CURRICULUM

FOR THE TRADE OF

TOOL AND DIE MAKER

(PRESS TOOLS, JIGS & FIXTURES)
UNDER

APPRENTICESHIP TRAINING SCHEME

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

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 CONTENTS

Sl. No. Topics Page No.

1. Acknowledgement 3
2. Background 4-5
1.1 Apprenticeship Training under Apprentice Act 1961
1.2 Changes in Industrial Scenario
1.3 Reformation

3. Rationale 6
4. Job roles: reference NCO 7-8
5. General Information 9
6. Course structure 10-11
Syllabus 12-29
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.
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 30-32
8.1 Assessment Guideline
8.
8.2 Final assessment-All India trade Test (Summative
assessment)
9. Further Learning Pathways 33
10. Annexure-I – Tools & Equipment for Basic Training 34-40
11. Annexure-II – Infrastructure for On-Job Training 41
12. Annexure-III - Guidelines for Instructors & Paper setter 42

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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. Larsen & Toubro, Mumbai

2. Maruti India Ltd., Gurugram
3. Volkswagan Academy, Pune
4. OCL Ltd. (Dalmia Group), Odisha
5. Bharat Heavy Electricals Ltd., Ranipet, Tamil Nadu
6. TATA Motors, Pune
7. JBM Group, Chennai
8. MTAB Technology (P) Ltd., Chennai

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

Co-ordinator for the course: Sh. Nirmalya Nath., ADT

Sl. Name & Designation Organization Remarks

No. Sh./Mr./Ms.
1. Anil.V. Bhide, Manager(Trg) NTTF, Peenya Campus, Expert
Bangalore

2. G.N. Eswarappa, DDT FTI, Bangalore Expert

3. N. Nath, ADT CSTARI, Kolkata Expert
4. R. N. Manna, T.O. CSTARI, Kolkata Expert

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 2. BACKGROUND

2. 1. Apprenticeship 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 Tool and Die Maker – Press Tool, Jigs & Fixture trade)

1. The greater degree of relevance of the training with latest advancements of the industry will
enhance the employability opportunities
2. It will enhance the ability to study blueprints, sketches or other instructions to determine
operational methods or sequences.
3. It will enhance the ability to visualize and compute dimensions, sizes, shapes, and tolerances of
assemblies, based on specifications.
4. It will enhance the ability to fit and assemble machine tools, parts or fixtures using machine
tools and hand tools.
5. It will enhance the ability to obtain required fixtures, cutting tools, measuring instruments and
other items from tool needs.
6. It will enhance the ability to develop and design tools, fixtures, or other devices for production
equipment.
7. It will enhance the ability to design jigs, fixtures, and templates for use as work aids in the
fabrication of parts or products.
8. It will enhance the ability to set-up and operate press so it is capable of performing work
assignments to the predetermined level of production and quality goals.
9. It will enhance the ability to set up and operate a hydraulic press or punch for routine
established work.
10. It will enhance the ability to select correct tooling for metal press forming task with setup
documents.
11. It will enhance the ability to load, install and correctly set up the tools required.
12. It will enhance the ability to lift work piece manually or with hoist, and positions and secures it
on machine table in drilling jig or holding fixture.
13. It will enhance the ability to perform assigned work to time standards and quality expectations.

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 4. JOB ROLES: REFERENCE NCO

Brief description of Job roles:

Tool Maker makes cutting and press tools, gauges, simple jigs, fixtures, etc.
mainly for use in machines. Studies drawings, samples and other specifications of tool or
gauge to be made. Selects required type of metal or alloy and marks it for various
operations, using vernier height gauges, sine plate, Vee blocks, etc. Cuts, files, grinds,
scrapes or otherwise shapes metal to specified dimensions frequently checking it while
working with measuring instruments such as micrometer, vernier, gauges, face plate etc.
as necessary. Anneals, shapes, hardens and tempers cutting tools ensuring correct cutting
angles, clearances, etc. according to standard or prescribed specifications. Assembles
part, finishes object. Checks accuracy with precision measuring instruments and shadow
graph if necessary to ensure desired performance. Calibrates and adjusts tools and
gauges where required and maintains them in good working order. Guides brazing of tips
to stalks and finishes them to make tip tools. Is designated as GAUGE MAKER if
engaged in making or reconditioning gauges. May repair and recondition tools for
further use. May design tools, jigs and fixtures and braze and weld metal parts.

