Rita Charitable Trust

Free Auto Component Assembly Fitter Course (6Months)

Auto Component Assembly Fitter:

Brief Job Description

An auto component assembly fitter is one who is skilled in operating machine tools for conducting assembly and fitment operations of vehicle components and aggregates as per the required assembly norms. The components assembled by the operators will be finally assembled in the given 2 wheeler, 3 wheeler, 4 wheeler and large commercial vehicles.

Personal Attributes

The person should have dexterity in operating machine tools. Dexterity in making , operating and repairing machines, ability to fix the right parts at the right places in the given time, Two hand and eye coordination, sense of time management, quality management and 5S & Safety, Proper vision and no colour blindness.

Maintain a safe and healthy working environment:

Elements and Performance Criteria

Identify and report the risks identified

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

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

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

KU3. knowledge of various types of PPEs and their usage

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

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

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

Generic Skills (GS)

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

GS1.     write basic level notes and observations

GS2.     read safety instructions put up across the plant premises

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

GS4.     effectively communicate information to team members

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

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

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

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

GS9.             use reasoning skills to identify and resolve basic problems

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

GS11. use reasoning skills to identify and resolve basic problems

Maintain 5S at the work premises:

Elements and Performance Criteria

Ensure sorting

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

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

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

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

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

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

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

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

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

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

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

Ensure proper documentation and storage ( organizing , streamlining)

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

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

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

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

Ensure cleaning of self and the work place

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

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

PC15.    keep all outside surfaces of recycling containers are clean

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

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

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

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

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

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

Ensure sustenance

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

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

PC23.    attend all training programs for employees on 5 s

PC24.    support the team during the audit of 5 s

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

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

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

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

KU2.     have basic knowledge of 5S procedures

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

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

KU5.     have skills to identify useful & non useful items

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

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

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

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

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

KU11. understand the importance of standardization in processes

KU12. understand the importance of sustainability in 5S

KU13. have knowledge of TQM process

KU14. have knowledge of various materials and storage norms

KU15. understand visual controls, symbols, graphs etc.

Generic Skills (GS)

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

GS1.     write basic level notes and observations

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

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

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

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

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

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

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

GS9.             persuade co team members to follow 5 S

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

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

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

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

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

GS15. ensure self-cleanliness on a daily basis

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

Industrial Training Institute – Ramakrishna Mission Vidyalaya, Coimbatore,  Tamil Nadu, India

Understand processes and equipment:

Elements and Performance Criteria

Understand the assembling requirements, assembling equipment and parameters to be set for the process

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

PC1..     understand the right assembling methodology and process( Bolting, tightening, riveting, fastening, adhesive clamping, crimping etc.) using mechanical, pneumatic, hydraulic means to be adopted for completing the work order through discussions with the supervisor/ master technician and reading the process manuals/ Work Instructions/Standard Operating Procedures

PC2.      understand the various assembling process parameters like cycle time,pressure, torque etc. before starting the assembling process, as mentioned in the Work Instructions/ SOP manual

PC3.      understand the material required and the equipment availability for executing the activity

PC4.      understand the type of nut runners and torqueing equipment required to be used for the assembling process

PC5.      understand the various nuts, bolts, rivets, fasteners, covering sheaths etc. kept in the various side trays ( Assembly kits)

PC6.      understand 5 S and Safety related aspects related to the work station, assembly Line

PC7..     clearly understanding the does and donts of the manufacturing process as defined in SOPs/ Work Instructions or defined by supervisors

Escalations of queries on the given job

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

PC8.      refer the queries to a competent internal specialist if they cannot be resolved by the assembler on own

PC9.      obtain help or advice from specialist if the problem is outside his/her area of competence or experience

PC10.. confirm self -understanding with the specialist holding discussions so that all doubts & queries can be resolved before the actual process execution

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1. relevant standards and procedures followed in the company

KU2. different types of products manufactured by the company

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

KU4. different types of assembling processes and associated equipment with the fool-proofing techniques employed there-in

KU5. the method of reading and interpreting the various gauges

KU6. how to visualize the final product output and conduct quality verification tests.

