NCMF
NCMF
FOR
(DRAFT)
i
Acknowledgement
The Uganda Business and Technical Examinations Board (UBTEB) sincerely extends its gratitude
to all panel members and institutions that participated in developing this modular assessment
guide.
UBTEB greatly acknowledges NCDC for their efforts in developing, dissemination and
monitoring the syllabus for national certificate in machining and fitting.
UBTEB further acknowledges the following ministries and institutions: Education science
Technology and Sports; works and Transport; Labour Gender and Social Development;
Directorate of Education Standards; National Council for Higher Education; Uganda Technical
and Vocational Institutes and the World of Work for providing for providing the required
information that has been used in developing the modular assessment guide.
Special thanks go to the Ministry of Education and Sports particularly the TVET department and
the funders for the financial support that enabled the development of the modular assessment
guide.
ii
List of Acronyms
iii
TABLE OF CONTENT
iv
1. PREAMBLE
National Development Plan (NDP II) emphasizes creation of skilled manpower for national
development. Government through this plan introduced a Technical Vocational Education and
Training (TVET) system that promotes employer led training and competence-based assessment.
Consequently, modularization of assessment has become a requirement to link the training and
occupational profiles that are available in the world of work or industry which will significantly
This Modular Assessment Guide (MAG) has been derived from the National Curriculum
FITTING (2015) currently being taught and assessed for trainees. The assessment is categorized in
nine packages/modules basing on the competences that a learner desires to achieve for a given trade.
These include; Module 1: Communication principles in engineering, Module 2: Bench work operations
and measurements; Module 3: Production of components using lathe machine; Module 4: Production
of components using milling machine; Module 5: Production of components by SMAW, shaping and
On completion of modules 3, 4, 5 and 6, the trainees are expected to go for industrial training as
The trainee to be assessed in any of the certificate modules in Machining and Fitting, he /she
/Vocational education.
1
There is an upward academic growth on completion of the certificate to diploma and eventually
a degree in the relevant field. The trainees shall be awarded certificates on completion of each
given set of modules and on completion of all the modules and industrial training done at least
twice, they will be awarded a National Certificate in Machining and Fitting (NCMF) in a period
2
2. IDENTIFIED MODULES
MODULE 1
COMMUNICATION
PRINCIPLES IN
ENGINEERING
MODULE 6 MODULE 2
FOUNDRY BENCH WORK
PROCESSES AND OPERATIONS AND
ENTERPRENUERSHIP MEASUREMENTS
NCMF
MACHINING
AND FITTING
MODULE 5
PRODUCTION OF MODULE 3
MECHANICAL PRODUCTION OF
COMPONENTS BY MECHANICAL
FUSION WELDING, COMPONENTS BY
SHAPING AND LATHE
GRINDING OPERATIONS
PROCESSES MODULE 4
PRODUCTION OF
MECHANICAL
COMPONENTS BY
MILLING
OPERATIONS
3
3.0 MODULES, LEARNING OUTCOME AND AWARD
The section describes the modules, expected learning outcome and awards before a student receives
a final National Certificate in Machining and Fitting (NCMF)
4
6. PRODUCTION OF Produce dimensionally accurate Certificate of
MECHANICAL component parts by foundry processes competence in accurate
COMPONENT BY with skills to set up business ventures. and safe foundry work
FOUNDRY operations and business
PROCESSES AND orientation.
ENTERPRENUERSHIP
SKILLS
Module code:
Module overview
This module introduces the learner to.day to day interactions, writing application letters, Curriculum
Vitae, (CV) and minutes; improve on their discourse writing skills, prepare and make presentations.
it also helps in technical communications, note taking, interpersonal communication skill; computer
skills of type setting documents and use of internet for searching; also carry out simple connections
and installations of a computer and its accessories; carry out printing, scanning of documents; basic
Kiswahili used in the industries and general public.
The module training consists of 3 sub modules and real-life project taking a total of 120 hrs.
Training outcome:
By the end of the module, the learner should be able to; communicate effectively in the field of work,
logically make discourse writing, prepare and make presentations, use and manipulate a computer to
prepare documents;
Search web-based information from the internet; prepare documents on spread sheets; should be able
to seek for help and transact business in Kiswahili.