Jig and Fixture Maker makes and repairs jigs and fixtures (device for holding
metal and guiding cutting tools) for mass production work. Studies drawing and checks
dimensions and other specifications of sample to calculate working details. Collects
material, gets surfaces finished by filing or machining and marks them off. Makes
different parts of required jig or fixture by cutting, filing, machining, grinding, scraping,
drilling, screwing, etc. and finishes them to required dimensions. Hardens and tempers
necessary parts or gets them done ensuring that they do not get demoted. Assembles
parts in proper sequence, fits hardened bushes or parts where specified to guide cutting
tools and checks easy fixing and removing of part to be machined to ensure operational
efficiency of jig or fixture made. Checks fitting of jig and fixture at each stage while
assembling to conform to specifications. Tests completed jig or fixture by trial
operations to ensure operational efficiency and accuracy in production work. May make
adaptors, pullers etc. for specific purposes. May machine and grind jig and fixture parts
himself.

Tool Setter, Press sets press tools (die and punch) in power and hand press for
manufacture of sheet metal products. Examines sample or studies drawings and
specifications of item for production. Selects appropriate pair of die and punch and
examines them for sharpness, cutting angle, clearance, etc. Fits punch in punch holder of

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machine and securely screws it in position. Places die on machine table and lowers
punch to fit in die. Adjusts position of die in relation to punch. Clamps die securely on
machine table with holders, plates, bolts and nuts and manually operate punch few times
to ensure that it passes clearly through die set. Starts machine and feeds metal to cut or
form trial pieces. Examines them for correctness in all respects, resets die if necessary,
and hands press over to operator for production work. May grind press tools on surface
grinder. May fit guide pin in die to avoid wastage of material. May fit die in bolster
(holding device) before setting. May supervise operators.

Plan and organize assigned work and detect & resolve issues during execution.
Demonstrate possible solutions and agree tasks within the team. Communicate with
required clarity and understand technical English. Sensitive to environment, self-learning
and productivity.

Perform TPM (Total Production Management), TQM (Total Quality Management) and
record keeping system.

Reference NCO:

i). NCO-2004: 7222.20

ii). NCO-2004: 7222.30
iii). NCO-2004: 7223.20
iv). NCO-2004: 7222.50
v). NCO-2004: 8211.10
vi). NCO-2004: 8211.15
vii). NCO-2004: 8211.22
viii). NCO-2004: 8211.30
ix). NCO-2004: 8211.38
x). NCO-2004: 8211.55
xi). NCO-2004: 8211.70

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 5. GENERAL INFORMATION

1. Name of the Trade : TOOL AND DIE MAKER (PRESS TOOLS,

JIGS AND FIXTURES)
2. N.C.O. Code No. : NCO-2004: 7222.20, 7222.30, 7222.50, 8211.10,
8211.15, 8211.22, 8211.30, 8211.38, 8211.55,
8211.70

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

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 : Passed 10th Class with Science and Mathematics under 10+2
system of Education or its equivalent
5. Selection of Apprentices: The apprentices will be selected as per Apprentices Act
amended time to time.

6. Rebate for ITI passed trainees : i) One year in the trade of TDM (Press Tools, Jig
& Fixtures)/Machinist/TDM (Dies & Moulds)

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 : TOOL AND DIE MAKER (PRESS TOOLS,

JIGS AND FIXTURES)
2) Hours of Instruction : 1000 Hrs. (500 hrs. in each block)
3) Batch size : 20
4) Power Norms : 29.6 KW for Workshop
5) Space Norms : 130 Sq. m.

6) Examination : The internal assessment will be held on

completion of each Block.
7) Instructor Qualification :

i) Degree/Diploma in Mechanical Engg. from recognized university/Board

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

ii) NTC/NAC in the trade of Tool & Die Maker (Press Tools, Jigs and
Fixtures) 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 & Duration

No. (in hours) Calculation (in hours)