KU7. the impact of various physical parameters like torqueing and tightening on the properties of final output product like durability, surface finish, part movement, aesthetics etc

KU8. hazards and safety aspects involved in assembling activities and usage of relevant PPEs

Generic Skills (GS)

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

GS1.     document information

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

GS3.     write information documents to internal departments/ internal teams or enter the information in online ERP systems under guidance of the supervisor

GS4.     read and interpret technical specifications of the assemble specimen

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

GS6.     read internal information documents sent by internal teams

GS7.             discuss task lists, schedules and activities with the supervisor

GS8.             effectively communicate with the team members

GS9.     question the assembling shop supervisor in order to understand the nature of the problem and to clarify queries

GS10. attentively listen with full attention and comprehend the information given by the speaker

GS11. plan and organize the work order and jobs received from the Operator

GS12. organize all process/ equipment manuals so that sorting/ accessing information is easy

GS13. keep fixtures, tools, drawings, Work Instructions, SOP manuals as per the part number, colour codes etc . as defined under the 5S systems

GS14. support the supervisor in scheduling tasks for helper and assistant supervisor

GS15. use common sense and make judgments during day to day basis

GS16. use reasoning skills to identify and resolve basic problems use intuition and keen observation skills to detect any potential problems which could arise during operations

GS17. follow instructions and work on areas of improvement identified

GS18. complete the assigned tasks with minimum supervision

GS19. complete the job defined by the supervisor within timelines and quality norms

GS20. detect problems in day to day tasks

GS21. support supervisor in using specific problem solving techniques and detailing out the problems

GS22. discuss possible solution with the supervisor for problem solving

GS23. make decisions in emergency conditions in case the supervisor is not available( as per the authority matrix defined by the organization

Indian automotive sector: Creating future-ready organisations

Prepare the assembling machine, auxiliaries and work pieces:

Elements and Performance Criteria

Arrange for availability tools, equipment and other material

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

PC1.    Understand the material required and the equipment availability for executing the activity

PC2.    Ensure that the required material is procured from the store before starting the assembling process availability of greases, lubricant oil, adhesives,marking equipment, ID stickers/ labels

PC3.    Ensure availability of tools required for the assembly process as per the components to be assembled. Tool sizes as mentioned in the Work Instructions/ SOPs for assembly

PC4.. Ensure that the helper/ assistant technician brings the required material and tools before the start of the assembling operations

Check & Clean theassembling equipment

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

PC5.    Setup the assembling apparatus as per the selected assembling process and the internal SOPs/ Work Instructions and the setting standards for the machine

PC6.    Ensure that the surface of the assembling gun/ Bolting gun is cleaned to remove dust and any other impurities

PC7.    Ensure that the hoists & cranes for lifting the parts are working in order as per the process requirement

PC8.    Immediately refer the queries to the supervisor to avoid any delay in the actual process

Escalations of queries for the given job

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

PC9.    Confirm self -understanding to the supervisor/ master technician during the discussions so that all doubts & queries can be resolved before the actual process execution

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.     relevant standards and procedures followed in the company

KU2.     different types of products manufactured by the company

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

KU4.     different types of assembling processes

KU5.     different equipment and components used in the assembly process bolts, nuts, screws, wires, fasteners, connectors, sealants, adhesive bonding equipment, boring drills, Torque testers

KU6.     different types of bolting guns/ riveting guns used in the assembly process

KU7.     size for tightening equipment like spanners, screw drivers, testers

KU8.     the method of reading and interpreting the various gauges

KU9.     impact of various assembly process like bolting, torqueing, fitting, greasing, hammering, sealing, clamping on the final component/ vehicle performance

KU10. how to visualize the final product output and conduct quality verification tests

KU11. hazards and safety aspects involved in assembling activities and usage of relevant PPEs

KU12. fool-proofing techniques employed in the assembly process.

