CURRICULUM

FOR THE TRADE OF

PLASTIC PROCESSING OPERATOR

UNDER

APPRENTICESHIP TRAINING SCHEME

GOVERNMENT OF INDIA
MINISTRY OF SKILL DEVELOPMENT & ENTREPRENURESHIP
DIRECTORATE GENERAL OF TRAINING

1
 CONTENTS
Sl. No. Topics Page No.
1. Acknowledgement 3

2. Background 4-5
2.1Apprenticeship Training under Apprentice Act 1961
2.2 Changes in Industrial Scenario
2.3 Reformation
3. Rationale 6
4. Job roles: reference NCO 7
5. General Information 8
6. Course structure 9-10
7. Syllabus 11-26
7.1 Basic Training
7.1.1 Detail syllabus of Core Skill
A. Block-I (Engg. drawing & W/ Cal. & Sc.)
B. Block-II (Engg. drawing & W/ Cal. & Sc.)
7.1.2 Detail syllabus of Professional Skill & Professional
Knowledge
A. Block – I
B. Block – II
7.1.3 Employability Skill
7.1.3.1 Syllabus of Employability skill
A. Block – I
B. Block – II
7.2 Practical Training (On-Job Training)
7.2.1 Broad Skill Component to be covered during on-job
training.
A. Block – I
B. Block – II
Assessment Standard 27-29
8.1 Assessment Guideline
8.
8.2 Final assessment-All India trade Test
for Apprentice
9. Further Learning Pathways 30
10. Annexure-I – Tools & Equipment for Basic Training 31-33
11. Annexure-II – Tools & Equipment for On-Job Training 34
12. Annexure-III - Guidelines for Instructors & Paper setter 35

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 1. ACKNOWLEDGEMENT
The DGT sincerely express appreciation for the contribution of the Industry, State Directorate,
Trade Experts and all others who contributed in revising the curriculum. Special acknowledgement to
the following industries/organizations who have contributed valuable inputs in revising the curricula
through their expert members:

1. Central Institute of Plastic Engg. & Technology, M.I.D.C. ,Chikalthana, Aurangabad

2. Shefield Technoplast Pvt Ltd, Vadodara

3. Neatfim Irrigation India Pvt Ltd, Vadodara
4. Profine India Window Technology Pvt Ltd, Vadodara
5. DVET,Maharashtra State
6. DET, Gujarat State

Special acknowledgement is extended by DGT to the following expert members who had
contributed immensely in this curriculum.

Co-coordinators for the course: Shri Sunil Wakde ,ADT, ATI, Mumbai and
Shri L K Mukherjee, DDT, CSTARI, Kolkata

Sl. Name & Designation Organization Remarks

No. Sh/Mr./Ms.
1. SA Pandav, RDD, Vadodara & Surat DET, Gujarat Expert

2. Mr. Maneshkumar K Patel Neatfim Irrigation India Expert

Pvt Ltd, Vadodara
3. Mr. Piyush Porwal Profine India Window Expert
Technology Pvt Ltd,
Vadodara
4. More Vilas K. ,Craft Instructor Govt. I.T.I., Panvel, Expert
5. Mr. Tamboli Madhukar T. , Craft Instructor Govt. I.T.I. Panvel, Expert

6. Mr.Chavan Padmakar G. , Craft Instructor Govt. I.T.I., Wangaon, Expert

7. Mr. Chavan Dattatray M. , Craft Instructor Govt. I.T.I., Wangaon Expert

8. Mr. Modi Alpesh V. , Principal Govt. I.T.I. Dholera , Expert

Dist. Ahmedabad (GJ)
9. Mr. Ravi Pratap Mishra Shefield Technoplast Expert
Pvt Ltd, Vadodara
10. Mr. Jayesh C Chaudhari Instructor Training Expert
Center, Tarsali,
Vadodara.
11. Mr Pravin Bachhav, Sr. Tech. Officer (P/T) CIPET, Aurangabad Expert

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 2. BACKGROUND

2.1Apprenticeship Training Scheme under Apprentice Act 1961

The Apprentices Act, 1961 was enacted with the objective of regulating the programme of
training of apprentices in the industry by utilizing the facilities available therein for
imparting on-the-job training. The Act makes it obligatory for employers in specified
industries to engage apprentices in designated trades to impart Apprenticeship Training on
the job in industry to school leavers and person having National Trade Certificate(ITI pass-
outs) issued by National Council for Vocational Training (NCVT) to develop skilled
manpower for the industry. There are four categories of apprentices namely; trade
apprentice, graduate, technician and technician (vocational) apprentices.
Qualifications and period of apprenticeship training of trade apprentices vary from trade to
trade. The apprenticeship training for trade apprentices consists of basic training followed
by practical training. At the end of the training, the apprentices are required to appear in a
trade test conducted by NCVT and those successful in the trade tests are awarded the
National Apprenticeship Certificate.

The period of apprenticeship training for graduate (engineers), technician (diploma holders
and technician (vocational) apprentices is one year. Certificates are awarded on completion
of training by the Department of Education, Ministry of Human Resource Development.

2.2 Changes in Industrial Scenario

Recently we have seen huge changes in the Indian industry. The Indian Industry registered
an impressive growth during the last decade and half. The number of industries in India have
increased manifold in the last fifteen years especially in services and manufacturing sectors.
It has been realized that India would become a prosperous and a modern state by raising
skill levels, including by engaging a larger proportion of apprentices, will be critical to
success; as will stronger collaboration between industry and the trainees to ensure the supply
of skilled workforce and drive development through employment. Various initiatives to
build up an adequate infrastructure for rapid industrialization and improve the industrial
scenario in India have been taken.