Module Assessment
Continuous assessment (Assignment 10%, Test 05%, Practical work 25%)
Final assessment 60%
5
Module details
S/N Sub Module Competences Duties and Content Duration
o Tasks
1. Life skills - Listens and takes - Listen and - Writing skills 120 hrs
Introduction to notes take notes Academic
communication - Speaks, interacts - Speak, writing
skills and conducts interact and Office and
meeting conducts business writing
- Makes an agenda meeting 10hrs
and conducts - Make an - Introduction to
meeting agenda and Communication
- Writes personal conducts skill 6hrs
CV, field report, meeting Fundamental
memos claim - Write skills
letters, circulars personal Conducting
demand notices CV, field meeting and
- Prepares report, interviews
workshop paper memos Interpersonal
for presentation claim letters, skills
- Writes suitable circulars Work place
adverts and demand communication
announcements notices - Discourse
16hrs - Prepare writting10hrs
- Correctly workshop Descriptive
describes events a paper for writing
logical manner presentation Narration and
- Narrates the order - Write argument
in which events suitable - Presentation 6hrs
happened and advert and seminar
gives objective announcem document, public
arguments ents 16hrs & report
6
- Prepares - Correctly preparation and
documents and describe presentation
presents them events a
logical
manner
- Narrate the
order in
which
events
happened
and give
objective
arguments
- Prepare
documents
and present
them
7
types and using key - Operating system
functions board 6hrs
- Formats page and - Describe Functions of an
document computer operating system
- Installs a printer to operation Classification of
a computer systems, operating system
- Removes used types and Installation of
cartridge toners functions windows
and replace - Format page - Desk top main
- Sends messages and menu 4hrs
via emails document Working with
- Prepares bill of - Install a desktop,
materials and printer to a background
applies excel computer Copying files,
formula - Remove used icons
- Draws graphs cartridge
using excel toners and - Word processing
- Prepares power replace 20hrs
point slides - Send Working with
- Activates messages via text
animation on the emails - Internet -email
selected slide - Prepare bill internet browsers
design of materials electronic mail
- Trouble shoots and apply security, safety
simple network excel formula and health
connection - Draw graphs practices while
problem using excel using internet
- Configures - Prepare - 16hrs
network to power point - Printing scanning
computer slides and coping 4 hr
- Activate Printing
animation on documents
8
the selected Scanning
slide design documents
- Trouble Copying
shoot simple Working with
network printing
connection cartridges and
problem toners
- Configure - Working with
network to spread sheet
computer 20hrs
Using formula
and functions
Entering data to
a worksheet
Inserting tables
to excel work
sheet
Printing a spread
sheet, page setup
gridlines
- Oral
communication
skills 6hrs
Listening and
specking
Conducting
meetings and
interviews
- Power point
presentation
14hrs
- Basic networking
9
Connect
computer to a
network18hrs
10
months of the - Identify and Parts of the body
year and tells the names parts - General
correct dates of the body vocabulary
- Identifies the and animals 10hrs
tools and in Kiswahili - Names of
equipment and - Mention the domestic
states their uses in days of the animals, birds,
Kiswahili week, name insects, objects in
- Identifies and the months environment
names materials of the year - Specific Trade
used in and tell the Vocabulary 6hr
engineering correct dates Name tools and
- Welcomes and - Identify the equipment used
handles tools and by technician
customers with equipment Titles of officers
care in Kiswahili and state in engineering
- Advertises the their uses in Names of
product in Kiswahili materials used in
Kiswahili - Identify and engineering
name - Customer care
materials language
used in - Advert of
engineering product
- Welcome - public relations
and handles and persuasive
customers business
with care in language
Kiswahili - Attitude of
- Advertise customers, public
the product and the job
in Kiswahili - Handling
customers,
11
welcoming them,
asking whether
they need help
and thanking
them 10hrs
Reading materials:
Bough B. (2005).101 Ways to improve Your Communication Skills Instantly.4th Edition; Goal Minds,
Inc
McKay M. And Davis, M. (2009). The Communication Skills Book. 3rd Edition; New Harbinger
Publications. .
Murray H., (2003). Teach Yourself Basic Computer Skills. New Edition; Teach Yourself Books.
Module code:
Module overview
This module introduces the student technician to; a range of bench work activities required in
manufacturing and maintenance processes. The module covers skills and knowledge to shape
materials to the right dimensions by using safe practices and appropriate hand tools. mathematical
skills that enable them to carry out measurements and estimation; understand employers’
responsibilities and employees’ health requirements., work place safety practices; calculations of cost
of materials and see pattern and predict the future.
The module training consists of 9 sub modules and real-life project taking a total of 600 hrs (5months)
and No industrial training.