1. Engineering Drawing: 30 Units & Measurements- FPS, 20

Introduction and its importance CGS, MKS/SI unit, unit of
Different types of standards used length, Mass and time.
in engineering drawing. Fundamentals and derived units
Drawing Instruments: their uses Conversion of units and applied
Drawing board, T-Square, Drafter problems.
(Drafting M/c), Set Squares,
Protractor, Drawing Instrument
Box (Compass, Dividers, Scale,
Diagonal
Scales etc.), Pencils of different
Grades, Drawing pins / Clips.
2. Lines : Material Science : properties -
types and applications in Drawing Physical & Mechanical, Types -
as per BIS SP:46-2003 Ferrous & Non-Ferrous,
Drawing geometrical object using difference between Ferrous and
all types of lines. Non-Ferrous metals
Drawing of Geometrical
Figures: Angle, Triangle, Square,
Rectangle and Circle.
Letters: - Lettering styles, Single
stroke letters and numbers as per
IS standard. Lettering practice
3. Dimensioning- Types of Mass .Weight and Density :
dimension, elements of Mass, Unit of Mass, Weight,
dimensions, Methods of difference between mass and
indicating Values, Arrangement, weight, Density, unit of density,
Alignment and indication of
dimensions.
Scales:-Types use and
construction. Representative
factor of scale.
4. Method of presentation of Speed and Velocity: Rest and
Engineering Drawing motion, speed, velocity,
- Pictorial View difference between speed and
- Orthogonal View velocity, acceleration,
- Isometric view retardation.
Average Velocity, Acceleration
& Retardation. Related
problems.

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 Circular Motion: Relation
between circular motion and
Linear motion, Centrifugal
force, Centripetal force
5. Constructions: - Draw Ratio & Proportion :
proportionate free hand sketches Simple calculation on related
of plane figures. Sketch problems.
horizontal, vertical and inclined Percentage: Introduction,
line by free hand, Draw circles by Simple calculation.
free hand using square and radial
line method, Draw arcs and
ellipse by free hand
6. Projections: Work, Power and Energy:
Concept of axes plane and work, unit of work, power, unit
quadrant. of power, Horse power of
Orthographic projections engines, mechanical efficiency,
Method of first angle and third energy, use of energy, potential
angle projections (definition and and kinetic energy, examples of
difference) potential energy and kinetic
Symbol of 1st angle and 3rd angle energy.
projection as per IS specification. Meaning of H.P., I.H.P.,
Free hand Drawing of B.H.P., and F.H.P. and CC
Orthographic projection from and Torque.
isometric/3D view of geometrical
blocks

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 B. Block- II
Basic Training

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

No. (in hours) Calculation (in hours)

1. Screw :- 30 Algebra: 20
Its Types and Sizes, Screw thread, Addition, Subtraction,
their standard forms as per BIS, Multiplication, Division,
external and internal thread. Algebraic formula, Linear
equations (with two variables).
2. Rivets and Joints:- Heat & Temperature:
Prepare a drawing sheet on rivets Heat and temperature, their
nomenclature and Joints. units, difference between heat
and temperature, boiling point,
melting point, scale of
temperature, relation between
different scale of temperature,
Thermometer, pyrometer,
transmission of heat,
conduction, convection,
radiation.
3. Free hand Sketches for simple Mensuration: Area and
pipe line with general fittings. perimeter of square, rectangle,
parallelogram, triangle, circle,
semi circle, Volume of solids -
cube, cuboid, cylinder and
Sphere.
Surface area of solids -cube,
cuboid, cylinder and Sphere.
Volume of cut-out solids:
hollow cylinders, frustum of
cone, block section. Volume
of simple solid blocks.
4. Reading of drawing. Simple Basic Electricity: Introduction,
exercises related to missing lines, use of electricity, how
dimensions. How to make queries. electricity is produced, Types
of current_ AC, DC, their
comparison, voltage, resistance,
their units. Conductor,
insulator, Types of connections
- series, parallel, electric power,
Horse power, energy, unit of
electrical energy. Concept of
earthling.
5. Simple exercises related to trade Simple machines
related symbols. Transmission of power: -
Basic electrical and electronic Transmission of power by belt,
symbols pulleys & gear drive.
Heat treatment process: -
Heat treatment and advantages.
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 Annealing, Normalizing,
Hardening, Tempering.

6. Free hand sketch of trade related Trigonometry:

components / parts /cutting tool Trigonometrical ratios,
indicating angles. measurement of angles.
Trigonometric tables.
Finding the value of unknown
sides and angles of a triangle by
Trigonometrical method.
Finding height and distance by
trigonometry.
Application of trigonometry in
shop problems. (viz. taper angle
calculation).
Calculate the area of triangle by
using trigonometry and
application of Pythagoras
theorem.
7. Concept of pressure -
Definition:-Force, Pressure,
and their units, atmospheric
pressure, gauges used for
measuring pressure, problems.
Introduction to pneumatics &
hydraulics systems.
8.
Simple exercises related to trade related Test Papers. Solution of NCVT test papers.