2.3 Reformation
The Apprentices Act, 1961 has been amended and brought into effect from 22nd December,
2014 to make it more responsive to industry and youth. Key amendments are as given
below:

 Prescription of number of apprentices to be engaged at establishment level instead of

trade-wise.

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 Establishment can also engage apprentices in optional trades which are not designated,
with the discretion of entry level qualification and syllabus.

 Scope has been extended also to non-engineering occupations.

 Establishments have been permitted to outsource basic training in an institute of their

choice.

 The burden of compliance on industry has been reduced significantly.

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 3. RATIONALE

(Need for Apprenticeship in “PLASTIC PROCESSING OPERATOR” trade)

Now a days the plastic processing industry is a relatively young industry of

mainly, based on the knowledge and skills that are acquired only the last 30 – 40
years. The sector has always been perceived to have a relatively low
technological value. However the increasing interest in plastic products and
components, and different innovations in the field of equipment and tooling,
products and applications are more and more demanding for the companies and
their staff. Laborers, such as production workers, machine operators and line
responsible, need to be trained to bring their knowledge and skill on a
(necessary) minimum level.

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 4. JOB ROLES: REFERENCE NCO

Brief description of Job roles:

The Following expectations are from the concern trade person/Technician as per
industry perspective can be fulfilled by ATS Scheme which are as follows –

1. Industrial Safety
2. Industry Related Record Keeping
3. Plastic Material, Tools & Equipment Handling
4. Testing & Quality Control of plastic materials
5. Various Plastic Processing Technology & Process Parameter Setting
6. Perfect Cycle time Management
7. Trouble Shooting
8. Machine & Mould/Die Maintenance
9. Electrical , Hydraulic, Pneumatic & Mechanical Maintenance
10. Cooling System Design & Maintenance
11. Total Workshop Management
12. Operation Excellence (Lean Manufacturing)

Reference NCO:

8232.15, 8232.18, 8232. 20, 8232.65, 8232.25, 8232. 30, 8232.35,8232. 40,
8232.70, 8232.45, 8232.50, 7222.50

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 5. GENERAL INFORMATION

1. Name of the Trade : PLASTIC PROCESSING OPERATOR

2. N.C.O. Code No. : 8232.15, 8232.18, 8232. 20, 8232.65, 8232.25,
8232. 30, 8232.35,8232. 40, 8232.70, 8232.45,
8232.50, 7222.50

3. Duration of Apprenticeship Training (Basic Training + Practical Training): 2 Years

3.1 For Freshers: - Duration of Basic Training: -
a) Block –I : 3 months
b) Block – II : 3 months
Total duration of Basic Training: 6 months
Duration of Practical Training (On -job Training): -
a) Block–I: 9 months
b) Block–II : 9 months
Total duration of Practical Training: 18 months
3.2 For ITI Passed: - Duration of Basic Training: - NIL
Duration of Practical Training (On -job Training): 12 months
4. Entry Qualification:

1. Passed 10th class examination under 10+2 system of education

with Science & Mathematics or its equivalent. OR

5. Selection of Apprentices: The apprentices will be selected as per Apprentices Act

amended time to time.
6. Rebate to ITI Passed out Trainees: One year for the trade of PPO

Note: Industry may impart training as per above time schedule for different block,
however this is not fixed. The industry may adjust the duration of training considering the
fact that all the components under the syllabus must be covered. However the flexibility
should be given keeping in view that no safety aspects is compromised .
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 6. COURSE STRUCTURE

Training duration details: -

Time 1-3 4-12 13-15 16-24

(in months)
Basic Training Block– I ----- Block – II ------
Practical Training ---- Block – I ------ Block – II
(On - job training)

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 Duration of Training in Months
Components of Training
1 1 1 1 1 1 1 1 1 1 2 2 2 2 2
1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4
Basic Training Block - I
Practical Training Block - I
Basic Training Block - II
Practical Training Block - II

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 7. SYLLABUS
7.1 BASIC TRAINING
(BLOCK – I & II)
DURATION: 06 MONTHS

GENERAL INFORMATION

1) Name of the Trade : Plastic Processing Operator.

2) Hours of Instruction : 1000 Hrs. (500 hrs. in each block)
3) Batch size : 20
4) Power Norms : 13.6 Kw
5) Space Norms : 300 Sq.m.

6) Examination : The internal assessment will be held on

completion of each Block.
7) Instructor Qualification :

i) Degree/Diploma in Plastic Technology/Engineering from recognized

university/Board, with one/two year post qualification experience respectively
in the relevant field.
OR

ii) NTC/NAC in the trade of Plastic Processing Operator with three year post
qualification experience in the relevant field.
Preference will be given to a candidate with Craft Instructor Certificate (CIC)

8) Tools, Equipments & Machinery required : - As per Annexure – I

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 7.1.1 DETAIL SYLLABUS OF CORE SKILL

A. Block– I
Basic Training

Topic a) Engineering Drawing Duration b) Workshop Science & Calculation Duration

No. (in hrs) (in hrs)

