Free Repair Welder Course (6Months)

Repair Welder:

Brief Job Description

A Welder is responsible for maintaining and operating all welding related works. The individual must be able to use hand welding techniques or welding equipment and tools to join various metal components and also carry out repair work on machinery and equipment.

Personal Attributes

An individual on this job requires to work as a part of team and must be able to work long hours. The individual should have good understanding of the welding machine andproper knowledge of the service related activities, schedules and maintenance of the equipment and tools.

Plan and organise work to meet expected outcomes:

Elements and Performance Criteria

Work requirements including various activities within the given time and set quality standards

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

PC1.              keep immediate work area clean and tidy

PC2.              treat confidential information as per the organisations guidelines

PC3.              work in line with organisations policies and procedures

PC4.              work within the limits of job role

PC5.              obtain guidance from appropriate people, where necessary

PC6.              ensure work meets the agreed requirements

Appropriate use of resources

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

PC7.              establish and agree on work requirements with appropriate people

PC8.              manage time, materials and cost effectively

PC9.              use resources in a responsible manner

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.    the organisations policies, procedures and priorities for area of work, role and responsibilities in carrying out that work

KU2.    the limits of responsibilities and when to involve others

KU3.    specific work requirements and who these must be agreed with

KU4.    the importance of having a tidy work area and how to do this

KU5.    how to prioritize workload according to urgency and importance and the benefits of this

KU6.    the organisations policies and procedures for dealing with confidential information and the importance of complying with these

KU7.    the purpose of keeping others updated with the progress of work

KU8.    who to obtain guidance from and the typical circumstances when this may be required

KU9.    the purpose and value of being flexible and adapting work plans

KU10. how to complete tasks accurately by following standard procedures

KU11. technical resources needed for work and how to obtain and use these

Generic Skills (GS)

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

GS1.    write in at least one language

GS2.    read instructions, guidelines/procedures

GS3.    ask for clarification and advice from appropriate persons

GS4.    communicate orally with colleagues

GS5.    make a decision on a suitable course of action appropriate for accurately completing the task within resources

GS6.    agree objectives and work requirements

GS7.    plan and organise work to achieve targets and deadlines

GS8.    deliver consistent and reliable service to customers

GS9.    check own work and ensure it meets customer requirements

GS10. anomalies to the concerned persons

GS11. analyse problems and identify work-arounds taking help from

GS12. apply own judgement to identify solutions in different situations

Work effectively in a team:

Elements and Performance Criteria

Effective communication

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

PC1.   maintain clear communication with colleagues

PC2.   work with colleagues

PC3.   pass on information to colleagues in line with organisational requirements

PC4.. work in ways that show respect for colleagues

PC5.   carry out commitments made to colleagues

PC6.   let colleagues know in good time if cannot carry out commitments, explaining the reasons

PC7.          identify problems in working with colleagues and take the initiative to solve these problems

PC8.          follow the organisations policies and procedures for working with colleagues

PC9.   ability to share resources with other members as per priority of tasks

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1. the organisations policies and procedures for working withcolleagues, role and responsibilities in relation to this

KU2. the importance of effective communication and establishing goodworking relationships with colleagues

KU3. different methods of communication and the circumstances inwhich it is appropriate to use these

KU4. benefits of developing productive working relationships withcolleagues

KU5. the importance of creating an environment of trust and mutualrespect

KU6. whether not meeting commitments, will have implications onindividuals and the organisation

KU7. different types of information that colleagues might need and theimportance of providing this information when it is required

KU8. the importance of problems, from colleagues perspective andhow to provide support, where necessary, to resolve these

Generic Skills (GS)

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

GS1.    complete well written work with attention to detail

GS2.    read instructions, guidelines/procedures

GS3.    listen effectively and orally communicate information

GS4.           make decisions on a suitable course of action or response

GS5.           plan and organise work to achieve targets and deadlines

GS6.           check that the work meets customer requirements

GS7.    deliver consistent and reliable service to customers

GS8.           apply problem solving approaches in different situations

GS9.           apply balanced judgements to different situations

GS10. apply good attention to detail

GS11. check that the work is complete and free from errors

GS12. get work checked by peers

GS13. work effectively in a team environment

Maintain a healthy,safe and secure working environment:

Elements and Performance Criteria

Resources needed to maintain a safe, secure working environment

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

PC1.   comply with organisations current health,safety and security policies and procedures

PC2. report any identified breaches in health,safety, and security policies and procedures to the designated person

PC3.. Coordinate with other resources at the workplace to achieve the healthy, safe and secure environment for all incorporating all government norms esp. for emergency situations like fires,earthquakes etc.

PC4.   identify and correct any hazards like illness, accidents, fires or any other natural calamity safely and within the limits of individuals authority

PC5.   report any hazards outside the individuals authority to the relevant person in line with organisational procedures and warn other people who may be affected

PC6.   follow organisations emergency procedures for accidents, fires or any other natural calamity

PC7.   identify and recommend opportunities for improving health,safety, and security to the designated person

PC8.   complete all health and safety records are updates and procedures well defined

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.    legislative requirements and organisations procedures for health, safety and security and individuals role and responsibilities in relation to this

KU2.    what is meant by a hazard, including the different types of health and safety hazards that can be found in the workplace

KU3.    how and when to report hazards

KU4.    the limits of responsibility for dealing with hazards

KU5.    the organisations emergency procedures for different emergency situations and the importance of following these

KU6.    the importance of maintaining high standards of health, safety and security

KU7.    implications that any non-compliance with health, safety and security may have on individuals and the organisation

KU8.    different types of breaches in health, safety and security and how and when to report these

KU9.    evacuation procedures for workers and visitors

KU10. how to summon medical assistance and the emergency services,where necessary

KU11. how to use the health, safety and accident reporting procedures and the importance of these

Generic Skills (GS)

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

GS1.    complete accurate, well written work with attention to detail

GS2.    read instructions, guidelines/procedures/rules

GS3.    listen and orally communicate information

GS4.    make decisions on a suitable course of action or response

GS5.    plan and organise work to achieve targets and deadlines

GS6.    build and maintain positive and effective relationships withcolleagues and customers

GS7.    apply problem solving approaches in different situations

GS8.    analyse data and activities

GS9.    apply balanced judgements to different situations

GS10. apply good attention to detail

GS11. check that the work is complete and free from errors

GS12. get work checked by peers

GS13. work effectively in a team environment

Perform and finish all assigned jobs related to welding;

Elements and Performance Criteria

Assist in the overall welding process

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

PC1..    determine required equipment and welding method to be used to weld a particular components / aggregate

PC2..    identify the different material specifications required to repair the weld joints

PC3..    assist in setting up or adjusting necessary equipment, such as shielded and electric arc welders and maintenance or other welding related machines

PC4..    operate manual or semi-automatic welding equipment to fuse metal segments, using processes such as gas tungsten arc, gas metal arc, flux-cored arc, plasma arc, shielded metal arc, resistance welding, and submerged arc welding

PC5..    operate manual and automated welding units and equipment by depositing metal from electrode to work piece and joining edges of work piece

PC6..    layout, position, and secure parts and assemblies according to specifications, using straightedge, combination square, callipers, and ruler

PC7..    tack-weld or weld components and assemblies, using electric, gas, arc, or other welding equipment

PC8..    cut work piece, using powered saws, hand shears, or chipping knife

PC9..    melt lead bar, wire, or scrap to add lead to joint or to extrude melted scrap into reusable form

PC10.. observe tests on welded surfaces, like dimension tolerance to evaluate weld quality and conformance to specifications

PC11.. monitor the fitting, burning, and welding processes to avoid overheating of parts or warping, shrinking, distortion, or expansion of material

PC12.. inspect grooves, angles, or gap allowances, using micrometer, calliper, and precision measuring instruments

PC13.. remove rough spots from work piece, using portable grinder, hand file, or scraper

PC14.. weld components in flat, vertical, or overhead positions

PC15.. heat, form, and dress metal parts, using hand tools, torch, or arc welding equipment

PC16.. ignite torch and adjust valves, amperage, or voltage to obtain desired flame or arc

PC17.. weld defect free weld joint and weld repair

PC18.. assist in examining finish products and spare parts and comparing them with samples to check whether the specifications are met

PC19.. ensure that all safety procedures are followed by using protective equipment like eye shields, nose masks etc.

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.    standard operating procedures to be followed for performing welding processes

KU2.    documentation requirements for each procedure carried out organisational and professional code of ethics and standards of practice

KU3.    safety, health and environmental policies and regulations for the workplace

KU4.    how to handle vehicle parts and machinery

KU5.    how to visually check the part for damage

KU6.    the methods and practices followed in the maintenance of tools, machinery, and layout of equipment and to carry out repair process

KU7.    which material or alloy to use while welding particular metal: steel aluminium and aluminium alloys copper and copper alloys nickel and nickel alloys titanium and titanium alloys zirconium and zirconium alloys

KU8.    the various welding techniques and processes such as gas metal arc welding tungsten inert gas welding oxy acetylene welding arc welding resistance welding solid state welding

KU9.    how to use the following tools and equipment required to carry out the welding process : blow torches : – motorized cutting torches – pattern cutting torches – welding torches gas welding or brazing or cutting apparatus : – brazing equipment – arc welding equipment – oxyacetylene welding equipment – portable gas operated arc welders manlift or personnel lift

: – hydraulic truck lifts – swing stages welding masks including various types of : – hand shields/gloves – welding eye shields welding tools : – rod ovens – storage ovens and hot boxes – welding guns workshop presses : – brakes – portable magnetic drill presses – punch presses

KU10. how to inspect equipment, structures, or materials to identify the cause of errors or other problems or defects

KU11. how to use either control mechanisms or direct physical activity to operate machines or processes (not including computers or vehicles) such as use precision measuring tools or equipment operate metal or plastic fabricating equipment/machine perform detailed welding techniques use fire suppression equipment use hand or power tools use non-destructive test equipment fabricate beams use acetylene welding/cutting torch weld together metal parts, components, or structures use gas welding equipment burn (cut), trim, or scarf metal objects use thermal-cutting equipment use braze-welding equipment solder metal parts or components together braze metal parts or components together use soldering equipment use arc welding equipment operate hoist, winch, or hydraulic boom

KU12. how to perform physical activities such as climbing, lifting, balancing, walking, stooping, and handling of materials

Generic Skills (GS)

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

GS1.    create documentation required for the welding process (includingwork sheets, etc.)

GS2.    enter, transcribe, record, store, or maintain information in written or electronic/magnetic form

GS3.    assist in maintaining appropriate service and repair records of the vehicle to be welded

GS4.    write in at least one language

GS5.    read work orders, blueprints, materials, specifications etc. related to the welding job

GS6.    read and interpret geometric dimensions and tolerances of the welding job

GS7.    interact with superiors and other support staff function

GS8.    provide signals directions or warnings to supervisors, co-workers, and subordinates by telephone, in written form, e-mail, or in person

GS9.    analyse information and evaluate results to choose the best solution and solve problems in case they arise during the welding procedure

GS10. decide when to contact superior in case of any discrepancy in the welding machine

GS11. plan a visual check on the piece for insuring that its damage free

GS12. plan and organise deliveries taking account of local conditions

GS13. ensure that customers requirements are assessed and satisfactory service is provided

GS14. detect equipment malfunctions or out of tolerance machining and adjusts machine within limits as required while insuring quality of production

GS15. identifying the underlying principles, reasons, or facts of information by breaking down information or data into separate parts

GS16. analyse and interpret geometric dimensions and tolerances

GS17. use logic and reasoning to identify the strengths and weaknesses of alternative solutions, conclusions or approaches to problems

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