Training outcome:
By the end of the module, the student technician should be able to shape various component using
bench tools and drilling machine; use measuring instruments and work within limits of tolerances;
select appropriate engineering materials; use bench practice techniques to produce components and
assemble components; use drilling machine to carry out drilling operations. apply the set theory in
batching engineering materials. apply the skills of illustrating histograms in drawing the site operation
programme.
12
Module Assessment
Module details
13
measures of
HIV 4hrs
- Impact and
interventions
- Differentiate of HIV and
accidents, AIDS 6hrs
risks and
hazards Health and
- Differentiates - Identify Safety
accidents, risks common practices
and hazards work place - Hand tools
- Identifies hazards - Powered
common work - Use machines
place hazards firefighting - Manual
and controls. equipment handling
- Uses firefighting - Use personal - Material
equipment protective handling
- Understands gear operations
health and safety - Observe and storage
signages and safety - Electricity
colours at practices. - Pollution
workplaces - Administers (Noise and
- Observes safety First Aids fumes)
practices - Fire
- Administer first - Heat
Aid - Maintenan
ce work
- Working at
heights
- First Aid
14
2. Basic Hand - Identifies tools - Identify - Introduction
tools and and their uses tools and to hand tools
Equipment their uses and devices
10hrs
3. Hazards - Organizes - Organize Maintain
associated workshop workshop hand tools
with hand - Practices good - Practice 4hrs
and electric house keeping good house
Powered - Checks tools keeping
tools before use - Check tools
- Uses personal before use
protective - Use personal
equipment protective
- Maintains tools in equipment
good working
condition - Maintain
tools in good
working
condition
15
in good
working
condition
16
- Locking
devices
- Construction
of bolts
- Positive
locking
device
- REAL LIFE
PROJECT 1
40hrs
17
7. Use of - Identifies types, - Identify the - Drilling
Drilling features and types, machine
machine motions features and 10hrs
- Ensures safety motions
precautions - Ensure safety
during drilling precautions
operations during
- Selects work drilling
holding and tool operations
holding devices - Select work
- Uses appropriate holding and
drilling operation tool holding
- Maintains drilling devices
machine in good - Use
working condition appropriate
drilling
operation
- Maintain
drilling
machine in
good working
condition
18
- Applies set theory intersection
in grouping of sets -
engineering - Apply set
materials theory in
grouping in
grouping
engineering
materials
- Basic SI
Units
Arithmetic
Algebra and
Mensuratio
n
- Apply metric
conversion of
- Converts SI units
- Metric
millimetres to - Apply
conversion
meters, kg to percentages,
of SI Units
Newtons and ratios and
and Algebra
tonnes proportions
Fractions
- Applies in material
Percentages,
percentages in costing
ratios and
calculating - Interpret
proportions
material costs drawings
8hrs
- Determines areas - Calculate
of irregular objects costs in
using Simpson rule relation to
- Mensuratio
and trapezoidal areas and
n
rules volumes
Calculation
of areas,
19
perimeter,
volume and
total surface
area
Interpretatio
n of given
drawings
/diagrams
Cost
- Add fraction calculations
to get a in relation to
common area and
denominator volume
- Adds fractions to - Manipulate Area of
get a common functions in irregular
denominator rules figures 12hrs
- Manipulates - Apply inverse
functions in rules of a function
- Applies inverse of - Draw graphs Elementary
a function functions
Draws graphs - Functions in
rules
- Functions
and the
- Record arithmetic
information functions
on frequency Inverse of
distribution function and
sheets graphs 10hrs
- Determine
the average of
given data
20
- Records - Draw Basic
information on histograms Statistics
frequency representing -Recording of
distribution sheets given information
- Determines the information and frequency
average of given - Apply the distribution
data assumed -Types of
- Draws histograms mean for averages
representing given calculating -Histograms
information standard -Calculation
Applies the deviation of of mean,
assumed mean for materials standard
calculating costs in the deviation and
standard deviation market assumed
of materials costs mean
in the market 14hrs
21
- Constructs to scale - Construct paper, tee
triangle circles perpendicula squares,
rs and - Drawing
parallel lines paper layout,
- Construct a types of title
triangle blocks
and inscribe - Types of
- Circumscribe lines
and escribe - Lettering
circles
Geometrical
constructions
- Construction
of
perpendicula
r and parallel
lines
- Construction
of angles by
bisection
- Bisection of
a line,
division of a
line
- Inscribing
escribing
and
circumscribe
d circle
- Determining
the centre of
circular arc
22
- Determining
circumferenc
e of circle.