30 Calculation (10) Science (10) 20

1 Engineering Drawing: Introduction and Unit: Systems of Material Science :
its importance unit- CGS, MKS/SI Properties -
Drawing Instruments : their Standard unit, unit of length, Physical &
and uses Mass and time, Mechanical, Types
- Drawing board, T-Square, Drafter Conversion of units –Ferrous & Non-
(Drafting M/c), Set Squares, Protractor, (2 Hrs) Ferrous, difference
Drawing Instrument Box (Compass, between Ferrous
Dividers, Scale, Diagonal Scales etc.), and non-Ferrous
Pencils of different Grades, Drawing metals (2Hrs)
pins / Clips. (2 Hrs)
Lines :
- Definition, types and applications in
Drawing as per BIS SP:46-2003
- Classification of lines (Hidden, centre,
construction, Extension, Dimension,
Section)
- Drawing lines of given length
(Straight, curved)
- Drawing of parallel lines,
perpendicular line
(2 Hrs)
2 Drawing of Geometrical Figures: Fractions : Mass ,Weight and
Definition, nomenclature and practice of Fractions, Decimal Density : Mass,
- Angle: Measurement and its types, fraction, L.C.M., Unit of Mass,
method of bisecting. H.C.F. Weight, difference
- Triangle -different types Multiplication and between mass and
- Rectangle, Square, Rhombus, Division of weight, Density,
Parallelogram, polygons. Fractions and unit of density,
- Circle and its elements. Decimals, specific gravity of
(4 Hrs) conversion of metals. (2Hrs)
Lettering and Numbering as per BIS Fraction to Decimal
SP46-2003: and vice versa.
- Single Stroke, Double Stroke, inclined, Simple problems
Upper case and Lower case using Scientific
(4 Hrs) Calculator. (2Hrs)
3 Practice of Lettering and Title Block Ratio & Speed and
(2 Hrs) Proportion : Velocity: Rest and
Dimensioning practice: Simple calculation motion, speed,
- Position of dimensioning on related velocity, difference
(unidirectional, aligned, oblique as per problems. (2Hrs) between speed and
BIS SP:46-2003) velocity,
- Symbols preceding the value of acceleration,
dimension and dimensional tolerance. retardation. (2Hrs)
(2 Hrs)

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4 Drawing of Solid figures (Cube, Percentage : Work, Power and
Cuboids, Cone, Prism, Pyramid, Introduction, Energy: work, unit
Frustum of Cone and Pyramid.) with Simple calculation. of work, power,
dimensions. Changing unit of power,
(4 Hrs) percentage to Horse power of
Free Hand sketch of hand tools and decimal and engines,
measuring tools used in respective fraction and vice- mechanical
trades. versa (2Hrs) efficiency, energy,
(4 Hrs) use of energy,
potential and
kinetic energy,
examples of
potential energy
and kinetic energy.
(2Hrs)
5 Free-hand sketches of Hand Tools, Mensuration : Heat &
Screw drivers, Pliers, Area and perimeter Temparature:
Spanner, Tweezer. Free-hand sketches of square, Heat and
of Vernier Caliper, micrometer, Depth rectangle, temperature, their
Gauge, Dial Test Indicator, Bevel parallelogram, units, difference
protractor (4 Hrs) triangle, circle, between heat and
ISI symbols of Generator, Voltmeter, semi circle, temperature,
Ammeter, Watt- meter. Resister, Volume of solids – boiling point,
inductor, Capacitor, Transformer, AC & cube, cuboid, melting point, scale
DC motors.etc. cylinder and of temperature,
Drawing of pressure control process Sphere. relation between
line(2 Hrs) Surface area of different scale of
solids – cube, temperature,
cuboid, cylinder Thermometer,
and Sphere. (2 pyrometer,
Hrs) transmission of
heat, conduction,
convection,
radiation. (2 Hrs)

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 B. Block- II
Basic Training
Topic a) Engineering Drawing Durati b) Workshop Science & Calculation Durati
No. on on
(in Calculation Science (in
hours) hours)

1 Drawing sketches of different types of 30 Archimedes’s Definition - viscosity, 20

valves, such as gate valve, globe valve, principle, principle flash point, fire point,
ball valve, Plug Valve, check valve etc. of floatation flash points of standard
(4 Hrs) hydrometers. lubricating oils, octane
Drawing of different types locking Centre of gravity number.
devices such as double nut, castle nut, and (2Hrs)
pin etc.(2 Hrs) Equilibrium
condition.
(2Hrs)
2 Symbolic representation of different Pressure, Newton's laws of
types of valves- gate valve, globe valve, temperature, motion unit of force,
butterfly valve, ball valve, diaphragm Boyle's law, find out resultant force
valve, control valve, non-return valve, Charles’s law, parallelogram law of
and needle valve. (2 Hrs) Equation of perfect forces,
Free hand sketches of Belt conveyor, gas. Calculations.. (2Hrs)
Screw conveyer, Bucket elevator (2 Hrs)
(4 Hrs)
3 Drawing of pressure, Level , flow and Centre of Gravity, Condition of
temperature control system. (C.G. Of square, equilibrium, kind of
(2 Hrs) rectangle, triangle, equilibrium, some
Free hand sketches of crushers, ball circle, semicircle, examples of equilibrium
mill, hammer mill and centrifuges (4 cone) & its in daily life,.
Hrs) calculations (2 Hrs) (2 Hrs)
4 Free hand sketches of steam jet ejector, Flow of fluids- Advantages &
steam trap (2 Hrs) Equation of Disadvantages of
Diagram of distillation column with all continuity, friction, Limiting
accessories Bernoulli’s theorem friction, Laws of
Free hand sketches of process (2 Hrs) limiting friction,
instrument- such as temperature Coefficient of friction,
indicator, level indicator, LIC, TIC, PI, angle of friction,
PIC, FI, FIC (4 Hrs) Inclined plane, Force of
friction (2 Hrs)
5 Injection Moulding Machine Sketch Flow measurement Latent heat, sensible
Injection Moulds .(Simple Insulated & by orifice meter, heat, saturated steam,
Hot Runner moulds) venturi meter, Rota wet steam, superheated
Runner & Gate Systems meter, U-tube steam.
Blow Moulding Machine Sketch manometer. Reynolds’s number, at
Blow Moulding Moulds ,Stretch Blow (2 Hrs) different velocities.
Moulds Extrusion Process Sketch (Pipe (2 Hrs)
,Film up Stroke & Down stroke, Wire,
Calendering Roto moulding Machine
Sketch Roto mould, FRP Technique
Sketch SMC & DMC
Sketch,Thermoforming& Vacuum
Machine Sketch Thermoforming&
Vacuume forming Moulds

