Free Helicopter Transmission Technician Course (6months)

 Helicopter Transmission Technician repairs and maintains transmission system for helicopters.

Brief Job Description of  Helicopter Transmission Technician: Helicopter Transmission Technician is responsible for performing sub-assembly operations like bearing staking, bush pressing (interference fits), and use of UTM for bearing push out load check.

Personal Attributes: key attributes for Helicopter Transmission Technician would include good communication skills, excellent written communication skills and good interpersonal skills with a keen eye for details.

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 organisation) 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

Organisational

Context

KA1. hazard identification and risk management as defined within the organisational 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 organisation

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

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: 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. analyses 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     Performing Helicopter Transmission Assembly Operations Performance Criteria   Preparing for assembly operations   PC1. identify damages in loaded parts and be able to check the documents for matching with the defined SOP and drawings PC2. refer to the process requirements as given in the standards, route books, and manuals PC3. understand the Gleason spiral bevel gear system and its manufacturing techniques/manufacturing machines PC4. study the process sheets/standard practices manuals / modification documents and evolutionary history of the transmission modules PC5. check condition of assembly/disassembly/dimension-torque checking tools and gauges PC6. use special tools used for giving load to the gear meshes, for alignment checks, backlash measurement of gears, bearing installation and staking tools PC7. ensure that improper use of tools and its damage to the parts beings assembled are gauged prior to assembly itself as a precautionary measure. PC8. understand the procedure of operating assembly machinery like the deep freezers, Universal testing machines, hydraulic presses of 10 Tons load, torque multipliers, hydraulic jacks, and overhead cranes PC9. safely use the electrical-electronic gadgets for actuated freewheel rigging operations, pneumatic tools and gauges PC10. check if the elastomeric is damaged-oozed out etc.   Performing assembly operations   PC11. assemble bearings in to the Magnesium housings/gear shafts PC12. assemble bushes (interference fits) using deep freeze-oven/heat guns PC13. install the pattern check tools in the gear boxes and apply 10 nm torque thru dead weights or by tightening the conical surfaces for achieving the desired patterns/ backlash values PC14. ensure proper rotational drag on parts with bearings to ensure that unnecessary pre-load is not given   PC15. give proper torque using calibrated torque wrenches, ensuring to wire lock parts thru positive wire locking PC16. check for burrs on edges of parts to prevent damage during assembly especially in critical areas of the gear boxes PC17. perform rigging of the actuated freewheels, installation of hydraulic actuators with the gear boxes PC18. perform assembly of shaft modules and balancing of the shafts PC19. perform bearing staking and proof load testing   Performing assembly operations post-testing   PC20. check for proper rotational drag/positive wire locking /line replaceable units’ installation/slippage marks/wpc application on the modules needs to be understood PC21. perform rigging of actuated freewheels, spring stiffness checks on assembly for the freewheel units, adjusting shims for achieving dynamic contact patterns in case of corrections PC22. perform calculations for achieving balance values post PI checks of shafts in the Ground test centers   Carrying out self inspection & 1st off inspection   PC23. check for FOD, elimination of blocked oil jets from the gear boxes, proper sequence of wire locking and usage of plastic sleeve in the wires to prevent damage to the magnesium housings, proper application of weather proofing compound/proper application of slippage marks PC24. record the critical interfacing dimensions during the assembly operations, proper application of slippage marks, proper installation of seals and o-rings   Knowledge and Understanding   Organisational   Context KA1. the user/individual on the Job needs to know & understand relevant DIN/AGMA standards & procedures followed in the Company for manufacturing and also know the philosophy of power transmission from engine to blades via the transmission system. International standards for transmission system like the ZF/FAR-JAR standards/company systems-manuals like AS/environmental standards/procurement standards/design documents like stress, heat and mass transfer etc., needs to be known KA2. different types of Spur/Helical Gears and Spline manufactured by the company and the machines on which it needs to be machined and the special process for heat treat, surface treatments etc. also to be known KA3. different departments that act as the supply chain to transmission shop also need to be understood KA4. process flow/routing of various components in the division and different facilities available for helicopter manufacture needs to be known   Technical Knowledge KB1. different types of machining processes carried out on Spur/Helical and Spline Gear Cutting, Broaching etc.   