Simple
Geometrical
plane figures
- Construction
of simple
plane figures
- The circles
and its
properties
Principle of
tangency
- Arc to
straight line
- Arc to Arc
externally
- Arc to Arc
internally
- Construction
of external
and internal
tangents to
equal and
unequal
circles
- Transform, Transformati
- Transforms reduces reduce and on
and enlarges plane enlarge plane enlargement
figures Figures and reduction
23
of plane
figures
- Transformati
on of given
shaped
- Construct figures to
- Constructs various s other shapes
various s types types of loci - Enlargement
geometrical and loci of and
points on reduction of
mechanisms planes
figures
Loci
- Construction
of an ellipse
using locus
concentric
circles
- Parabola
- Determine the using locus
- Determines the true true shape of a circumscribi
shape of a cut surfacecut surface by ng rectangles
by auxiliary auxiliary and
- Makes surface - Make surface parabolic
development development envelope
- Determines curves - Determine methods
of penetration curves of Surface
penetration
- Determines true length development
of a line in space - Determine - Importance
by rebatement, true length of - Methods
triangulation, and a line in space - Parallel lines
auxiliary projection by - Radial lines
24
rebatement, - Triangulatio
triangulation, n
and auxiliary - Panel
projection Interpenetrate
of common
solids
- Use of
- sections
True length
and true
shape
Methods of
determining
true length
Reading materials:
Backhouse (1985), Pure Mathematics, 4th Edition, Longman.
Bruce. J. Black 1984 Workshop processes, practices and materials by Edward Arnold (publishers) Ltd.
Elhance, D.N., and Aggarwal, B. M. (2000) Fundamental of Statistics. New Delhi, Kitab Mahal
Groover M.P (2002) Fundamentals of modern manufacturing; John Wiley &Sons, Inc.
Singh R., (2006) introduction to basic manufacturing processes and workshop technology; New Age
international ltd publishers.
25
MODULE 03: PRODUCTION OF MECHANICAL COMPONENTS BY LATHE
OPERATIONS
Module Code:
Module overview
This module introduces the learner to the safe use of the lathe machine in the production of flat,
cylindrical and conical shapes internal or external. The module covers skills and knowledge to
produce components to the right dimensions by assessing hazards during lathe work operations,
identifying work holding and tool holding devices, proper planning of activities and appropriate lathe
operations.; covers skills and knowledge.in engineering drawing and geometrical construction,
workshop science and calculations; skills of analysing and troubleshooting electronic systems.
The module training consists of 7 sub modules and real-life project taking a total of 570 hrs and
industrial training 150hrs. Total duration of the module will be 720hrs (6months)
Training outcome:
By the end of the module, the student technician should be able to; produce various shapes
cylindrical, offset, conical internal or external surfaces using lathe machine; assess hazards associated
with lathe machine operations; select different types of lathe machines, work /tool holding devices
used on the lathe machine, the structure; prepare working drawing and sequence activities; classify
cutting tools and cutting methods; reduce material wastage by restoring scrape/ worn out part by
shielded metal arc welding; carry out lathe work operations; learner should be able to construct
drawings using basic engineering drawing principles; analyse the effects of internal and external forces
in mechanical elements, analyse and trouble shoot electronic systems
Module Assessment
Continuous assessment (Assignment 10%, Test 05%, Practical work 25%)
Final assessment 60%
26
Module details
27
- Enough
lighting system
- Safe working
practices with
SMAW
Maintains
workshop in safe - Maintain Workshop
working condition workshop in safety practices
safe working
condition
- Working
- Maintain gang environment
ways, stairs - Relevance of
and floor in house keeping
safe working
Consequences
condition
of house
- keep tools and keeping
materials in
the right places
identify waste,
sort
28
- Identifies tool - Identify tool - Elements of
holding devices holding devices machine drives
- Identifies Machine - Identify - Lubrication
drives Machine drives systems
-
3. Working - Identifies tools - Identify tools Working
drawing and needed for an needed for an Drawings
operation operation operation - Preparation of
sequence - Develops - Develop single component
Sequence the Sequence the drawings from
operations operations assemblies
- Identifies - Identify
materials needed materials
- Interprets needed
engineering - Interpret
drawing engineering
- Prepares a parts drawing
list and title block - Prepare a parts
on assembly list and title
. block on
assembly
29
- Selects correct - Select correct - Motions graphs
machine machine and their uses in
- Assembles - Assemble cam
machine parts machine parts - profile
- Draws view with - Draw view with construction
orthographic orthographic - cam construction
projection projection for in line
- Prepares a parts list condition
and title block on Principles of
assembly orthographic
- Introduction to
orthographic
projection
- Projection
methods
- Three view
drawing of solid
objects in 1st
angle 3rd angles
- Dimensioning
techniques
- Types of
dimensions
Sectional views
8hrs
- First auxiliary
projection 8hrs
- Isometric and
oblique
projection 16hrs
Conventional
representation of
30
common features
and materials 8hrs
- Conventional of
materials
- Common
abbreviations of
details
Machine assembly
Drawing
- Assembling of
given machine
parts to form a
functioning unit
- Orthographic
projections
- Sectional views
of assemblies
- Dimensioning of
working drawing
- Preparation of
parts list and title
block
-
4. Classificatio - Identifies tool - Identify tool - Cutting tools
n of cutting material, types of material, types 12hrs
tools and cutting tools used of cutting tools
cutting on lathe machine used on lathe
methods - Identifies Causes machine
of wear/ tool life - Identify Causes
- Mixes and uses of wear/ tool
cutting fluid life
- Grinds tool angles
31
- Mix and use
cutting fluid
- Grind tool
angles
32
- Prepares CNC - Prepare CNC
lathe and uses lathe and use
part program part program
33
- Understands the - Understand Electrical science
principles of the principles &Electronics
electro static of electro static - Basic electricity
charge charge - Current
- Calculates - Calculate Electricity
inductive inductive - DC circuits
capacitance and capacitance - Magnetism
parallel gradient and parallel - Fundamentals of
- Calculates the gradient electronic
quantity of charge - Calculate the induction
of electronic quantity of - Introduction to
components charge of electronics
- Analyses DC electronic - Science of
circuits components electronic
- Makes magnets - Analyse DC materials
by induction and circuits - Essential
electrical methods - Make magnets Electronics
- Applies by induction
fundamentals of and electrical
electronic methods
induction - Apply
- Calculates fundamentals
inductance of electronic
,resistance and induction
conductance for -
circuits in parallel
and series
- Describes the
basic concept of
electronics
34
- Describes the
composition of
semi-conductors
- Draws and
analyses
electronic circuits
- Draws and
analyses logic
electronic circuits
- Interprets logic
gates and circuits
- Selects amplifiers
Reading materials:
Backhouse (1985), Pure Mathematics, 4th Edition, Longman
Jain R.K., (2001) production technology 16th edition; Delhi, Khanna Publishers
Khurmi R. S, (2004) A text book of Workshop Technology; Manufacturing processes, S. Chand Publishers
35
MODULE 04: PRODUCTION OF MECHANICAL COMPONENTS BY MILLING
OPERATIONS
Module code:
Module overview
This module introduces the learner to the safe use of the milling machine in the production of
components. The module covers skills and knowledge to produce components to the right dimensions
by assessing hazards during lathe work operations, identifying work holding and tool holding devices,
proper planning of activities and appropriate milling operations; By the end of this module the learner
should be able to use trigonometry to set out structures and simple templates, evaluate vectors and
apply the laws of indices and logarithms
The module training consists of 6 sub modules and real-life project taking a total of 480hrs and
industrial training 150 hours. Total duration for the module will be 5 months and 1 week (630hrs).
Training outcome:
By the end of the module, the student technician should be able to produce various surfaces flat, cam,
slots using milling machine; assess hazards associated with milling machine operations select different
types, construction, motions and cutters used on milling machines; identify and use different tool
holding devices, work holding devices and attachments; prepare working drawing and sequence
activities; use milling machine to carry out milling operations; use trigonometry to set out structures
and simple templates, evaluate vectors and apply the laws of indices and logarithms
Module Assessment
Continuous assessment (Assignment 10%, Test 05%, Practical work 25%)
Final assessment 60%
Module details
S/No Sub Module Competences Duties and Content Duration
Tasks
1.. Hazards - Classifies cutting - Classify 480hrs
associated fluids cutting fluids
with milling - Organizes - Organize
workshop workshop
36
machine - Practices good - Practice good
operations house keeping house
- Checks milling keeping
machine parts for - Check
alignments before milling
use machine
- Uses personal parts for
protective alignments
equipment before use
- Observes safety - Use personal
while carrying protective
heavy components equipment
- Maintains milling - Observe
machine in good safety while
working condition carrying
- Observes safety heavy
practices during components
milling operations - Maintain
milling
machine in
good
working
condition
- Observe
safety
practices
during
milling
operations
37
construction - Differentiates - Differentiate milling
and cutters between Down cut between machines. 4hrs
and up cut Down cut - Milling cutters
- Calculates speed, and up cut 2hrs
feed and power - Calculate - Speed, feed and
speed, feed power for milling
and power cutters.