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 7.1.2 DETAIL SYLLABUS OF PROFESSIONAL SKILLS & PROFESSIONAL
KNOWLEDGE
A. Block –I : Basic Training
Week Professional Skills( 275Hrs ) Professional Knowledge( 120 Hrs )
No.
1 Familiarization & importance of trade training , Safety: Firefighting equipment its precautions observed
machinery used in the trade, types of jobs made by in the section. Introduction about occupational health
the trainees in the trade : safety and firefighting hazards followed in plastic industries
equipment and their use
2 Marking, Hacksawing, Filing on mild steel flat using Linear measuring tools. Introduction to hand tools used
steel rule, calipers, punches etc. for marking, punching, sawing, filing etc. marking table
3 Practice of drilling on flat surfaces. Forming internal Bench vice-its types and parts.
threads with taps to standard size and preparing studs Files – its description types, grades & cut.
and bolts Hacksaw - its type use and care.
4 Safety precaution and first aid about electricity while Tap &dies its use and care. Vernier caliper, micrometer,
working on machines. Basic knowledge about fixing height gauge, bevel protector. Least count calculation
and connecting of electrical accessories. and its measurements

5 Making hydraulic and pneumatic circuits by using Safety precaution and first aid while working on
flow control valves, pressure control valves. Logic machine. Drilling machines-its type – (portable, bench
valves, pumps and compressor. type, and pillar type), parts & working procedure.
6 Testing of Various Plastics Material: Operating and maintenance of hydraulic and pneumatic
Tensile test, Compressive test, Shear test, Hardness components- flow control valves, pressure control
test, MFI test, Melting point test. Identification of valves. Logic valves, pumps and compressor
plastics practical by simple methods like burning

7 Injection Moulding: Identification of Various Plastics Material Thermo

Basic idea of mechanical electrical and hydraulic Plastic:PE,PP,ABS,POM,SAN,PMMA,PS,PC,NYLON,
system of IMM & its different parts and their PVC,PET,CN,CA,CAP,PBT Thermosetting Plastic:
respective functions. Operating and controlling of PF,MF,UF ,EPOXY,SILICON,POLYESTER
IMM in IRO & TRO. Parameters setting. RESIN,SMC,DMC) its properties and applications.
Practical on Hand injection, vertical
Injection/Horizontal injection
8 Microprocessor Controlled & PLC IMM, Machine Injection moulding:
setting procedure, setting for process-parameters. Introduction about injection moulding machine – its
Types of moulds, Types of runners and gates. types. Moulds and its parts. Processing defects, causes,
remedies. Trouble shooting of IMM
9 Oiling, lubrication and preventive maintenance of Microprocessor Controlled & PLC Injection Moulding
injection moulding machine machine. Its comparison .Thermoset Injection Moulding
All electrical & Multi Injection Moulding Machines,
Types of moulds .Types of runners and gates.
10 Compression Moulding: Preventive maintenance of IMM
Basic idea of mechanical electrical and hydraulic Compression moulding:
system of CMM and its different parts and the Types of CMM its different parts and functions.
irrespective functions. Operating and controlling of Moulds and its parts. Processing Defects, Causes, and
CMM in IRO & TRO Remedies etc. Trouble shooting of CMM
11 Oiling, lubrication and preventive maintenance of Transfer Molding
compression molding machine
12 & Fiber Reinforce Plastic (FRP) process Introduction of fiber reinforced plastic processing
13. (hand lay-up process). method.

Internal Assessment 03days

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 B. Block –II
Basic Training

Week Professional Skills ( 275Hrs ) Professional Knowledge( 120Hrs )

No.
1 Blow Moulding Process: Blow Moulding Process:
Familiarization with basic idea of mechanical, Types Blow moulding machine (Hand operated &
electrical, hydraulic and pneumatic system of Automatic) –its description, different parts & their
blow moulding machine and its different parts respective functions. Sequence of operation BM
Process and its latest processing
and their respective functions.
techniques.(Stretch blow, extrusion stretch blow,
injection stretch blow multilayer blow ) .
2 Operating and controlling of blow moulding Description about Blow Moulds and its parts.
machine in IRO & TRO (setting of die, adjusting Processing defects, causes, remedies etc.
mandrel, controlling Parisian, adjusting thickness Trouble shooting of Blow moulding machine.
uniformity).
3 Oiling, lubrication and preventive maintenance of preventive maintenance of Blow moulding
Blow moulding machine machine
4 Extrusion process: Extrusion Process: Extrusion machine – its
Familiarization with basic idea of mechanical, description, use of different parts and their
electrical and hydraulic system of extrusion functions. PVC compounding and its chemical
machine and its different parts and their ingredients. Its latest processing techniques.(
respective functions. multi-layer film, co-extruded sheets, corrugated
pipes )
5 Extrusion machine in IRO & TRO. Changing and Description about extrusion dies and its parts.
cleaning of screws in extruder, adjusting and Processing defects, causes, remedies etc.
controlling temperature, screen pack arrangement, Trouble shooting of extruder machine.
variable speed, setting and die head for pipe, profile,
reprocessing and blown film.
6 Oiling, lubricating and preventive maintenance of Introduction about Oiling, lubrication and
extruder machine. preventive maintenance of extruder machine.
7 Operating and controlling of thermoforming & Thermoforming & vacuum forming – its brief
vacuum forming machine in IRO & TRO. description and use. Processing technique of
different plastic material.
8 Demo about rotational moulding machine. Introduction about Rotational Moulding process.

9 Practice for Annealing, Stress Relieving, Post Moulding Operations: Annealing, Stress
Warpage Control, De-flashing and Printing of Relieving, Warpage Control, De-flashing and
finish products. Printing.
10 Practice of Pre-drying of Plastics Materials Importance of Pre-drying of Plastics Materials
Pre drying equipments and ancillaries
11 Fabricating acrylic sheet ABS- sheet, HIPS sheet, Machinery used for buffing, sanding, welding
HMHDPE blocks. Involving, drilling screwing and their application. Types of plastic casting
buffing sanding. Types of plastic casting
12 & Demo on Preservation/storage methods. (scaling, Hot runner moulds, cold runner moulds, blow
13. corrosion, blocking, sliding, revolving parts) moulds, Stretch mould& dies.

Internal Assessment 03 days

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 7.1.3 EMPLOYABILITY SKILLS
GENERAL INFORMATION

1) Name of the subject : EMPLOYABILITY SKILLS

2) Applicability : ATS- Mandatory for fresher only

3) Hours of Instruction : 110 Hrs. (55 hrs. in each block)

4) Examination : The examination will be held at the end of

two years Training by NCVT.

5) Instructor Qualification :

i) MBA/BBA with two years experience or graduate in sociology/social

welfare/Economics with two years experience and trained in Employability skill from
DGET Institute.
And
Must have studied in English/Communication Skill and Basic Computer at 12th
/diploma level
OR
ii) Existing Social Study Instructor duly trained in Employability Skill from DGET
Institute.

17
 7.1.3.1 SYLLABUS OF EMPLOYABILITY SKILLS
A. Block – I
Basic Training

Topic Topic Duration

No. (in hours)

English Literacy 15
1 Pronunciation :
Accentuation (mode of pronunciation) on simple words, Diction (use of word and
speech)
2 Functional Grammar
Transformation of sentences, Voice change, Change of tense, Spellings.

3 Reading
Reading and understanding simple sentences about self, work and environment

4 Writing
Construction of simple sentences Writing simple English

5 Speaking / Spoken English

Speaking with preparation on self, on family, on friends/ classmates, on know, picture
reading gain confidence through role-playing and discussions on current happening
job description, asking about someone's job habitual actions. Cardinal (fundamental)
numbers ordinal numbers. Taking messages, passing messages on and filling in
message forms Greeting and introductions office hospitality, Resumes or curriculum
vita essential parts, letters of application reference to previous communication.
I.T. Literacy 15

1 Basics of Computer
Introduction, Computer and its applications, Hardware and peripherals,
Switching on-Starting and shutting down of computer.
2 Computer Operating System
Basics of Operating System, WINDOWS, The user interface of Windows OS, Create,
Copy, Move and delete Files and Folders, Use of External memory like pen drive,
CD, DVD etc, Use of Common applications.
3 Word processing and Worksheet
Basic operating of Word Processing, Creating, opening and closing Documents, use
of shortcuts, Creating and Editing of Text, Formatting the Text, Insertion & creation
of Tables. Printing document.
Basics of Excel worksheet, understanding basic commands, creating simple
worksheets, understanding sample worksheets, use of simple formulas and functions,
Printing of simple excel sheets
4 Computer Networking and INTERNET
Basic of computer Networks (using real life examples), Definitions of Local Area
Network (LAN), Wide Area Network (WAN), Internet, Concept of Internet (Network
of Networks),
Meaning of World Wide Web (WWW), Web Browser, Web Site, Web page and
Search Engines. Accessing the Internet using Web Browser, Downloading and
Printing Web Pages, Opening an email account and use of email. Social media sites
and its implication.

18
 Information Security and antivirus tools, Do's and Don'ts in
Information Security, Awareness of IT - ACT, types of cyber crimes.

Communication Skill 25

1 Introduction to Communication Skills

Communication and its importance
Principles of Effective communication
Types of communication - verbal, non verbal, written, email, talking on phone.
Non verbal communication -characteristics, components-Para-language
Body - language
Barriers to communication and dealing with barriers.
Handling nervousness/ discomfort.
Case study/Exercise
2 Listening Skills
Listening-hearing and listening, effective listening, barriers to effective listening
guidelines for effective listening.
Triple- A Listening - Attitude, Attention & Adjustment.
Active Listening Skills.
3 Motivational Training
Characteristics Essential to Achieving Success
The Power of Positive Attitude
Self awareness
Importance of Commitment
Ethics and Values
Ways to Motivate Oneself
Personal Goal setting and Employability Planning.
Case study/Exercise
4 Facing Interviews
Manners, Etiquettes, Dress code for an interview
Do's & Don'ts for an interview
5 Behavioral Skills
Organizational Behavior
Problem Solving
Confidence Building
Attitude
Decision making
Case study/Exercise

19
 B. Block– II
Basic Training

Topic Topic Duration

No. (in hours)

Entrepreneurship skill 10

1 Concept of Entrepreneurship
Entrepreneurship- Entrepreneurship - Enterprises:-Conceptual issue
Entrepreneurship vs. Management, Entrepreneurial motivation. Performance &
Record, Role & Function of entrepreneurs in relation to the enterprise & relation to
the economy, Source of business ideas, Entrepreneurial opportunities, The process of
setting up a business.
2 Project Preparation & Marketing analysis
Qualities of a good Entrepreneur, SWOT and Risk Analysis. Concept & application
of Product Life Cycle (PLC), Sales & distribution Management. Different Between
Small Scale & Large Scale Business, Market Survey, Method of marketing, Publicity
and advertisement, Marketing Mix.
3 Institutions Support
Preparation of Project. Role of Various Schemes and Institutes for self-employment
i.e. DIC, SIDA, SISI, NSIC, SIDO, Idea for financing/ non financing support
agencies to familiarizes with the Policies /Programmes & procedure & the available
scheme.
4 Investment Procurement
Project formation, Feasibility, Legal formalities i.e., Shop Act, Estimation & Costing,
Investment procedure - Loan procurement - Banking Processes.
Productivity 10

1 Productivity
Definition, Necessity, Meaning of GDP.

2 Affecting Factors
Skills, Working Aids, Automation, Environment, Motivation
How improves or slows down.
3 Comparison with developed countries
Comparative productivity in developed countries (viz. Germany, Japan and Australia)
in selected industries e.g. Manufacturing, Steel, Mining, Construction etc. Living
standards of those countries, wages.
4 Personal Finance Management
Banking processes, Handling ATM, KYC registration, safe cash handling, Personal
risk and Insurance.
Occupational Safety, Health & Environment Education 10
1 Safety & Health
Introduction to Occupational Safety and Health importance of safety and health at
workplace.

20
 2 Occupational Hazards
Basic Hazards, Chemical Hazards, Vibro-acoustic Hazards, Mechanical Hazards, Electrical
Hazards, Thermal Hazards. Occupational health, Occupational hygienic, Occupational
Diseases/ Disorders & its prevention.
3 Accident & safety
Basic principles for protective equipment.
Accident Prevention techniques - control of accidents and safety measures.
4 First Aid
Care of injured & Sick at the workplaces, First-Aid & Transportation of sick person
5 Basic Provisions
Idea of basic provision legislation of India.
of safety, health, welfare under legislation of India.
6 Ecosystem
Introduction to Environment. Relationship between Society and Environment,
Ecosystem and Factors causing imbalance.
7 Pollution
Pollution and pollutants including liquid, gaseous, solid and hazardous waste.
8 Energy Conservation
Conservation of Energy, re-use and recycle.
9 Global warming
Global warming, climate change and Ozone layer depletion.
10 Ground Water
Hydrological cycle, ground and surface water, Conservation and Harvesting of water
11 Environment
Right attitude towards environment, Maintenance of in -house environment
Labour Welfare Legislation 5

1 Welfare Acts
Benefits guaranteed under various acts- Factories Act, Apprenticeship Act, Employees State
Insurance Act (ESI), Payment Wages Act, Employees Provident Fund Act, The Workmen's
compensation Act.
Quality Tools 5

1 Quality Consciousness :
Meaning of quality, Quality Characteristic
2 Quality Circles :
Definition, Advantage of small group activity, objectives of quality Circle, Roles and
function of Quality Circles in Organization, Operation of Quality circle. Approaches to
starting Quality Circles, Steps for continuation Quality Circles.
3 Quality Management System :
Idea of ISO 9000 and BIS systems and its importance in maintaining qualities.
4 House Keeping :
Purpose of Housekeeping, Practice of good Housekeeping.
5 Quality Tools
Basic quality tools with a few examples
Leadership and Team Building skills. 5

Leadership
Discipline and Morale
Team Work
Case Study/ Exercise
Meet the Mentor 5
Role - play as a Supervisor

21
 Organizing and Planning. 5

Time Management
Group Dynamics
Case Study/ Exercise

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 7.2 PRACTICAL TRAINING (ON-JOB TRAINING)
(BLOCK – I & II)
DURATION: 18 MONTHS (9 months in each block/1500 Hrs )

GENERAL INFORMATION

1) Name of the Trade : Plastic Processing Operator

2) Batch size : a) Apprentice selection as per Apprenticeship
Guidelines
b) Maximum 20 candidates in a group
3) Examination : i) The internal assessment will be held on
completion of each block
ii) NCVT exam will be conducted at the end of
2nd year.
4) Instructor Qualification :

i) Degree/Diploma in PLASTIC TECHNOLOGY/Engineering from recognized

university/Board With one/two year post qualification experience in the relevant
field.
OR

ii) NTC/NAC in the trade of Plastic Processing Operator with three year post
qualification experience in the relevant field.
Preference will be given to a candidate with Craft Instructor Certificate (CIC)

5) Tools, Equipments & Machinery required : - As per Annexure – II

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6.2.1 BROAD SKILL COMPONENT TO BE COVERED DURING ON-
JOB TRAINING

A. BLOCK – I

1. Safety and best practices (5S, KAIZEN etc.)

2. Record keeping and documentation
3. Identification and testing of plastics and polymers
4. Repair & Maintenance work
DURATION: 09 MONTHS (39 WEEKS)
SL NO LIST OF OPERATIONS/SKILLS TO BE COVERED DURING ON JOB TRAINING
1. Study of personal & plant safety procedures and use of safety equipment, fire and
fire fighting facilities/techniques, handing of hazardous chemicals and poisons
substances.
2. Understand the different activities of the plant with plant capacity and production.
3. Testing of various plastic materials/Components
 Testing & identification of Plastics ( Smell/ Burn Test)
 Mechanical Properties testing ( Tensile / Impact / Hardness)
 Thermal Properties testing ( Ash, Flamibility)
 Rheo Properties Testing ( MFI)

4. Understanding of compression molding operations & its control.

 Compression Molding M/c & Auxiliaries.
 Compression Molding Process
 Compression mold & It Types.
 Troubleshooting

5. Understanding of Injection molding operations & its controle.

 Injection Molding M/c & Auxiallaries.
 Injection Molding Process
 Injection mold & It Types.
 Troubleshooting
6.
Understanding of Film Extrusion operations & its controle.
 Extruder M/c & Auxillaries
 Extrusion Process
 Extrusion Dies & Die Setting.
 Troubleshooting
7. Computerized Documentation and Its Analysis
8. Understanding of Material Conveying and Feeding system.
9. Understanding of M/c & Mold ( Die) Maintenance
 Routine Maintenance
 Breakdown Maintenance
 Preventive Maintenance
 Predictive Maintenance
 Autonomous Maintenance

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B. BLOCK – II
1. Safety and best practices (5S, KAIZEN etc.)
2. Store procedure, Record keeping, inventory management and documentation
3. Identification and testing of plastics and polymers
4. Repair & Maintenance work of Molding and Extrusion Machines

DURATION: 09 MONTHS (39 WEEKS)

SL NO LIST OF OPERATIONS/SKILLS TO BE COVERED DURING ON JOB TRAINING
1. Operation and controlling of Blow molding machines.
Understanding of Blow Molding operations & its control.
 Blow Molding M/c & Auxiliaries.
 Blow Molding Process
 Blow Molding Dies & Die Setting.
 Troubleshooting
2. Understanding of advance injection molding techniques.
3. Operation and controlling of Thermoset molding machines.
Understanding of Thermoset Molding operations & its control.
 Thermoset Molding M/c & Auxiliaries.
 Thermoset Molding Process
 Thermoset Dies.
 Troubleshooting
4. Operation and controlling of extrusion process machines such as plastic extruder
Understanding of Extrusion Process & its control.
 Extruders & Auxiliaries.
 Extrusion Process
 Extrusion Dies.
 Troubleshooting
5. Understanding of Co- Extrusion Operation & its control.
 Co- Extruders & Auxiliaries.
 Co- Extrusion Process
 Co- Extrusion Dies.
 Troubleshooting
6. Understanding the Hand layup / Spray up / vacuum bag molding Operation & its Control.

7. Understanding of Sheet Extrusion Operation & its control.

 Sheet Extruders & Auxiliaries.
 Sheet Extrusion Process
 Sheet Extrusion Dies.
 Troubleshooting
8. Understanding of Wire & Cable Extrusion Operation & its control.
9. Fiber reinforce plastic (FRP) process
10. Understanding of ISO Management System
 QMS
 EHS & OHSAS
 EMS

25
11. Operation Management System
 Lean Manufacturing
 Six Sigma

26
 8. ASSESSMENT STANDARD
8.1 Assessment Guideline:
Appropriate arrangements should be made to ensure that there will be no artificial
barriers to assessment. The nature of special needs should be taken into account while
undertaking assessment. Due consideration to be given while assessing for team work,
avoidance/reduction of scrape/wastage and disposal of scarp/wastage as per procedure,
behavioral attitude and regularity in training.

The following marking pattern to be adopted while assessing:

a) Weightage in the range of 60-75% to be allotted during assessment under following

performance level:

For this grade, the candidate with occasional guidance and showing due regard for safety
procedures and practices, has produced work which demonstrates attainment of an
acceptable standard of craftsmanship.

In this work there is evidence of:

 good skill levels in the use of hand tools, machine tools and workshop equipment
 Many tolerances while undertaking different work are in line with those demanded
by the component/job.
 a fairly good level of neatness and consistency in the finish
 Occasional support in completing the project/job.

b) Weightage in the range of above75%- 90% to be allotted during assessment under

following performance level:

For this grade, the candidate, with little guidance and showing due regard for safety
procedures and practices, has produced work which demonstrates attainment of a
reasonable standard of craftsmanship.

In this work there is evidence of:

 good skill levels in the use of hand tools, machine tools and workshop equipment
 the majority of tolerances while undertaking different work are in line with those
demanded by the component/job.
 a good level of neatness and consistency in the finish
 little support in completing the project/job

27
c) Weightage in the range of above 90% to be allotted during assessment under
following performance level:

For performance in this grade, the candidate, with minimal or no support in organization
and execution and with due regard for safety procedures and practices, has produced
work which demonstrates attainment of a high standard of craftsmanship.

In this work there is evidence of:

 high skill levels in the use of hand tools, machine tools and workshop equipment
 Tolerances while undertaking different work being substantially in line with those
demanded by the component/job.
 A high level of neatness and consistency in the finish.
 minimal or no support in completing the project

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 8.2 FINAL ASSESSMENT- ALL INDIA TRADE TEST FOR APPRENTICE

SUBJECTS Marks Sessional Marks Full Pass Marks Duration of Exam.

Marks
Practical 300 100 400 240 08 hrs.

Trade Theory 100 20 120 48 3 hrs.

Workshop Cal. & Sc. 50 10 60 24 3 hrs.
Engineering Drawing 50 20 70 28 4 hrs.
Employability Skill 50 -- 50 17 2 hrs.
Grand Total 550 150 700 -

Note: - The candidate pass in each subject conducted under All India Trade Test.

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 9. FURTHER LEARNING PATHWAYS
 On successful completion of the course trainees can opt for Diploma course
(lateral entry). {Applicable for candidates only who undergone ATS after CTS}
 They can also undergo CITS course in the relevant trade to become instructor in
the ITI’s

Employment opportunities:

On successful completion of this course, the candidates shall be gainfully

employed in the following industries:

1. Production & Manufacturing in Plastic industries.

2. Structural Fabrication FRP, Roof structures, Furniture
3. Automobile Parts and allied industries
4. Professional, Scientific and Technical Activities, Education
5. Agricultural Products
6. Infrastructure and defence organisations
7. In public sector industries like BHEL,HAL,CIPET,IPI etc and private industries in
India & abroad.
8. Self employment

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 ANNEXURE – I

10.TOOLS & EQUIPMENT FOR BASIC TRAINING

INFRASTRUCTURE FOR PROFESSIONAL SKILL & PROFESSIONAL

KNOWLEDGE

TRADE: PLASTIC PROCESSING OPERATOR

LIST OF TOOLS & EQUIPMENTS FOR 20 APPRENTICES

A : TRAINEES TOOL KIT:-

Quantity
Sl. No. Name of the items
(indicative)
1. Steel Rule 15 cm with metric graduation 20
2. Try Square 10 cm blade. 20
3. Caliper inside /Out Side 15 cm spring. 20
4. Straight Scriber 15 cm. 20

5. Screw driver 15 cm 16 nos. 20

6. Hammer ball peen 0.45 kg. With handle 20

7. File flat 25 cm. second cut 20

8. Dot slot punch 10 cm. 20

9. Plier 20

10. Hacksaw frame fixed 30 cm. 20

B : TOOLS INSTRUMENTS AND GENERAL SHOP OUTFITS

Quantity
Sl. No. Name of the items
(indicative)
11. Plate surface 45 cm * 45 cm 2
12. Marking table 91 * 91 * 122 cm height 1
13. Vernier caliper 20 cm 1
14. Micrometer 25-50 mm outside 3
15. Vice Bench 12 cm jaw 20
16. Taps and dies complete set in box (Metric/Inches) Each 1
17. Multimeter 2
18. Bench working 240 cm * 120 cm * 60 cm 4

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C : GENERAL MACHINERY INSTALLATIONS:-
Sl. Name & Description of Machines Quantity
No. (indicative)
1. Pillar Drill Machine - Motorized up to 13 mm Capacity 1
2 Melt Flow Index Dester 1
3 Universal Testing Machine For Plastic 1
4 Plastic Scrap Grinder 1

5 Material Pre Dryer 1

6 Pedestal Grinder - Double Ended - 200 mm 1

7 Hand operated Injection Moulding machine 15g & 30 gm 2 Nos each

Hand operated Compression Moulding Machine with moulds – 30 to 60 T.
8 1
capacity
Hand operated Blow Moulding Machine with moulds and accessories of 250
9 1
ml capacity with clamping system.
10 Thermo/Vacuum forming Machine with Mould 1

11 Hydraulic & Pneumatic trainer kit 1

12 High Frequency Plastic welding Machine 1

13 Air compressor with air treatment accessories 5 HP 1

Mono block pump 2HP
14 1
Cooling tower 10TR

Note: In case of basic training setup by the industry the tools, equipment and
machinery available in the industry may also be used for imparting basic training.

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 INFRASTRUCTURE FOR WORKSHOP CALCULATION & SCIENCE AND
ENGINEERING DRAWING

TRADE: PLASTIC PROCESSING OPERATOR

LIST OF TOOLS& EQUIPMENTS FOR 20 APPRENTICES

1) Space Norms : 45 Sq. m.(For Engineering Drawing)

2) Infrastructure:
A : TRAINEES TOOL KIT:-

Sl. Quantity
Name of the items
No. (indicative)
1. Draughtsman drawing instrument box 20
2. Set square celluloid 45⁰ (250 X 1.5 mm) 20

3. Set square celluloid 30⁰-60⁰ (250 X 1.5 mm) 20

4. Mini drafter 20

5. Drawing board (700mm x500 mm) IS: 1444 20

B : FURNITURE REQUIRED
Sl. Quantity
Name of the items
No. (indicative)
1 Drawing Board 16
2 Models : Solid & cut section As required
3 Drawing Table for trainees As required

4 Stool for trainees As required

5 Cupboard (big) 01
6 White Board (size: 8ft. x 4ft.) 01
7 Trainer’s Table 01
8 Trainer’s Chair 01

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 ANNEXURE – II

11. TOOLS & EQUIPMENT FOR ON- JOB TRAINING

Infrastructure for Professional Skills & Professional Knowledge

TRADE: PLASTIC PROCESSING OPERATOR

For Batch of 20 APPRENTICES

General Machinery Installations –

Actual training will depend on the existing facilities available in the establishments.
However, the industry should ensure that the broad skills defined against On-Job Training
part (i.e. 9 months + 9 months) are imparted. In case of any short fall the concern industry
may impart the training in cluster mode/ any other industry/ at ITI.

34
 ANNEXURE-III

12.GUIDELINES FOR INSTRUCTORS AND PAPER SETTERS

1. Due care to be taken for proper & inclusive delivery among the batch. Some of the
following some method of delivery may be adopted:

A) LECTURE
B) LESSON
C) DEMONSTRATION
D) PRACTICE
E) GROUP DISCUSSION
F) DISCUSSION WITH PEER GROUP
G) PROJECT WORK
H) INDUSTRIAL VISIT

2. Maximum utilization of latest form of training viz., audio visual aids, integration of
IT, etc. may be adopted.

3. The total hours to be devoted against each topic may be decided with due diligence to
safety & with prioritizing transfer of required skills.

35