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 7.1.2 DETAIL SYLLABUS OF PROFESSIONAL SKILLS & PROFESSIONAL
KNOWLEDGE
A. Block –I
Basic Training

Week Professional Skills Professional Knowledge

No.
1. Safety: - its importance, classification, personal, Importance of safety and general precautions
general, workshop and job safety. observed in the in the industry/shop floor. All
Occupational health and safety. necessary guidance to be provided to the new
comers to become familiar with the working of
Basic injury prevention, Basic first aid, Hazard Institute system including stores procedures.
identification and avoidance, safety signs for
Danger, Warning, caution & personal safety Introduction of First aid. Safety attitude
message. development of the trainee by educating him to
use Personal Protective Equipment (PPE).
Preventive measures for electrical accidents & steps Response to emergencies eg; power failure,
to be taken in such accidents. fire, and system failure.
Accidents- Definition types and causes.
Importance of housekeeping & good shop floor First-Aid, nature and causes of injury and
practices. utilization of first-aid.
Disposal procedure of waste materials like cotton
waste, metal chips/burrs etc. Introduction to 5S concept & its application.
Fire: - Types, causes and prevention methods.
Fire& safety: Use of Fire extinguishers. Fire Extinguisher, its types.

Global warming its causes and remedies.

Industrial Waste its types, sources and waste
Management.
2. Identification of tools & equipments as per desired Introduction hacksaw cutting, marking, filling
specifications for marking & sawing( Hand tools , operation, need and application, types of files
Fitting tools & Measuring tools) and their construction and usage
Perpendicularity, parallelism.
Uses of marking tools, Punch, Try square & basic
measuring tools, caliper, steel rule. Marking out Hand tools and its importance, steel rule, Try
lines, gripping suitably in vice jaws, hacksawing to square, chisel, surface gauge and care &
given dimensions, sawing different types of metals maintenance, Hacksaw frame, blades.
of different sections.
Classification and types of chisels, files & uses,
Filing, Chipping & scraping flat surfaces and vices - its constructions and uses. Hammers
measure using different measuring instruments. and its types. Related safety.

Marking block, Steel rule, and calipers-

different types and uses. Hacksaw blade,
Hacksaw frame and its types. Drill bits- parts,
Types & uses.

Different measuring instruments and gauges

17
 used in shop floor, their construction and
usage.

Selection of Cutting parameters and work

holding devices.

3. Mounting and dismantling of different dills on Identification of different parts, accessories,

machines and different practical exercises. attachments’, operations and tools used in
drilling machines.
Marking and Drilling holes on flat pieces. Tapping
as per simple drawing. Introduction to Hand Taps & Dies and their
types, applications, care and maintenance.
Exercise on use of pillar drill in drilling, counter Familiar with tap and drill size, Thread
sinking, counter boring. Spot facing and use of spot Terminology.
facing tools.

Further practice of drilling of Radial drills. Practice

of reaming on drilled holes.

4. Lathe: Holding of round job in an independent Introduction to lathe. Its types, engine lathe
chuck and truing it. Holding the tool in a tool post, construction, detail function of parts size and
centering the job with the tool. Facing & drilling. specification. Safety points to be observed
while working on a lathe.
Parallel turning between centers, parting off,
chamfering using roughing, finishing and parting Lathe tools their angles & uses. Driving
off tools. mechanism, speed and feed mechanism & lathe
accessories.
Holding the job in three jaw chuck truing, centering
facing. Step turning undercutting, knurling drilling
and boring.

5. Taper turning by swiveling compound rest, setting Chucks-different types of job holding devices
the compound rest to correct degree, checking the on lathe and advantages of each type.
tool height, clamping the saddle for no longitudinal Mounting and dismounting of chucks.
movement, checking up with precision instruments.
Taper introduction, types and uses.
Cutting V thread external and internal in a lathe. Calculations of tapers. Measurement of taper
Checking up with screw pitch gauge. Cutting by sine bar and slip gauges.
square thread external & internal on a lathe.
Different thread forms their related dimensions
Cutting square threads (right hand only) on a lathe- and calculations screw cutting in a lathe.
checking with thread gauge-grinding of tool and

18
 setting in correct position.

6. Introduction to milling machine, demonstration on Milling machine importance of milling

working principle, setting of job, setting of cutter in machine, types and specification of milling
arbor, setting of vice on table. Safety points to be machine, driving and feed mechanism of
observed while working on a milling machine. milling machine.