2hrs
- Types of milling
operations
2hrs
38
- Interprets - Identify
engineering materials
drawing needed
- Develops bill of - Interpret
material/ parts list engineering
drawing
- Develop bill
of material/
parts list
39
Flat and
angular
surfaces
- Maintain
milling
machine in
good
working
condition
40
logarithmic
functions,
exponential
functions and
logarithmic
graph
- National
- Calculates for logarithms 20hrs
sine, cosine and - Calculate
tangent of right- for sine, Trigonometry
angled triangle cosine and - Trigonometry
- Determines tangent of - The general
ladder safe right-angled angle
leaning angles triangle - Pythagoras
and roof pitches - Determine theorem
- Manipulates ladder safe - Graphs of
trigonometrical leaning trigonometrical
ratios of 300, 450, angles and functions
600 and their roof pitches - Trigonometrical
application in - Manipulate ratios of 30,
finding areas of trigonometri 45,60
plots of land cal ratios of - The sine
- Draws 300, 450, 600 formula
trigonometrical and their - Cosine formula
graphs application - Tangent
- Determines the in finding formulae
heights and other areas of - Half angle
distances using plots of land formulae
sine, cosine, - Draw - Heights and
tangent formulae trigonometri distances 26hrs
- cal graphs
41
- Determine
the heights
and other
distances
using sine,
cosine,
tangent
formulae
42
Represents - Represent - Types of
vectors on graphs vectors on vectors
- graphs - Addition of
- vectors
- Subtraction of
vectors 16
hours
-
INDUSTRIA - - - 150hrs
L TRAINING
Reading materials:
Elhance, D.N., and Aggarwal, B. M. (2000). Fundamental of Statistics. New Delhi, Kitab Mahal
Khurmi R. S, (2004) A text book of Workshop Technology; Manufacturing processes, S. Chand Publishers
Stroud K. A. (1995). Engineering Mathematics. 4th Edition, Macmillan Press
Module overview
This module introduces the learner to production of components by shaping process, welding
process, grinding process and maintenance of basic machines. The module covers skills and
knowledge that include; assessment of risks, production of components by use of shaping machines,
welding machine, grinding machine and basic maintenance activities; concepts of complex numbers
and it equips the learner with the skills of representing numbers in polar form ,graphical and imaginary
form ; engineering calculus used in determining the estimated loads which machines and structures
are expected to carry; skills of analysing mathematical expressions that yield simple to polynomial
expressions
The module training consists of 5 sub modules and real-life project taking a total of 480 hrs and
industrial training 150 hours. Total: 5 months 1 week (630hrs)
Training outcome:
43
By the end of the module, the learner should be able to; produce components by shaping processes,
make sound joints by SMAW and Gas welding processes, fine finish produced components to desired
surface finish and dimension; maintain basic metal forming machines; to solve equations involving
complex numbers, evaluate polynomials equations applied in vibrating systems of vehicles and
structures; apply calculus in determining the bending moments of beams and other structures, apply
binomial theorem in determining oscillations and frequencies of materials.
Module Assessment
Continuous assessment (Assignment 10%, Test 05%, Practical work 25%)
Final assessment 60%
Module details
S/No Sub Module Competences Duties and Content Duration
Tasks
1. Produce - Carries out Risk - Carry out - Shaping 150hrs
components by assessment of risk operations 10hrs
use of shaping hazards assessment of - Tool holding for
machine associated with hazards internal and
shaping machine associated external surfaces
operations with shaping 6hrs
- Identifies the machines
features, controls, - Identify the
motions and drive features,
mechanism of controls,
shaping machines motions and
- Identifies and set drive
work holding mechanism
devices on of shaping
shaping machine machines
- Carries out Tool - Identify and
setting for set work
holding
44
particular devices on
operation shaping
- Produces flat machines
horizontal and - Carry out
vertical surfaces, tool setting
key ways for particular
- Restores work operations
area - Produce flat
horizontal
and vertical
surfaces, key
ways
- Restore work
area.
45
- Sets up on the
equipment for structure
welding - Identify and
- Applies Welding store
techniques Electrodes
- Identifies welding - Prepare
defects by visual material for
inspection welding
- Tests weldment - Set up
by non- Equipment
destructive set up for
methods welding
- Apply
Welding
techniques
- Identify
welding
defects by
visual
inspection
- Test
weldment by
non-
destructive
methods
46
- Identifies types, - Inspect - Work holding
features and grinding /tool
motions of wheel holding10hrs
grinding - Identify - Grinding
machine types, operations 30hrs
- Sets up grinding features and
machine motions of
- Selects work grinding
holding machine
- Select - Set up
appropriate grinding
Grinding machine
operations - Select work
- Understands the holding
effect of heat to - Select
final component appropriate
- Applies Cutting Grinding
fluid operations
- Maintains wheel - Know effect
in good working of heat to
condition final
- Restores work component
area - Apply
Cutting fluid
- Maintain
wheel in
good
working
condition
- Restore
work area
47
4. Maintain basic - Prepares - Prepare - REAL LIFE
metal forming maintenance maintenance PROJECT
machines. schedule schedule
- Assesses risks - Assess risks
associated with associated
maintenance with
activities maintenance
- Interprets activities
maintenance - Interpret
manual/order maintenance
card manual/orde
- Prepares hand r card
tools, cleaning - Prepare hand
materials and oils tools,
needed cleaning
- Carries out materials and
routine oils needed
maintenance - Carry out
- Reports fault/ routine
diagnose /trouble maintenance
shoot - Report fault/
- Applies right diagnose
Procedure for /trouble
dismantling and shoot
assembling of - Apply
machine Procedure for
- Replaces part, dismantling
seal. and
- Restores work assembling of
area machine
- Tests run and - Replace part,
make a report seal.
48
- Restore work
area
- Test run and
make a report
- Differentiat
- Differentiates e the
the variables variables
from first from first Differentiation
principle principle - Differentiation
- Differentiates - Differentiat - Differentiation
the product and e the from first
quotient principle
49
- Applies product and - Differentiation of
differentia quotient product and
equations in - Apply quotient
determining differentia - Choice of
beam deflections equations in variable
determining 14hrs
been
deflections
- Applies integral
equations to - Apply
evaluate the integral Integration,
extent of beam equations to single and double
deflections evaluate the integrals
- Determines extent of - Standard
graph gradient of beam integrals
curve deflections - Functions of
- Uses integration linear functions
principles to - Determine of x
determine the graph - Integration of
size and area of gradient of polynomial
a simple curve functions
structure - Use - Integration by
integration partial fractions
principles to - Areas under
determine curves 16 hrs
the size and
area of a
simple
structure
50
- Evaluate
- Evaluates independent
independent variables Expression of
variables - Transpose Equations
- Transposes various - Evaluating
various formulae formulae expressions
- Applies the - Apply the - Equations
transposition of transpositio - Evaluating
formulae in n of independent
manipulating formulae in variables
and solving manipulatin - Transposition of
production g and formulae
related problems solving 12hrs
- Factorises production
quadratic related
equation problems
- Factorise
quadratic
equation
- Solves - Solve
polynomial polynomial Polynomial
equations by equations Equation
applying the by applying - Polynomial
reminder the expressions,
theorem reminder equations of
Solves general theorem polynomials
polynomial - Solve - Remainder
equations general theorem
51
polynomial Factorization of
equations quadratic
polynomials
- Expresses
binomial Binomial
theorem on - Express Theorem
pascal’s triangle binomial - Expansion of
- Manipulates theorem on binomial
binomial pascal’s expressions
theorem triangle pascals
equations - Manipulate triangle, the
binomial binomial
theorem theorem for n,
equations positive integer
- The general
binomial
expansion
(1x1<1 and for
1x1>1 14hrs
INDUSTRIAL 150hrs
TRAINING
Reading materials:
Bird J. O. and,May, A.J.C.,(1982).Technician Mathematics. Longman Higher Education Publisher
Elhance, D.N.,and Aggarwal, B. M. (2000).Fundamental of Statistics.New Delhi, Kitab Mahal.
Groover M.P (2002) Fundamentals of modern manufacturing; John Wiley &Sons, Inc.
Jain R.K (2001) production technology 16th edition; Delhi, Khanna Publishers
Khurmi R.S, (2004) A text book of Workshop Technology; Manufacturing processes, S. Chand Publishers
Ltd. Singh R., (2006) introduction to basic manufacturing processes and workshop technology; New Stroud
K. A. (1995). Engineering Mathematics. 4th Edition,Macmillan Press
Age international ltd publishers.
52
MODULE 06: PRODUCTION OF MECHANICAL COMPONENTS PARTS BY FOUNDRY
PROCESSES
Module code:
Module overview
This module introduces the learner to the safe production of components by foundry processes. The
module covers skills and knowledge.in pattern making, preparation of sand, core making for simple
castings melting, inspection of casting and testing, fettling of final casting. Also the learner will acquire
entrepreneurship skills to turn challenges into opportunities by taking risks through planning,
creativity and innovation.
The training module consists of 6 sub modules and real-life project taking a total of 480 hrs and
industrial training 150 hours. Total duration of the module will be 5 months and1 week (630hrs).
Training outcome:
By the end of the module, the maintenance technician should be able to; assess hazards associated
with foundry processes to avoid accidents; prepare various patterns from different materials with good
pattern attributes; prepare moulding sand with different grain sizes and properties; prepare sand
mould cavities using various patterns both solid and hollow castings; produce sound castings using
sand casting method; confidently practice entrepreneurship, mobilize resources, start-up business,
53
produce quality goods and services, control business finances and manage human resources of the
business
Module Assessment
Continuous assessment (Assignment 10%, Test 05%, Practical work 25%)
Final assessment 60%
Module details
54
- Inspect crucible
and other tools
before use
- Use proper
PPE
55
- Take care of
pattern, coding
and storage of
pattern
56
- Cleans /mend and - Follow
dress cavity moulding
- Prepares core procedure
making equipment - Clean /mend
- Identifies types of and dress
cores and core boxes cavity
- Prepares core sand - Prepare core
- Understands; core making
setting, core equipment
dressing, core - Different types
baking, core sizing of cores and
- Uses gaggers and core boxes
chaplets - Manual Core
sand
preparation
- Terms; core
setting, core
dressing, core
baking, core
sizing
- Use of gaggers
and chaplets
57
- Practices good - /Heat colours
pouring practices - Practice good
- Inspects casting for pouring
defects using practices
inspection methods Inspect casting
- Cleans casting by for defects using
grinding, lathe inspection
work, milling methods
operations, shot Clean casting by
blasting grinding, lathe
- Heat treats metal work, milling
for mechanical operations, shot
properties blasting
Heat treat metal
- for mechanical
properties
58
- Develop
business plan
and
implement it
- Develops Business
plan and
implements it
- Business
planning 9hrs
- Implementing a
Business Plan
4hrs
Production
costing and
Marketing
- Production
6hrs
- Marketing 6hrs
59
- Applies Creativity - Manage Management
and innovativeness business 6hrs
- Motivates staff records - Contracting
- Manages human - Understand process 6hrs
resource (Shares packaging and - Banking 6hrs
responsibility) value addition - Insurance for
- Recognises the - Apply 4Ps in small businesses
contribution of marketing mix 6hrs
staff - Carry out Taxation and
- Identifies causes of sales other Dues 6hrs
conflicts. promotion
- Calculates VAT services
- Manage
human
resource
Reading materials:
C.B Gupta and N.P Shrivasan (2010) Entrepreneurship development sultan, Chand and sons
Aruna Kaulgad ( 2003) Entrepreneurship management, Thompson learning
Singh R., (2006) introduction to basic manufacturing processes and workshop technology; New Age
international ltd publishers.
60
Groover M.P (2002) Fundamentals of modern manufacturing; John Wiley &Sons, Inc.
Jain R.K (2001) production technology 16th edition; Delhi, Khanna Publishers
REFERENCES
Backhouse (1985), Pure Mathematics, 4th Edition, Longman
Bird J. O. and, May, A.J.C., (1982). Technician Mathematics. Longman Higher Education Publisher
Bolton, R. (1986). People: How to Assert Yourself, Listen to Others, and Resolve Conflicts. Touchston
Bough B. (2005).101 Ways to improve Your Communication Skills Instantly.4th Edition; Goal Minds, Inc.
Khurmi R.S,(2004) A text book of Workshop Technolgy ; Manufacturing processes ,S.Chand Publishers
McKay M. And Davis, M. (2009).The Communication Skills Book. 3rd Edition; New Harbinger
Publications.
Murray H., (2003).Teach Yourself Basic Computer Skills. New Edition; Teach Yourself Books.
Raisi F. A.,(2011).Basic Computer Skills. 1st Edition; Sultan Qaboos, University College of Science
Stroud K. A. (1995). Engineering Mathematics. 4th Edition, Macmillan Press
61