KB2. different types of assembly/disassembly tools, special tools used for bearing pressing shim grinding machines KB3. basic fundamentals of machines & mechanical sub-assemblies on helicopter and assembly -disassembly tools needs to be known KB4. interpreting drawings/3d Catia models/use of computer for wind-chill software application needs to be known KB5. all functions of Assembly balancing machines and assembly machines/tools KB6. basic principles of 5S manufacturing-cleaning, sorting, scrap handling etc. KB7. application of coolant & lubricants KB8. basic arithmetic and calculation methods for tolerance limits Core Skills/ Generic Skills Writing Skills The user/ individual on the job needs to know and understand how to: SA1. write basic level notes on technical features of the transmission modules SA2. interpret basic level geometrical parameters from transmission assembly drawings and quality control charts   Reading Skills The user/individual on the job needs to know and understand how to: SA3. read & comprehend instruction sheet/ route books, process documentation & quality control plan SA4. interpret/ comprehend the information given in the instruction sheet/ work instruction & notes SA5. read & interpret symbols given on equipment’s a nd work area e.g. fire kits SA6. rea d instruction sheet/ work instruction drawings/ engineering drawings, sketches regarding transmission assembly modules   Oral Communication (Listening and Speaking skills) The user/individual on the job needs to know and understand how to: SA7. discuss task lists and job requirements with co-workers SA8. effectively discuss and communicate regarding Targets, activities, processes etc with supervisor and co-workers SA9. discuss with supervisor in order to understand the nature of problems faced on routine and special basis SA10. attentively listen with full attention and comprehend the information given by the speaker     Professional Skills   Decision Making     The user/ individual on the job needs to know and understand: SB1. judge when to ask help from supervisor SB2. suggest options to operators in case of any issue are observed during operations     Plan and Organize The user/individual on the job needs to know and understand: SB3. plan, organise & prioritise the job received from the Production Manager SB4. validate all the process/equipment manuals so that the final process selection is correct SB5. support the supervisor in scheduling tasks for timely completion of the job   Customer Centricity The user/ individual on the job needs to know and understand: SB6. ensure that customer needs are assessed properly problem and every effort is made to provide satisfactory service   Problem Solving The user/individual on the job needs to know and understand how to: SB7. recognise a work place problem or a potential problem and take action SB8. determine problems requiring priority action SB9. gather information and provide assistance as required to solve problems SB10. refer problems outside area of responsibility to concerned person/ group   Analytical Thinking The user/individual on the job needs to know and understand how to: SB11. 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: SB12. analyse, evaluate and apply information gathered from observation, experience, reasoning or communication to act efficiently     Maintain 5s at the work premises   Performance Criteria   Ensure sorting   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 SO PC4. segregate the items which are labeled as red tag items for the process area and keep them in the correct places PC5. sort the tools/ equipment/ fasteners/ spare parts as per specifications/ utility into proper trays, cabinets, lockers as mentioned in the 5S guidelines/ work instructions PC6. ensure that areas of material storage areas are not overflowing PC7. properly stack the various types of boxes and containers as per the size/ utility to avoid any fall of items/ breakage and also enable easy sorting when required PC8. return the extra material and tools to the designated sections and make sure that no additional material/ tool is lying near the work area PC9. follow the floor markings/ area markings used for demarcating the various sections in the plant as per the prescribed instructions and standar   Ensure proper documentation and storage   PC10. follow the proper labeling mechanism of instruments/ boxes/ containers and maintaining reference files/ documents with the codes and the lists PC11. check that the items in the respective areas have been identified as broken or damaged PC12. follow the given instructions and check for labeling of fluids, oils, lubricants, solvents, chemicals etc. and proper storage of the same to avoid spillage, leakage, fire etc. PC13. make sure that all material and tools are stored in the designated places and in the manner indicated in the 5S instructions   Ensure cleaning of self and the work place   PC14. check whether safety glasses are clean and in good condition PC15. keep all outside surfaces of recycling containers are clean PC16. ensure that the area has floors swept, machinery clean and generally clean. In case of cleaning, ensure that proper displays are maintained on the floor which indicate potential safety hazards PC17. check whether all hoses, cabling & wires are clean, in good condition and clamped to avoid any mishap or mix up PC18. ensure workbenches and work surfaces are clean and in good condition PC19. follow the cleaning schedule for the lighting system to ensure proper illumination PC20. store the cleaning material and equipment in the correct location and in good condition PC21. ensure self-cleanliness – clean uniform, clean shoes, clean gloves, clean helmets, personal hygiene   Ensure sustenance   PC22. follow the daily cleaning standards and schedules to create a clean working environment PC23. attend all training programs for employees on 5S PC24. support the team during the audit of 5S PC25. participate actively in employee work groups on 5S and encourage team members for active participation PC26. follow the guidelines for What to do and What not to do to build sustainability in 5S as mentioned in the 5S check lists/ work instructions   Knowledge and Understanding     Organisational   Context   KA1. relevant standards, procedures and policies related to 5S followed in the company   Technical Knowledge   KB1. have basic knowledge of 5S procedures KB2. know various types 5s practices followed in various areas KB3. understand the 5S checklists provided in the department/ team KB4. have skills to identify useful & non useful items KB5. have knowledge of labels , signs & colours used as indicators KB6. have knowledge on how to sort and store various types of tools, equipment, material etc. KB7. how to identify various types of waste products KB8. understand the impact of waste/ dirt/ dust/unwanted KB9. substances on the process/ environment/ machinery/ human body KB10. have knowledge of best ways of cleaning & waste disposal KB11. understand the importance of standardization in processes KB12. understand the importance of sustainability in 5S   KB13. have knowledge of TQM process KB14. have knowledge of various materials and storage norms KB15. understand visual controls, symbols, graphs etc.     Core Skills/ Generic Skills Writing Skills The user/ individual on the job needs to know and understand how to: SA1. write basic level notes and observations SA2. note down observations (if any) related to the process SA3. write information documents to internal departments/ internal teams   Reading Skills The user/individual on the job needs to know and understand how to: SA4. read 5S instructions put up across the plant premises   Oral Communication (Listening and Speaking skills) The user/individual on the j ob needs to know and understand how to: SA5. effectively communicate information to team members inform employees in the plant and concerned functions about 5S SA6. question the process head in order to understand the 5S related issues SA7. attentively listen with full attention and comprehend the information given by the speaker during 5S training programs       Professional Skills Thinking The user/individual on the job needs to know and understand how to: SB1. use common sense and make judgments during day to day basis SB2. use reasoning skills to identify and resolve basic problems using 5S   Persuasion The user/individual on the job needs to know and understand: SB3. persuade co team members to follow 5S SB4. ensure that the co team members understand the importance of using 5S tool   Creativity The user/individual on the job needs to know and understand: SB5. use innovative skills to perform and manage 5S activities at the work desk and the shop floor SB6. exhibit inquisitive behavior to seek feedback and question on the existing set patterns of work   Self-Discipline The user/individual on the job needs to know and understand how to: SB7. do what is right, not what is a popular practices SB8. follow shop floor rules& regulations and avoid deviations; make 5S an integral way of life SB9. ensure self-cleanliness on a daily basis SB10. demonstrate the will to keep the work area in a clean and orderly manner  Model Curriculum Helicopter Transmission Technician   Follow safety and security procedures   comprehend the organisation’s safety and security policies and procedures  comprehend the regulatory guidelines on safe conduct of operations and maintenance of conditions to thwart any acts of unlawful interference  report any identified breaches of safety, and security policies and procedures to the designated person  coordinate with other resources at the workplace (within and outside the organization) to achieve safe and secure environment  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  report any hazards outside the individual’s authority to the relevant person in line with organisational procedures and regulatory guidelines  follow organisation’s emergency procedures for accidents, fires or acts of unlawful interference  identify and recommend opportunities for improving health, safety, and security to the designated person  complete all health and safety records are updates and procedures well defined   Performing Helicopter Transmission Assembly Operations    identify damages in loaded parts and be able to check the documents for matching with the defined sop and drawings  refer to the process requirements as given in the standards, route books, and manuals  understand the Gleason spiral bevel gear system and its manufacturing techniques/manufacturing machines  study the process sheets/standard practices manuals / modification documents and evolutionary history of the transmission modules  check condition of assembly/disassembly/dimension-torque checking tools and gauges  use special tools used for giving load to the gear meshes, for alignment checks, backlash measurement of gears, bearing installation and staking tools  ensure that improper use of tools and its   damage to the parts beings assembled are gauged prior to assembly itself as a precautionary measure  understand the procedure of operating assembly machinery like the deep freezers, Universal testing machines, hydraulic presses of 10 Tons load, torque multipliers, hydraulic jacks, and overhead cranes  safely use the electrical-electronic gadgets for actuated freewheel rigging operations, pneumatic tools and gauges  check if the elastomeric is damaged-oozed out etc.  assemble bearings in to the Magnesium housings/gear shafts  assemble bushes (interference fits) using deep freeze-oven/heat guns  Install the pattern check tools in the gear boxes and apply 10 nm torque thru dead weights or by tightening the conical surfaces for achieving the desired patterns/ backlash values  ensure proper rotational drag on parts with bearings to ensure that unnecessary pre-load is not given  give proper torque using calibrated torque wrenches, ensuring to wire lock parts thru positive wire locking  check for burrs on edges of parts to prevent damage during assembly especially in critical areas of the gear boxes  perform rigging of the actuated freewheels, installation of hydraulic actuators with the gear boxes  perform assembly of shaft modules and balancing of the shafts  perform bearing staking and proof load testing  check for proper rotational drag/positive wire locking /line replaceable units’ installation/slippage marks/wpc application on the modules needs to be understood  perform rigging of actuated freewheels, spring stiffness checks on assembly for the freewheel units, adjusting shims for achieving dynamic contact patterns in case of corrections  perform calculations for achieving balance values post PI checks of shafts in the Ground test centers  check for FOD, elimination of blocked oil jets from the gear boxes, proper sequence of wire locking and usage of plastic sleeve in the wires to prevent damage to the   magnesium housings, proper application of weather proofing compound/proper application of slippage marks  record the critical interfacing dimensions during the assembly operations, proper application of slippage marks, proper installation of seals and o-rings   Maintain 5S at the work premises    follow the sorting process and check that the tools, fixtures & jigs that are lying on workstations are the ones in use and un- necessary items are not cluttering the workbenches or work surfaces.  ensure segregation of waste in hazardous/ non Hazardous waste as per the sorting work instructions  follow the technique of waste disposal and waste storage in the proper bins as per SOP  segregate the items which are labeled as red tag items for the process area and keep them in the correct places  sort the tools/ equipment/ fasteners/ spare parts as per specifications/ utility into proper trays, cabinets, lockers as mentioned in the 5S guidelines/ work instructions  ensure that areas of material storage areas are not overflowing  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  return the extra material and tools to the designated sections and make sure that no additional material/ tool is lying near the work area  follow the floor markings/ area markings used for demarcating the various sections in th e plant as per the prescribed instructions and standards  follow the proper labeling mechanism of instruments/ boxes/ containers and maintaining reference files/ documents with the codes and the lists  check that the items in the respective areas have been identified as broken or damaged  follow the given instructions and check for labeling of fluids, oils, lubricants, solvents, chemicals etc. and proper storage of the same to avoid spillage, leakage, fire etc.  make sure that all material and tools are stored in the designated places and in the manner indicated in the 5S inst ructions  check whether safety glasses are clean and in good condition   keep all outside surfaces of recycling containers are clean  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  check whether all hoses, cabling & wires are clean, in good condition and clamped to avoid any mishap or mix up  ensure workbenches and work surfaces are clean and in good condition  follow the cleaning schedule for the lighting system to ensure proper illumination  store the cleaning material and equipment in the correct location and in good condition  ensure self-cleanliness – clean uniform, clean shoes, clean gloves, clean helmets, personal hygiene  follow the daily cleaning standards and schedules to create a clean working environment  attend all training programs for employees on 5S  support the team during the audit of 5 S  participate actively in employee work groups on 5S and encourage team members for active participation  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     Unique equipment used;  Cut-out model of a typical helicopter engine  Test bed  Engine hoist  Slings  Ground Power Unit (GPU)  Video/2D or 3D software based audio-visual training package  Common & special tool kits  Common & special gauges and testers  Common & special cranes  Fork lift, special high lift equipment  personal protective equipment (PPE) (consisting of safety jacket, safety goggles, ear plugs, gloves, safety shoes & safety helmet)     Guidelines for Assessment 1. Criteria for assessment for each Qualification Pack will be created by the Sector Skill Council. Each Performance Criteria (PC) will be assigned marks proportional to its importance in NOS. SSC will also lay down proportion of marks for Theory and Skills Practical for each PC 2. The assessment for the theory part will be based on knowledge bank of questions created by the SSC 3. Individual assessment agencies will create unique question papers for theory part for each candidate at each examination/training center (as per assessment criteria below) 4. Individual assessment agencies will create unique evaluations for skill practical for every student at each examination/training center based on this criteria 5. To pass the Qualification Pack, every trainee should score a minimum of 70% in aggregate 6. The marks are allocated PC wise, however, every NOS will carry a weightage in the total marks allocated to the specific QP