Sequence of milling six faces of a solid block. Classification & different types of milling
Checking the accuracy with the help of try-square cutters & their use. Parts and nomenclature.
scribing block and vernier height gauge.
Vernier height gauge construction, graduations
Step milling using side and face cutter checking vernier setting & reading, vernier bevel
with micrometer. protractor, construction graduation setting and
reading. Care and maintenance of vernier
height gauge and bevel protractor.

7. Straddle and gang milling operations including up- Different milling operations plain-face,
milling and down milling. angular, form, slot, gang and straddle milling
etc. Up and down milling.
Milling concave and convex surfaces.
Different types of milling attachments and their
Introduction to indexing head types, setting and uses.
aligning of indexing head with reference to job on
milling machine. Indexing-introduction & types. Indexing head-
constructional details, function of indexing
Milling square and hexagonal job by simple plates and the sector arms. Calculation for
indexing method. various types of indexing.

8. Milling dovetail and ‘T’slots both male & female Introduction surface and cylindrical grinding
matching each other. machine, identification of different parts,
accessories, attachments’, operations and tools
Milling of spur gear. used in grinding machines. Selection of
Introduction to grinding machine surface grinder, grinding wheels, balancing and mounting of
cylindrical grinder. Driving and feed mechanism, grinding wheels.
job holding devices mounting of wheels. Types of Abrasives and their uses, Glazing and
Different practical exercises with different accuracy loading of wheels. Explain the importance and
levels. necessity of quality.

Wheel balancing & truing. Grinding of parallel and

stepped jobs. Dressing of grinding wheels.

9-10 Tool & Cutter Grinder: Tool & Cutter Grinder:

Grinding of single point cutting tool blank. Description of tool and cutter grinding
19
 Grinding of plain and face milling cutter. machine. Work (cutting tool) holding devices
for tool & cutter grinder machine.
Setting process of cutting tools and grinding
wheel on tool & cutter grinding machine.
11-12 Wire Cut Wire Cut
Machining practice / observation on Wire cut Electrical discharge machining (EDM) -
Machine. Introduction, principle of operation,
advantages & disadvantages and its
applications.
Wire cut machine - introduction, principle of
operation, advantages & disadvantages and its
applications.
13. Revision & Internal Assessment

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 B. Block –II
Basic Training

Week Professional Skills Professional Knowledge

No.
1-3. JIGS & FIXTURES: JIGS & FIXTURES:
Identify different elements of jigs and fixture. Definition and application of jigs and fixtures.
Manufacture simple parts as per drawing with Explain the constructional features, different
different machining operations elements and working principles of jigs and
fixture.

4-8 PRESS TOOL: PRESS TOOL:

Identify different parts of press and different Introduction of press machine, its types and
elements of different press tools. Demonstrate application of press and press tools. Explain the
about safety precautions followed during working constructional features and working principles of
on press machine. Manufacture and assembly of different types of press and press tools
different press tools viz., Blanking die, piercing
die and progressive die. Extrusion process – Process overview, type of
extrusion dies with sketches, advantages of
different extrusion processes, manufacturing and
Inspection of extrusion dies.
Concept of Unitized tooling – advantages and
limitations.
Fine Blanking Technology – Tool Construction,
type of Fine Blanking tools.

9 Hydraulics & Pneumatics Hydraulics & Pneumatics

Identification and familiarization of various Basic principles of hydraulic & pneumatic
types of hydraulic & pneumatic elements such system. Advantages & disadvantages of
as cylinder, valves, actuators and filters. hydraulic and pneumatic system. Theory of
Study of simple hydraulic & pneumatic circuits. Pascal's law, Brahma's press, pressure & flow.
Type of valves used in hydraulic and pneumatic
system.
10-12 Program generation & Simulation (Turning, Basic concept of CNC Machine and its different
Milling and Machining of punch & dies) with code (G and m code) for programming. Practice
CAD/CAM software. of simple programming.
Inspection of machined punch and dies with CAD (Theory)/ CAM
measuring instruments. Basic concepts of inspection of 3D surfaces
(Finishing of punch and Die).
Importance of Technical English terms used in
industry –(in simple definition only)Technical
forms, process charts, activity logs, in required
formats of industry, estimation, cycle time,

21
 productivity reports, job cards.

Concept of TPM & TQM.

13. Revision & Internal Assessment

22
 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.

