’s instructions as to which parts to restore or replace with respect to the auto body/ chassis components
PC3. select, calibrate and use the appropriate tools and equipment for the body component/ chassis repair of the vehicle
PC4. remove upholstery, accessories, electrical window-and-seat- operating equipment, and trim to gain access to vehicle bodies and fenders
PC5. cut and tape plastic separating film to outside repair areas to avoid damaging surrounding surfaces during repair procedure, and remove tape and wash surfaces after repairs are complete
PC6. assist in performing repair work under supervision of senior body technician such as:
 body panel repair
 minor structural damage
 major welding panels
 body components using lead wiping
 major sectional repair
 chassis/ frame and associated components
 
PC7. assist in removal and replacement related work under supervision of Senior Body Technician such as:
 vehicle body panels, panel sections and ancillary fittings
 protector mouldings, transfers and decals
 mechanical units/assemblies
 electrical/electronic units/assemblies PC8. install various vehicle component seals PC9. prepare surface and apply window tainting
PC10. file, grind, sand and smooth fill or repair surfaces, using power tools and hand tools
PC11. assist in clamping frames and sections to alignment machines that use hydraulic pressure to align damaged components
PC12. assist in removal of damaged sections of vehicles using metal- cutting guns, air grinders and wrenches, and install replacement parts using wrenches or welding equipment
PC13. assist in mixing polyester resins and hardeners to restore damaged areas
PC14. assist in fitting and securing windows, vinyl roofs, and metal trim to vehicle bodies, using caulking guns, adhesive brushes, and mallets
PC15. assist in filling small dents that cannot be worked out with plastic or solder
PC16. assist in removal of small pits and dimples in body metal using pick hammers and punches
PC17. ensure any malfunctions or repair requirements observed in vehicles (and beyond own scope of work) are reported to the concerned person
PC18. ensure any malfunctions observed in tools and equipment are reported to the concerned person
PC19. clean work areas, using air hoses, to remove damaged material and discarded fiberglass strips used in repair procedures
PC20. ensure that trainings organized by the OEM from time-to-time are attended and knowledge levels are upgraded (esp. in case of newly launc hed products, product refreshes)
 


Airline Ground Support Equipment Mechanic





Knowledge and Understanding
 
Organizational Context
KA1. standard operating procedures of the Organisation/ Dealership for inspection and repair of vehicles for the body/ chassis components
KA2. standard operating procedures for repair and replacement of automotive body parts mandated by the OEM
KA3. safety requirements for equipment and components (e.g. preventing/ dealing with oil spillage and inflammable materials)
KA4. standard operating procedures recommended by the Dealership/ Suppliers/OEM for using tools and equipment to be followed as per the manufacturer instructions (e.g. maintaining safety while using welding and soldering equipment)
KA5. documentation requirements for each procedure carried out as part of roles and responsibilities as specified by the organization
KA6. organisational and professional code of ethics and standards of practice KA7. safety, health, environmental policies and regulations for the workplace as well as for Automotive trade in general (e.g. safe practices while working in pits/ under vehicles)
KA8. workplace policies and schedules for housekeeping activities and equipment maintenance
 
Technical Knowledge
KB1. the tools and methods used to assess and confirm structural damage that cannot be determined through a visual inspection, including use of a tape measure or atram bar, a tram gauge, and self-centering gauges
KB2. the kind of tools and procedures required based on the damage sustained by the vehicle including:
 power tools and hand tools (e.g. hammers)
 air hoses
 various clamps, holding jigs, relevant special equipment KB3. drills, drill bits, bolts, nuts and washers
 
KB4. the storage location for the tools and materials used in the workshop
KB5. the procedure for measurement of:
 length
 squareness
 flatness
 angles
 roundness
 depth
 clearance
 any measurement that can be taken from analogue or digital devices
 
KB6. how to assist in repairing and fixing the following non-permanently attached body panels:
 wings
 doors
 bonnet
 boot lids & tail gate
 
KB7. the various welding techniques
KB8. the correct alignment of panels and components and the applicable methods
KB9. the various cleaning agents/sprays (de-waxing, detergents, degreasers, special purpose agents)
KB10. the appropriate tools required for structural repairs
KB11. the repair procedure to be followed for particular damage KB12. the measures to be adopted to protect the vehicle from damage
before, during and after removing and fitting activities KB13. appropriate personal and vehicle protection to be used for various procedures

Core Skills/ Generic Skills
Writing Skills
The user/ individual on the job needs to know and understand how to:
SA1. record and document the basic details of repairs performed on various body and chassis aggregates/ components
SA2. write in at least one language
Reading skills
The user/individual on the job needs to know and understand how to: SA3. read work order, specification, etc. related to the job including instructions mentioned on the job card given by service
advisor/supervisors
SA4. read any specific safety related guideline (applicable for CNG/ LPG/ Electric vehicle)
Oral Communication (Listening and Speaking skills)
The user/individual on the job needs to know and understand how to: SA5. communicate the damage caused to vehicle and its body parts SA6. interact with the customer/ service advisor and senior technicians SA7. interact with team members including colleagues in the workshop
to work efficiently
 
Professional Skills
making
The user/individual on the job needs to know and understand how to: SB1. judge when to seek assistance from a superior
Plan and organize
The user/individual on the job needs to know and understand how to: SB2. plan work according to the required schedule and location
Customer centricity
The user/individual on the job needs to know and understand how to:
SB3. ensure that customer needs regarding the denting and body/ chassis related jobs are assessed and satisfactory service is provided
Problem solving
The user/individual on the job needs to know and understand how to: SB4. inspect damaged vehicles and assist in repairs required
SB5. inspect equipment to ensure proper working order and take any corrective actions as required
SB6. ensure that all dents which can’t be repaired to be referred to superiors to take an appropriate decision
Analytical thinking
The user/individual on the job needs to know and understand how to:
SB7. check the usefulness of shop tools to see if they are suitable for work on new models of vehicles
Critical thinking
The user/individual on the job needs to know and understand how to:
SB8. evaluate the information gathered from the customer report/ job card and assess repairs
diagnosis of vehicle for repair requirements
 
Performance Criteria
 
Carry the diagnosis of the vehicle identify the root cause of the trouble
PC1. understand the auto component manufacturer specifications related to the various components/ aggregates in the vehicle
PC2. understand the functioning of each system, component and aggregate (including both mechanical and electrical aggregates) of a vehicle
PC3. follow standard operating procedures for using workshop tools and equipment for fault diagnosis or troubleshoot problem in a vehicle
PC4. obtain sufficient information from customer/ service advisor to make an assessment of service and repair needs of the vehicle
PC5. review the job card and understand customer complaints
PC6. follow standard operating procedure set out for diagnosing faults (in case of complex faults take the assistance of the senior diagnosis technician/ technical manager)
PC7. use checklists and standard OEM operating procedures to understand if the fault is because of improper servicing, or low levels of oils, coolants, grease etc. or poor quality oil/ air filters etc.
PC8. conduct inspection of the engine and aggregates to diagnose need for repairs or adjustment in various engine aggregates
PC9. conduct inspection of mechanical, electrical and electronic systems to diagnose need for repairs, adjustment or part replacement
PC10. dismantle and reassemble aggregates of a vehicle (with help from other technicians and helper)
PC11. conduct routine and non-routine inspections for pre-purchase assessment, vehicle fitness assessment, emission testing, safety assessment, post-accident diagnostic assessment, post-repair serviceability assessment and manufacturer recall assessment
PC12. compare results of diagnostic inspections and tests against vehicle specifications and any regulatory requirements PC13. finalise the list all the service, repair and replacement requirements of the vehicle post the diagnosis in consultation with service advisor/ supervisor
PC14. follow standard operating procedures for using workshop tools and equipment
PC15. ensure all workshop tools, equipment and workstations are adequately maintained by carrying out scheduled checks, calibration and timely repairs where necessary
PC16. ensure any malfunctions observed in tools and equipment are reported to the concerned persons
PC17. understand the various precautions to be taken to avoid damage to the vehicle and its components while working on diagnosis or tro ubleshooting the vehicle for any faults
PC18. request assistance from a superior when required(esp. in cases where the complex diagnosis needs to be done and is out of scope)
PC19. assist junior technicians in their work
PC20. ensure that trainings organized by the OEM from time-to-time are attended and knowledge levels are upgraded (esp. in case of newly launched products, product refreshes)
PC21. drive a relevant 2/3/4 wheeler vehicle which is an important part of the diagnosis of the type of vehicle that is dealt by the relevant OEM
 
Knowledge and Understanding
 
Organizational Context
KA1. standard operating procedures of the organization / dealership for inspection and diagnosis of faults in a vehicle as prescribed by the OEM/ components manufacturer
KA2. standard operating procedures recommended by the dealership/ suppliers/OEM for using tools and equipment for diagnosis or troubleshooting of various aggregates
KA3. safety requirements for equipment and components during the diagnosis or troubleshooting the various aggregates for root cause analysis of the fault
KA4. documentation requirements for each procedure carried out as part of roles and responsibilities as specified by OEM/ auto component manufacturer for the diagnosis of troubleshooting the vehicle for faults
KA5. organisational and professional code of ethics and standards of practice
KA6. safety, health, environmental policies and regulations for the workplace as well as for automotive trade in general (e.g. safe practices while working in pits/ under vehicles
 
Technical KnowledgeKB1. the basic technology used in and functioning of various components and aggregates of the vehicle including:
 engines and fuel system (diesel, petrol, electrical, gas, hybrid etc.)
 cooling system
 air supply systems
 emission and exhaust system
 ignition systems
 clutch assembly
 clutch operating system
 gearbox (manual and automatic)
 drivelines and hubs
 drive-train assembly and transmission systems (manual, automatic etc.)
 steering system
 suspension system
 brake system (including regenerative braking systems)
 tyres and wheels (including wheel alignment)
 radiator
 batteries and power storage system
 power-generating systems (including charging systems especially for electrical and hybrid vehicles)
 electrical wire harness, lighting, ignition, electronic and air- conditioning systems etc.
 energy recuperation systems, if applicable (e.g. in electric, gas and hybrid vehicles)
 electronic systems including active and passive safety, media, comfort and convenience, supplementary restraint systems (SRS), networking and other systems
 electronic control unit
 hydraulic and pneumatic system
 various lubrication systems
 
KB2. the tools used to assess and confirm technical faults that cannot be determined through a visual inspection, including use of:
 organic light emitting displays — anti-lock braking system abs/air bag scan tools, automotive scanners, graphing scanners, modular diagnostic information systems
 pressure indicators: fuel pressure testers, manifold gauge sets, oil pressure gauges, tire pressure gauges
 measuring equipment: vernier calipers, micrometer, feeler gauges, multimetre, flow metre, temp gauge, dial gauge etc.
 
electrical and electronic testing equipment: volt meters, ammeters, ohmmeters, battery testing equipment, dedicated and computer based diagnostic equipment, oscilloscopes etc.
 other tools: laptops
 
KB3. the various sources of information available for assessing service and repair requirements of the vehicle including:
 diagnostic displays
 visual inspections
 test drives
 vehicle/equipment manufacturer specifications
 standard operating procedures for diagnosis
 
KB4. typical symptoms of common technical faults in a vehicle including fluid levels, leaks, wear and tear, damage to a part/ aggregate and need for adjustments (e.g . HEOC- High Engine Oil Consumption, oil leakage, tyre wear etc.)
KB5. the various values and tolerance limits of various components across the mechanical/ electrical aggregates (e.g. within the engine assembly the following sub-aggregates : bore diameter, Liner fitment, piston height and butt clearance of piston rings, permissible imbalance in crankshaft (main and BE journal), axial and radial play in the camshaft etc.)
KB6. basic computer skills including the following:
 OEM specific computer applications
 basic computer based tasks (e.g. use of productivity tools such as word, excel etc.)
 basic internet based tasks (e.g. accessing and responding to emails etc.)
 
Core Skills/ Generic Skills
Writing Skills
The user/ individual on the job needs to know and understand how to:
SA1. create documentation required on the job (including diagnosis cards, work sheets, etc.) regarding the basic diagnosis and of various fault identification tests performed using various equipment as per the OEM/ auto component and aggregate guidelines
SA2. complete and maintain workplace records on inspection, diagnosis and repair activities
SA3. record all diagnostic inspections and tests carried out on a vehicle SA4. write any additional work to be done (on the job card) basis the
diagnosis of the vehicle (in major mechanical & electrical aggregates) and convey it to the service advisors and other technicians to carry out the work
SA5. write in at least one language
Reading Skills
The user/individual on the job needs to know and understand how to
SA6. read and interpret workplace related documentation including job cards, safety instructions, OEM guidelines etc. from supervisors and the service advisor basis the information conveyed by the customer on the issue/ fault faced
SA7. read various sources of information available for vehicle diagnosis including service manual and diagnostic and visual displays put up in the workshop
SA8. read the technical brochures, new service schedules, service bulletins (refresher and new) released by the OEM/ auto components manufacturer related to diagnosis of the various faults across vehicle aggregates
SA9. read policies and regulations pertinent to the job, including OEM guidelines,
SA10. health and safety instructions etc.
Oral Communication (Listening and Speaking skills)
The user/individual on the job needs to know and understand how to:
SA11. clearly communicate workplace information and ideas with workplace colleagues (verbal and non-verbal)
SA12. use terms, names, grades, and other nomenclature pertaining to the automotive trade, tools, specific workshop equipment etc.
SA13. communicate with colleagues to handle verbal enquiries, such as clarifying indicated faults and problems indicated on a job card which would lead to the proper diagnosis of the issue to do an effective root cause analysis
SA14. communicate to the juniors technicians on the changes in technical brochures, new service schedules, service bulletins (refresher and new) released by the OEM/ auto components manufacturer related to diagnosis of the various faults across vehicle aggregates
SA15. communicate to the customer through the service advisor, the results of the test performed and appropriate values to find the root case of the problem (e.g. in case of HEOC – High Engine Oil Consumption issue, post the dismantled engine convey the appropriate condition of piston ring, crank shaft and cylinder block etc.)
 
 
Professional Skills
Decision Making
The user/individual on the job needs to know and understand how to:
SB1. analyse information and evaluate results to choose the best solution and solve problems
SB2. decide on the repair/ replacement of any aggregate (including those in the electric al and mechanical sub- assemblies) post the diagnosis (with help from a superior technical manager in case of complex diagnosis)
SB3. judge when to ask for help from a superior
Plan and Organize
The user/individual on the job needs to know and understand how to: SB4. plan work according to the required schedule and location
SB5. organize schedule to complete diagnosis on the vehicle so that repair/ replacement of aggregates/ components post diagnosis can
start and vehicle can be delivered in a timely and cost effective manner
SB6. organise the workplace and work according to the principles of 5S
Customer Centricity
The user/individual on the job needs to know and understand how to:
SB7. interpret the needs of customers understanding the key issue plaguing the poor performance of the vehicle and doing a proper diagnosis consulting the service advisor to minimise the repeat complaints
SB8. ensure that the service provided is of the highest order to ensure customer satisfaction
SB9. follow up with the Service Advisor on any unfavourable feedback received from customer on the complaints reported on the vehicle
Problem Solving
The user/individual on the job needs to know and understand how to:
SB10. recognise a workplace problem or a potential problem and take action prior to diagnosis (e.g. during diagnosis of the engine, ensure that engine aggregates are placed in proper place so that it doesn’t cause any hindrance to other vehicles parked near the vehicle which is being diagnosed)
SB11. determine problems needing priority action
SB12. refer complex diagnosis outside area of responsibility to superior
Analytical Skills
The user/individual on the job needs to know and understand how to:
SB13. analyse the complexity of work to determine if it can be successfully carried out(e.g. refer a vehicle to a superior in case of complex diagnosis for any fault which has not occurred before)
SB14. analyse the different components for the tolerance values post the diagnosis to understand the root cause of the issue
Critical Thinking Skills
The user/individual on the job needs to know and understand how to:
SB15. analyse, evaluate and apply the information gathered from observation, experience, reasoning, or communication to act efficiently
SB16. use the diagnosis results to take an appropriate decision on repair/ replacement of an aggregates (including mechanical and electrical subassemblies) in consultation with the supervisor/ service advisor
 
 
Carry out service and major repairs in mechanical aggregates and overhauling of a vehicle
 
Performance Criteria
Servicing and major repairs of a mechanical aggregates in a vehicle
PC1. understand the auto component manufacturer specifications related to the various components/ aggregates in the vehicle (including major aggregates like engine. gear box, transmission systems like propeller shaft etc.)
PC2. follow standard operating procedures for using workshop tools and equipment for fault diagnosis or troubleshoot problem in a vehicle
PC3. review the job card and understand service and repair work to be carried out in the various aggregates( including overall of various aggregates like engine)
PC4. ensure that the correct spare parts, lubricants, tools and other materials required have been obtained
PC5. service, repair and overhaul:
 engines and fuel system (diesel, petrol, electrical, CNG, LPG etc.)
 cooling system
 radiator
 emission and exhaust system
 brake system
 clutch assembly
 gearbox, drive-train assembly and transmission systems (manual, automatic etc.)
 steering syst em
 suspension system
 tyres and wheels
 hydraulic and pneumatic system
 various lubrication systems
 
PC6. conduct routine and non-routine inspections for vehicle fitness assessment, emission testing, safety assessment and post-repair serviceability assessment
PC7. dismantle, assess, repair, clean, replace, adjust and reassemble the vehicle mechanical aggregates/ components
PC8. identify and change vehicle components requiring change due to continuous wear and tear(including oil and air filters in the engine aggregate)
PC9. ensure all dismantled components and aggregates are cleaned and conditioned prior to reassembly
PC10. carry out service, repair and overhauling activities safely to ensure:
 no damage to the vehicle or other vehicles
 no damage to vehicle components and systems
 no contact with hazardous materials
 
PC11. ensure disposal of materials (including waste oil, scrap of failed parts/ aggregates)in accordance with the organisation’s policies PC12. ensure, in consultation with the service advisor, approval of the
customer on all repairs carried out
PC13. record all service and repairs carried out and ensure completeness of tasks assigned before releasing vehicle for the next procedure
PC14. ensure any other repair requirements observed in the other components/ aggregates systems (like engine, gear box etc.) while repairing/ overhauling of braking systems are communicated to service advisor
PC15. follow standard operating procedures for using workshop tools and equipment
PC16. ensure all workshop tools, equipment and workstations are adequately maintained by carrying out scheduled checks, calibration and timely repairs where necessary
PC17. ensure any malfunctions observed in tools and equipment are reported to the concerned persons
PC18. inform the relevant persons where repairs/ overhauling of the aggregates are economically or technically infeasible
PC19. request assistance from a senior technician when required PC20. assist junior technicians in their work
PC21. ensure that trainings organized by the OEM from time-to-time are attended and knowledge levels are upgraded (esp. in case of newly launched products, product refreshes)
 
Knowledge and Understanding
 
Organizational Context
KA1. standard operating procedures for servicing, repair and replacement of parts in various aggregates of the vehicle
KA2. standard schedules and checklists recommended by the OEM for servicing and repair of various components and aggregates in the vehicle
KA3. safety requirements for equipment and components prescribed by the OEM (e.g. preventing/ dealing with oil spillage and inflammable materials
KA4. identification codes, nomenclature of various components and aggregates
KA5. correct and appropriate grade of engine oil, coolant or lubricant grease to be used for the corresponding engine and other aggregates as specified by the OEM and auto component manufacturer
KA6. standard operating procedures recommended by the dealership/ suppliers/ OEM for using tools and equipment to be followed related to various aggregates and components in a vehicle as per the tool manufacturer instruction
KA7. standard operating procedures for rectification of errors in information (e.g. rectification of job card, reissue of correct tools and equipment etc.)
KA8. documentation requirements for each procedure carried out as part of roles and responsibilities as specified by OEM/ auto component manufacturer
KA9. organisational and professional code of ethics and standards of practice
KA10.safety, health and environmental policies and regulations for the workplace and automotive trade in general(e.g. safe working practices inside pits/ under vehicles)
KA11.regulatory requirements for vehicles including road safety, refrigerant handling, fuel storage and other requirements
KA12.operating specifications provided by the OEM for limits, fits and tolerances relating to engine mechanical, hydraulic and fluid systems for the vehicle
 
Technical Knowledge
KB1. the basic technology used in and functioning of various components and aggregates of the vehicle including:
 e ngines and fuel system (diesel, petrol, electrical, gas etc.)
 radiator
 emission and exhaust system
 brake system
 clutch assembly
 gearbox, drive-train assembly and transmission systems (manual, automatic etc.)
 steering system
 suspension system
 electrical wire harness, lighting, ignition, electronic and air- conditioning systems etc.
 electronic active and passive safety, media, comfort and convenience, supplementary restraint systems (SRS), networking and other systems
 
· electronic control unit
 tyres and wheels
 cooling system
 hydraulic and pneumatic system
 various lubrication systems KB2. Basic principles of:
 ohms Law, voltage, power, current (AC/DC) resistance, magnetism, electromagnetism and electromagnetic induction etc.
 vehicle earthing and earthing methods
 vehicle engine systems (e.g. types, applications and operation of sensors, actuators, etc.)
 types of circuit protection and their use
 electrical safety procedures
 the operation of warning, charging and starter circuits
 symbols, units and terms associated with electric systems and components
 battery charging
 electrical/electronic control systems
 operation of electronic and electric engine systems (including electrical component function, electrical inputs, outputs, voltages and oscilloscope patterns, digital and fibre optics principles)
KB3. the tools used to assess and confirm technical faults that cannot be determined through a visual inspection, including use of:
 organic light emitting displays — anti-lock braking system abs/air bag scan tools, automotive scanners, graphing scanners, modular diagnostic information systems
 pressure indicators: fuel pressure testers, manifold gauge sets, oil pressure gauges, tire pressure gauges
 pullers: ball joint separators, bearing pullers, gear puller tools, slide hammers
 specialty wrenches: alignment wrenches, chain wrenches, locking wrenches, lug wrenches
 trim or moulding tools: carbon scrapers, gasket scrapers, scrapers, spoons
 measuring equipment: vernier calipers, micrometer, feeler gauges, multimetre, flow metre, temp gauge, dial gauge etc.
 other tools: hand tools, power tools, lifting and jacking equipment, tensioning equipment, laptops, brake roller tester, chassis dynamometer, suspension activation, security activator etc.
 tools for other tasks such as cleaning of vehicles, tools, equipment and workshop
KB4. how to select the right materials for the job such as seals, sealants, fittings, gaskets, joints, fasteners etc.
KB5. how to carry out routine maintenance including:
 checking vehicle condition against OEM specifications to identify damage, corrosion, wear and tear, fluid levels, leaks and other problems in serviceability
 make adjustments to settings, alignment, pressures, tension, speeds and levels relevant to:
– engine and aggregates (including fuel injection pump, ignition, intake and exhaust systems)
– steering system
– clutch and brake assembly
– transmission system (including gearbox, differential, propeller shaft and axles)
– Other component (including tyre and body fittings)
 
KB6. the various sources of information available for assessing serviceability of the vehicle including:
 diagnostic displays
 visual inspections
 test drives
 vehicle/equipment manufacturer specifications
 standard operating procedures
 
KB7. how to repair and replace engine and its components including overhauling of the aggregates
KB8. how to dismantle, assess, repair, clean, condition, replace, adjust, reassemble and test mechanical components for correct operation
KB9. the method to correctly tag, seal and package checked engine components and aggregates
KB10. how to troubleshoot faults and document the causes in engines and other allied components
KB11. how to dispose of replaced components in accordance with safety, health and environmental policies and regulations
KB12. how to measure/ inspect the machining or any other repair done from an outside source/ local machining garages on the various aggregates (like machining of the piston, cylinder head, cylinder block in the engine aggregate)
KB13. how to carry out the full overhaul of the engines (with support from the other technicians and machine shops from local garages)
KB14. precautions to be taken to ensure the following while working (including specific precautions to be taken when working with alternative fuel/ hybrid vehicles):
 no damage to the vehicle or other vehicles
 no damage to vehicle components and systems
 no contact with hazardous materials
 