Generic Skills (GS)

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

GS1.     document information

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

GS3.     write information documents to internal departments/ internal teams or enter the information in online ERP systems under guidance of the supervisor

GS4.     read and interpret technical specifications of the assemble specimen

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

GS6.     read internal information documents sent by internal teams

GS7.             discuss task lists, schedules and activities with the supervisor

GS8.             effectively communicate with the team members

GS9.     question the assembling shop supervisor in order to understand the nature of the problem and to clarify queries

GS10. attentively listen with full attention and comprehend the information given by the speaker

GS11. plan and organize the work order and jobs received from the Operator

GS12. keep fixtures, tools, drawings, Work Instructions, SOP manuals as per the part number, colour codes etc .as defined under the 5S systems

GS13. organize all process/ equipment manuals so that sorting/ accessing information is easy

GS14. visualize the final job product after understanding the given drawing/ sketches/ Work Instruction/ SOP

GS15. co relate the type of job output required with the assembling methodology to be used

GS16. identify the strengths and weakness of various assembling process

GS17. use common sense and make judgments during day to day basis

GS18. use reasoning skills to identify and resolve basic problems

GS19. follow instructions and work on areas of improvement identified and complete the assigned tasks with minimum supervision

GS20. complete the job defined by the supervisor within the timelines and quality norms

GS21. take self-initiatives in driving small projects with the supervisor like operation improvement, training of helpers and assistant operators, 5S, Kaizen etc

Perform the mechanical assembly operation:

Elements and Performance Criteria

Read and interpret the assembly drawing/ blue print/Work Instruction

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

PC1.       understand the assembly operations from the assembly drawing/ blue print work instructions/ sops supplied on the assembly line

PC2..      understand the correct method of the assembly operation such as angle for holding the bolting gun/ riveting gun, direction of applying torque, position of technician hand/ body to complete the assembly operation keeping in mind safe working procedure

PC3.       read the specifications manuals and plan assembly or building operations

PC4..      ensure drop of sub-assemblies like frame ,base, tubes, pipes, channels . at the respective stations without damaging the components in case

Arrange the parts to be assembled in the given position

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

PC5.       correctly position or align components for assembly, manually or using hoists

PC6.       ensure that hoists are used to lift the right material from the conveyors, bins, part trolleys etc

PC7.       ensure part clearances as specified in the work instructions/ standard operating processes

PC8.                assemble the required parts using pneumatic, hydraulic/ plc controlle assembly tools

PC9.                pick the right fastening part and right tightening tool from the right tray/ kit trolley as

identified in the drawing/ standard operating procedure/ work instruction and is correctly

PC10.     in case of robotic assembly line, ensure that the correct details are fed into the system and the right program is selected ( corresponding to the component/ vehicle under assembly)

Conduct the Assembly operations for the components

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

PC11.     carefully insert the right bolts, screw, rivet in the required place in the part of be assembled

PC12.     perform tightening of nuts and bolts using bolting guns/ riveting guns as per the required specifications for fitment of each part

PC13.     ensure right amount of torque application for tightening the bolted components.

PC14..    check the torque values using a torqueing meter and validate the same with the torque chart provided on the assembly station

PC15..    ensure all pneumatic and hydraulic components in the vehicles and the relevant auto components are installed using the correct methodology as indicated in the work instructions/ sops/ control plans

PC16.     ensure proper sealing of the required areas to prevent any leakage of water/ air etc. during the usage of the component/ vehicle

PC17.     ensure completion of other relevant assembly processes like adjustment, id sticker application and minor rework procedures like hammering etc. for the component assembly process adhere to the assembly quality norms specified by the organization

PC18.     ensure proper lubrication of parts as instructed in the work instructions/ sop

PC19.     ensure that the assembly operations are completed as per the specified time and performance levels

PC20.     ensure that the fixtures and the assembly equipment is kept back to their respective locations once the process has been completed

PC21..    ensure that the tools and fixtures are maintained in the proper locations and are checked as per the checklist provided by the maintenance team

PC22.     ensure proper quality checks at each assembly station and validate the conformance to the drawing/ blueprint/ work instruction/ sops supplied to the assembly station

PC23.     ensure that while assembling the components at a particular work station/platform, care is taken to ensure fitment of the components in the successive stations

PC24..    ensure that while assembling the components, the aesthetic properties of the final output like component is maintained

PC25.     ensure proper disposal of residual greases, adhesives, metal chips and scrap,plastic and paper waste etc. in the designated place as per the standard operating procedure for waste disposa

PC26.     ensure proper storage of extra grease, lubrication oil etc. to prevent any contamination through moisture, dust, dirt

Conduct physical inspection of the assembled components

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

PC27.     ensure full inspection of the physical body of the auto component to detect any quality related defects related to body surface, paint, dents, grooves,cracks, rough edges etc

PC28. . inspection of the specimen in proper lighting so that detection of errors is fast and accurate

PC29.     ensure part clearances as specified in the work instructions/ standard operating processes

PC30.                mark all the observed physical detects using a chalk stick or any other erasable substance

to identify the potential rework areas which can be immediately addressed to

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.     relevant standards and procedures followed in the company

KU2.     different types of products manufactured by the company

KU3.     knowledge of functional processes like store management, inventory management, quality management and key contact points for query resolution

KU4.     different types of assembling processes and component storage process (Kitting)

KU5.     different equipment and components used in the assembly process bolts, nuts, screws, wires, fasteners, connectors, sealants, adhesive bonding equipment etc. ( Knowledge of shapes, size and utility)

KU6.     different types of bolting guns/ riveting guns/ Hand held/ Power drills used in the assembly process

KU7.     size for tightening equipment like spanners, screw drivers, wrenches, pliers testers

KU8.     numbering/ identification nomenclature for the various assembly and tightening equipment

KU9.     the method of reading and interpreting the various gauges, meters, graphs,dials

KU10. Reading and interpreting torqueing charts and usage of Torque Meters

KU11. impact of various assembly process like bolting, torqueing, tightening, fitting, greasing, hammering, sealing, clamping on the final component/ vehicle performance

KU12. different types of defects which may arise due to improper tightening and torqueing . Fool- proofing techniques employed in the assembly operations

KU13. how to visualize the final product output and conduct quality verification tests

KU14. how to operate both in automatic and manual mode

KU15. available reaction plan for all operational efficiencies as mentioned in the SOP/ Work Instruction/ Control Plan for eventualities of drop in air pressure, power supply discontinuation, key characteristics out of control and any other operational abnormality

KU16. hazards and safety aspects involved in assembling activities and usage of relevant PPEs

Generic Skills (GS)

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

GS1.     document information

GS2.     read equipment manuals and process documents to understand the equipment and processes better

GS3.     read internal information memos shared by internal customers ( other functions within the organization)

GS4.     discuss task lists, schedules, and work-loads with co-workers

GS5.     question internal customers/ assemble shop supervisor in order to understand the nature of the problem and make a diagnosis

GS6.     plan and organize the work order and jobs received from the internal customers

GS7.     plan and organize the design/ process/quality documents received from internal customers

GS8.     keep fixtures, tools, drawings, Work Instructions, SOP manuals as per the part number, colour codes etc. as defined under the 5S systems

GS9.     organize all process/ equipment manuals so that sorting out information isfast

GS10. carefully analyse the body part for various assembling defects at every station

GS11. carefully run the production line with relevant actions as listed in SOP/WI if some delay, or power supply problem happens

Assessment Guidelines

  1. Criteria for assessment for each Qualification Pack will be created by the Sector Skill Council. Each Element/ Performance Criteria (PC) will be assigned marks proportional to its importance in NOS. SSC will also lay down proportion of marks for Theory and Skills Practical for each Element/ PC.
  • The assessment for the theory part will be based on knowledge bank of questions created by the SSC.
  • Assessment will be conducted for all compulsory NOS, and where applicable, on the selected elective/option NOS/set of NOS.
  • Individual assessment agencies will create unique question papers for theory part for each candidate at each examination/training center (as per assessment criteria below).
  • Individual assessment agencies will create unique evaluations for skill practical for every student at each examination/ training center based on these criteria.
  • To pass the Qualification Pack assessment, every trainee should score the Recommended Pass % aggregate for the QP.
  • In case of unsuccessful completion, the trainee may seek reassessment on the Qualification Pack.