23
 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),

24
 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.
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

25
 B. Block– II
Basic Training

Topic Topic Duration

No. (in hours)

Entrepreneurship skill 15

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 15
1 Safety & Health
Introduction to Occupational Safety and Health importance of safety and health at
workplace.

26
 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 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 10

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

27
 7.2 PRACTICAL TRAINING (ON-JOB TRAINING)
(BLOCK – I & II)
DURATION: 18 MONTHS (9 months in each block)

GENERAL INFORMATION

1) Name of the Trade : TOOL AND DIE MAKER (PRESS TOOL,

JIGS & FIXTURE)
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 Mechanical Engg. from recognized university/Board

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

ii) NTC/NAC in the trade of Tool & Die Maker (Press Tools, Jigs and Fixtures)
with three year post qualification experience in the relevant field.

Preference will be given to a candidate with Craft Instructor Certificate (CIC)

5) Infrastructure for On-Job Training : - As per Annexure – II

28
7.2.1 BROAD SKILL COMPONENT TO BE COVERED DURING ON-
JOB TRAINING

A. BLOCK – I (09 months)

1. Safety and best practices/Basic Industrial Culture (5S, KAIZEN, etc.)

2. Prepare different types of documentation as per industrial need by different methods of recording
information.
3. Produce finished components on a lathe & milling machine and check for accuracy.
(Conventional/CNC machine)
4. Produce finished components on a surface and cylindrical grinding machines and check for
accuracy.
5. Reading & understanding of Jigs & fixtures, drawing etc. Use of limits fits & tolerances.
6. Grind/ re-sharpen of single point and multipoint cutting tools. (different types of milling cutters)
using Tool and cutter grinding machine
7. Material selection for the manufacture of different elements of Press Tool - Jigs and Fixtures and
Gauges. Heat treatment - It's effects on functioning of different parts - different methods of heat
treatment etc. Material Testing - hardness - tensile and compressive strength - crack - X-ray etc.
8. Manufacture different components using wire cut EDM.
9. Tool length measurement training with different types of tool holders like HSK63, BT40, BT30,
BT50, HSK40 etc. automatic machine or with height gauge with dial indicator.
10. Practical exposure to working on Engraving machine.
11. Manufacture of forming tools like coining, embossing, hole flanging, planishing.

B. BLOCK – II (09 months)

1. Manufacture of different types of jigs and fixtures.

2. Manufacture and assembly of different press tools viz., Blanking die, piercing die and progressive
die.
3. Manufacture and assemble different press tools viz., compound die, V bending die, and drawing
die.
4. Identify and explain the function of cylinder, valve , actuator and filters in the machines available
in work shop like hydraulic press, surface and cylindrical grinder
5. Process planning - machining sequence, cutting tools selection, cutting parameters, work holding
devices.
6. Develop different elements of punches and dies using CAD/CAM software.
7. Measurement of surface finish. Measuring straightness, flatness circularity & roundness,
cylindricity, profile of any line or surface, parallelism, perpendicular &squareness, angularity,
position concentricity & coaxially symmetry.
8. Factors infusing surface quality. Grinding allowance, hardness requirement.Working on
surface finishing processes like broaching, honing & lapping.
9. Hydraulic clamping, pneumatic clamping, vacuum clamping & magnetic clamping Indexing
devices - linear indexing devices & rotary indexing devices. Template jigs & pot jigs-
description of parts & function.
29
10. Accuracy & repeatability concept for jigs & fixtures. Automated jigs & fixture by use of
pneumatics & hydraulics
11. Identify potential causes for non-conformities to quality assurance standards for different press
tools, jigs and fixtures, ISO standards – Trouble shooting – Rectification of tools – Maintenance
of tools – Simple hydraulic/ pneumatic circuits
12. Material selection for the manufacture of different elements of press tools, jigs and fixtures.
Factors to be considered for the selection of material like Load, Heat Resistance, Machinability
etc. Selection of material on the basis of manufacture aspects and processing aspects. Application
of non-ferrous materials for the manufacture of press tools, jigs and fixtures. Fundamental
designing of small tools. Heat treatment its effect on functioning of different parts – different
methods of heat treatment etc.
13. Quality and Inspection of Tools - Stage inspection - Inspection of additional tooling like
electrodes, templates, masters etc.. Use of profile projectors, tool maker's microscope,
comparators - Three co-ordinate measuring machine - surface measuring equipment etc. and
documentation.
14. CNC machine operations and setting of CNC machines verification and simulation of CNC part
programs. