Free Painting Technician Level 4 Course (6Months)
Painting Technician Level 4:
Brief Job Description
A painting technician would do final painting , touch up and inspection of the body of the vehicle under painting.
Personal Attributes
The person should have the attributes like Correct Vision & dexterity, No Color Blindness, Non Allergic to Chemicals and Paints and Thinner, Hand Eye Coordination, Ability to work in difficult environment, orientation to safety and quality, Patience and attitude to conduct repeated operations.
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 process and equipment requirement to complete the task:
Elements and Performance Criteria
Understand the process requirements, painting equipment and parameters
To be competent, the user/individual on the job must be able to:
PC1. . understand the right painting methodology and process 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 painting process parameters like temperature, air pressure, thinner pressure, paint pressure in the pipe lines, gun type, gun distance, cycle time etc before starting the painting 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 paint and thinner ratio to be used for the painting process
PC5. . understand 5 s related to the work station, line area
PC6. . 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:
PC7. . refer the queries to a competent internal specialist if they cannot be resolved by the painter on own
PC8. . obtain help or advice from specialist if the problem is outside his/her area of competence or experience
PC9. . 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 painting processes and associated equipments
KU5. different types of guns
KU6. the method of reading and interpreting the various gauges
KU7. how to visualize the final product output and conduct quality verification tests.
KU8. the impact of various physical parameters like temperature, pressure, gun distance, electric current, voltage on the properties of final output product like durability, surface finish etc
KU9. hazards and safety aspects involved in painting 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 painting 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 paint specimen
GS5. read equipment manuals and process documents to understand the equipments 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 painting 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. 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 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)
Preparing the painting machine:
Elements and Performance Criteria
Arrange for equipment, PPEs and material as per the requirement
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 painting process
PC3. . ensure that the helper/ assistant technician brings the required material and tools before the start of the painting operations
Clean the painting equipment before executing the painting process and setup the equipment
To be competent, the user/individual on the job must be able to:
PC4. . ensure that the helper/ assistant operator cleans the surface of the painting gun to remove dust and any other impurities
PC5.. setup the painting apparatus as per the selected painting process and the internal sops/ work instructions and the setting standards for the machine
Prepare the surface of the part ( work pieces) on which painting needs to be conducted
To be competent, the user/individual on the job must be able to:
PC6. . ensure that the helper/ assistant operator cleans the surface of the metal parts(work pieces) which need to be painted
PC7. . ensure that the pre-treatment is completed as per the quality standards .
Escalations of queries for the given job
To be competent, the user/individual on the job must be able to:
PC8. . immediately refer the queries to the supervisor to avoid any delay in the actual process
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 painting processes and associated equipments
KU5. different types of guns
KU6. the method of reading and interpreting the various gauges
KU7. how to visualize the final product output and conduct quality verification tests
KU8. the impact of various physical parameters like temperature, pressure, gun distance, electric current, voltage on the properties of final output product parameters like adhesion, durability, surface finish etc
KU9. hazards and safety aspects involved in painting 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 painting 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 paint specimen
GS5. read equipment manuals and process documents to understand the equipments 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 painting 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. visualize the final job product after understanding the given drawing/ sketches
GS14. co relate the type of job output required with the painting methodology to be used
GS15. identify the strengths and weakness of various painting process
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
Performing the Painting operation:
Elements and Performance Criteria
Clean the body before painting
To be competent, the user/individual on the job must be able to:
PC1.. ensure that the body is free from all dust particles
Check the balancing of the booth and atomizer setting
To be competent, the user/individual on the job must be able to:
PC2. . parameter must be in the specified range, if these are not in the range then paint defects like orange peel, overspray may appear
PC3. . if the booth is not balanced inform the control room or supervisor
PC4. . ensure that the paint atomizer is cleaned and required solvent and air pressure is maintained
PC5.. if the paint pressure is out of range then defect like rundown or thin paint may appears
Check booster and bell cup operations during painting
To be competent, the user/individual on the job must be able to:
PC6. . check the air booster compressor by starting it. in case air booster does not start immediately inform control room or supervisor.
PC7. . ensure that the bell cup is properly fit on each atomizer
PC8.. at shift end remove the bell cup, clean it and keep it in bell cup box
PC9. . insert the model no as per model
Check the home position of each robot Do purging Select automatic button
To be competent, the user/individual on the job must be able to:
PC10.. body must be in home position prior to starting of painting.
PC11.. operate station start , verify that it is displayed on screen
PC12.. do long purging and short purging
PC13. . select the button as per requirement, for final painting
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 defects which may arise due to improper booth parameters
KU5. knowledge on how to operate both in automatic and manual mode
KU6. ability to visualize the final product output and hence decide on the key steps to be followed
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 equipments and processes better
GS3. read internal information memos send by internal customers ( other functions within the organization)
GS4. discuss task lists, schedules, and work-loads with co-workers
GS5. question internal customers/ paint 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. organize all process/ equipment manuals so that sorting out information is fast
GS9. carefully analyze the body part for various painting defects at every tank level
GS10. carefully run the production line with relevant actions as listed in SOP/WI if some delay, or power supply problem happens
Performing the Touch up and Final Inspection:
Elements and Performance Criteria
Ensure sanding on defective areas of the body for Paint defects
To be competent, the user/individual on the job must be able to:
PC1. . after sanding please ensure there must be no edge at corners of the sanded area.
Apply air dry sealant in areas where defects/ cracks are observed
To be competent, the user/individual on the job must be able to:
PC2. . ensure that the air dry sealant is applied on the areas
PC3. . sealant to be applied with sealant gun and then rectification- application to be done for smooth finish
Do sanding and filling of putty
To be competent, the user/individual on the job must be able to:
PC4. . do putty application with the help of putty knife and after putty application bake in infrared lamp
PC5. . ensure that after baking, sanding of that area is done to level the surface with emery paper
Ensure for DFT, gloss
To be competent, the user/individual on the job must be able to:
PC6.. ensure lux level required for the surface inspection
Conduct sanding and polishing of the surface where required
To be competent, the user/individual on the job must be able to:
PC7. . ensure sanding with with the help of sanding paper of grit size of certain no.( extremely fine as per wi ) and then wipe the body with tag rag
PC8. . ensure effective polishing and then polisher application to be done
Touch of defective areas
To be competent, the user/individual on the job must be able to:
PC9. . ensure that the touch up paint is applied on the defected areas with the help of spray gun as prescribed in the work instructions/ control plan
PC10. . ensure that here must be no overspray of paint
Merge to fade out thinner with the help of spray gun
To be competent, the user/individual on the job must be able to:
PC11.. ensure that there should be no overspray of paint
Final inspection & documentation
To be competent, the user/individual on the job must be able to:
PC12.. visual inspection for achieving acceptable level of finish /adhesion ; verification test as per recommended frequency.
PC13. . send to the assembly line after completing wo/ logbook/inspection /lot quantity control documentation.
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 defects which may arise due to improper touch up painting
KU5. knowledge on how to operate gun in manual mode
KU6. ability to visualize the final product output, conduct verification tests and hence decide on the key steps to be followed
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 equipments and processes better
GS3. read internal information memos send by internal customers ( other functions within the organization)
GS4. discuss task lists, schedules, and work-loads with co-workers
GS5. question internal customers/ paint shop supervisor appropriately 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 documents received from internal customers
GS8. organize all process/ equipment manuals so that sorting out information is fast
GS9. carefully analyze the body part for various surface defects
GS10. carefully run the production line if some delay, abnormal event happens as per the recommended reaction plan.
Assessment Guidelines
- 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.
