Free Casting Technician Sand Molding Course (6Months)

Casting Technician Sand Moulding:

Brief Job Description

This role primarily involves managing the specifications of the sand and molten metal, setting up and operating the casting equipment and forming & finishing the final output

Personal Attributes

Reading, writing and communication skills, ability to plan and prioritize, quality consciousness, safety orientation, Physique to sustain strenuous conditions, Dexterity, Ability to use fingers, hands and feet with ease to complete the assigned task (Dexterity), high precision and sensitivity to problem solving and sensitivity towards safety for self and equipment.

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

Understand and interpret engineering drawings and sketches related to casting:

Elements and Performance Criteria

Identify the right drawing to be used for the process

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

PC1. . check the version of the engineering drawing provided.

PC2. . select the latest version of the available engineering drawing so that the final measurements and design is available with the team

Understand the engineering drawings, sketches and work order and identify required work steps

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

PC3. . thoroughly understand the work order ( work output) required from the process

PC4. . clearly understanding the does and donts of the manufacturing process as defined in sops/ work instructions or defined by supervisors

PC5. . refer all engineering drawings and sketches related to the work output to understand the measurement dimensions and shape of the required work output

PC6. . identify the required activities which need to be executed in order achieve the final output as per the work order

PC7. . ensure that the process adopted is according to the work instructions/ standard operating procedures adopted

Documentation and storage of the drawings/ sketches

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

PC8. . store the drawings in a proper place where they cannot be damaged by moisture, chemicals, fire and can be easily accessed by the user

PC9. . observe any modification, changes required in the drawing and communicate the same to the concerned team in the organization

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.    sketches and engineering drawings and how to interpret meaningful information from the drawings

KU5.    dimensions and characteristics of the final product output

KU6.    different types of sand making, core making and mould making processes and associated equipment

KU7.    different types of tools and machinery for casting and trim the output

KU8.    sketches and engineering drawings

KU9.    basic principles of geometric and drawing

KU10. final product visualization from the drawing

KU11. impact of various physical parameters like temperature, etc on the properties of final output product like strength, shape etc

Generic Skills (GS)

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

GS1.    document information from the sketches and engineering drawings

GS2.    prepare draft drawings for the final output product

GS3.    write drawings to internal customers on the requirement of apparatus, hand toolsetc

GS4.    read and interpret engineering drawing and sketches

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

GS6.    read internal information drawings send by internal customers ( other functions within the organization)

GS7.    discuss task lists, schedules, and work-loads with co-workers

GS8.    question internal customers/ casting shop supervisor appropriately in order to understand the nature of the problem and make a diagnosis

GS9.    avoid using jargon, slang or acronyms when communicating with a customer, unless it is required

GS10. plan and organize the work order and jobs received from the internal customers

GS11. plan and organize the design documents received from internal customers

GS12. organize all process/ equipment manuals so that sorting out information is fast

GS13. use common sense and make judgments during day to day basis

GS14. use reasoning skills to identify and resolve basic problems

GS15. use intuition to detect any potential problems which could arise during operations

GS16. follow instructions and work on areas of improvement identified

GS17. complete the assigned tasks with minimum supervision

GS18. complete the job defined by the supervisor within the timelines and quality norms

GS19. detect problems in day to day tasks

GS20. support supervisor in using specific problem solving techniques and detailing out the problems

GS21. discuss possible solution with the supervisor for problem solving

GS22. make decisions in emergency conditions in case the supervisor is not available( as per the authority matrix defined by the organization)

Understand Casting and sand moulding processes:

Elements and Performance Criteria

Determine the type of sand, core and mould requirement

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

PC1..   understand the specifications and dimensions of output and determine the type of sand to be used to prepare core and mould

PC2. . understand the specifications and dimensions of output and determine the dimensions of core and mould

Determine the sand casting requirements, equipment and parameters

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

PC3. . determine the casting methodology and process to be adopted for completing the work order

PC4. . determine the various casting parameters like temperature, pouring speedetc. before starting the process

PC5. . determine the equipment availability for executing the activity

Escalations of queries on the given job

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

PC6. . refer the queries to a competent internal specialist if they cannot be resolved by the operator on own

PC7. . obtain help or advice from specialist if the problem is outside his/her area of competence or experience

PC8. . confirm self understanding to the specialist once the query is resolved 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 specifications of sand to be used for preparing cores and moulds

KU5.    different types of core making and mould making methodologies

KU6.           different types of sand casting processes and associated equipments

KU7.           different types of tools and machinery to prepare and trim the output

KU8.    different types of automated processes pertinent to sand making, core making, mould making or casting

KU9.    different types of metallurgical processes

KU10. sketches and engineering drawings

KU11. final product output and hence decide on the key steps to be followed for preparing output and trimming

KU12. impact of various physical parameters like temperature, etc on the properties of final output product like strength, shape etc

KU13. basic principles of geometric and drawing

KU14. hazards and safety aspects involved in handling molten metal

Generic Skills (GS)

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

GS1.    document information from the sketches and engineering drawings

GS2.    prepare draft drawings for the final output product

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 engineering drawing and sketches

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

GS6.    read internal information drawings send by internal customers ( other functions within the organization)

GS7.    discuss task lists, schedules, and work-loads with co-workers

GS8.    effectively communicate with the team members

GS9.    question internal customers/ shop supervisor appropriately in order to understand the nature of the problem and make a diagnosis

GS10. avoid using jargon, slang or acronyms when communicating with a customer, unless it is required

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

GS14. use common sense and make judgments during day to day basis

GS15. use reasoning skills to identify and resolve basic problems

GS16. use intuition 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

Prepare the machine (apparatus) and auxiliaries:

Elements and Performance Criteria

Determine the process requirements, tools, equipment and parameters to be used for sand making, core making, mould making and sand casting

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

PC1. .   determine the type of sand and apparatus to be used for making the same to produce desired moulds

PC2. .   determine the right methodology to prepare cores and moulds and various parameters like temperature, geometric dimensions etc.

PC3. .   determine the right casting and trimming methodology and process to be adopted for completing the work order

PC4. .   correctly determine the various casting and trimming parameters like temperature, geometric dimensions etc. before starting the process

PC5. .   determine the material required and the equipment availability for executing the activity

Clean the dies and equipment & tools before executing the sand making, core making, mould making and casting process and setup the equipment

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

PC6. .   ensure cleaning of machinery like mixers, hoppers, feeders etcby spraying or brushing surfaces with parting agents to ensure smoothness and prevent sticking or seepage

PC7. .   ensure cleaning of the other machine and tools, auxiliaries(spatulas, chippers etc) before the initiation of the process

PC8. .   setup the respective apparatus as per the selected sand making/ core making/ mould making/ casting processand the standards used in the automobile industry

Prepare sand, core, mould and output as per the product specification

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

PC9. .   correctly analyze the geometric specifications for the output and ensure the core, mould and output are in line with product drawing/ sketches available

PC10. . in case the output is not as per the given measurements, remove extra material by using chippers, grinders etc

Escalations of queries for the given job

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

PC11. . immediately refer the queries to a competent internal specialist if they cannot be resolved by the operator on own

PC12. . obtain help or advice from specialist if the problem is outside his/her area of competence or experience

PC13. . confirm self -understanding to the specialist once the query is resolved 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 cleaning techniques, sand making, core making, mould making and sand casting processes and associated equipment

KU5.    different tools and equipment being used for sand making

KU6.           different tools and equipment being used for core making

KU7.           different tools and equipment being used for mould making

KU8.    different tools and equipment being used for trimming and casting

KU9. different types of cleaning agents being commonly used

KU10. measuring instruments like verniercalipers, micrometers

KU11. sketches and engineering drawings

KU12. final product output and hence decide on the key steps to be followed for casting and trimming

KU13. basic principles of geometry and drawing

Generic Skills (GS)

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

GS1.    document information from the sketches and engineering drawings

GS2.    prepare draft drawings for the final output product

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 engineering drawing and sketches

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

GS6.    read internal information drawings sent by internal customers ( other functions within the organization)

GS7.    discuss task lists, schedules, and work-loads with co-workers

GS8.    effectively communicate with the team members

GS9.    question internal customers/ shop supervisor appropriately in order to understand the nature of the problem and make a diagnosis

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. visualize the final job product after understanding the given drawing/ sketches

GS14. analyze the final output and its alignment with the given drawing

GS15. finalize the optimum levels of physical parameters so that the job output meets the prescribed job standards

GS16. use common sense and make judgments during day to day basis

GS17. use reasoning skills to identify and resolve basic problems

GS18. follow instructions and work on areas of improvement identified complete the assigned tasks with minimum supervision

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

GS20. take self initiatives in driving small projects with the supervisor like operation improvement, training of helpers and assistant operators, 5S, Kaizen etc

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.