Core Skills/ Generic Skills
Writing Skills
The user/ individual on the job needs to know and understand how to:
SA1. create documentation required on the job (including job cards, work sheets, etc.) regarding the basic details of repair , maintenance and service performed on the various aggregates (including engine and other aggregates overhauling)
SA2. complete and maintain workplace records on inspection, diagnosis and repair activities
SA3. write any additional requirement of work on the vehicle for service, maintenance or repair found during the work done as specified in the job card ( e.g. while working on the engine overhauling, if the clutch/ pressure plate is worn off, then convey to the superiors and service advisor)
SA4. write in at least one language
Reading Skills
The user/individual on the job needs to know and understand how to:
SA5. read job cards and instructions from service advisor regarding the repair and service of various vehicle aggregates
SA6. read various sources of information available for assessing service and repair requirements of vehicle aggregates including service manual and diagnostic and visual displays put up in the workshop
SA7. read policies and regulations pertinent to the job, including OEM guidelines, health and safety instructions etc. while working on the vehicle aggregates
SA8. read the technical brochures, new service schedules, service bulletins (refresher and new) released by the OEM/ auto components manufacturer related to service and maintenance of various vehicle aggregates
Oral Communication (Listening and Speaking skills)
The user/individual on the job needs to know and understand how to:
SA9. clearly communicate workplace information and ideas with workplace colleagues (verbal and non-verbal)
SA10. use terms, names, grades, and other nomenclature pertaining to the automotive trade, tools, specific workshop equipment etc.
SA11. communicate with colleagues and customers to handle verbal enquiries, such as clarifying indicated faults and problems indicated on a job card which would lead to the proper diagnosis of the issue to do an effective root cause analysis
SA12. interact with customer hrough service advisor/ supervisor in case of any additional repair and service needs to be done on the vehicle aggregates
SA13. communicate to the juniors technicians on the changes in technical brochures, new service schedules, service bulletins (refresher and new) released by the OEM/ auto components manufacturer related to diagnosis of the various faults across vehicle aggregates
Professional Skills
 
Decision Making
The user/individual on the job needs to know and understand how to:
SB1. analyse information and evaluate results to choose the best solution and solve problems
SB2. be proactive and creative in responding to workplace problems, changes and challenges
SB3. decide on the repair/ replacement of any engine aggregate post the diagnosis (with help from a technical manager in case required)
SB4. decide on whether the whole aggregate (gear box or engine overhaul) needs to be overhauled or some components/ parts needs to be changeda
Plan a nd Organize
The user/individual on the job needs to know and understand how to: SB5. plan work according to the required schedule and location
SB6. plan the assigned aggregate repair work (including the specific engines or other aggregate that needs to be overhauled)on a daily basis and provide estimates of time required for each piece of work(e.g. by evaluating work assigned on a job card and providing time estimates for each service/ repair activity)
SB7. organise the workplace and work according to the principles of 5S SB8. prioritise actions to achieve required outcomes
SB9. plan the assigned engine repair work (including the specific engines that needs to be overhauled)and provide estimates of time required for each engine overhaul repair
SB10. organise the schedule to complete work on the engine aggregate timely in case other aggregate repairs/ maintenance work is also required to be done
Customer Centricity
The user/individual on the job needs to know and understand how to:
SB11. interpret the needs of customers by evaluating job cards and talking to Service Advisor and superiors
SB12. ensure that customer needs are assessed and satisfactory service is provided
SB13. follow up with the Service Advisor on any unfavourable feedback received from customer
Problem Solving
The user/individual on the job needs to know and understand how to:
SB14. recognise a workplace problem or a potential problem and take action
SB15. determine problems needing priority action
SB16. refer problems outside area of responsibility to appropriate person(e.g. unavailability of required spare parts or materials in the workshop)
SB17. gather information and provide assistance as required to solve problems
SB18. use a range of problem-solving techniques
SB19. develop practical responses to common breakdowns in workplace systems and procedures
Analytical Skills
The user/individual on the job needs to know and understand how to:
SB15. analyse the complexity of work to determine if they can successfully carry them out and if required, escalate to a superior
Critical Thinking Skills
The user/individual on the job needs to know and understand how to:
SB17. analyse, evaluate and apply the information gathered from observation, experience, reasoning, or communication to act efficiently
 
 
Guidelines for Assessment

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
The assessment for the theory part will be based on knowledge bank of questions created by the SSC
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 this criteria
To pass the Qualification Pack, every trainee should score a minimum of 70% in aggregate
The marks are allocated PC wise, however, every NOS will carry a weightage in the total marks allocated to the specific QP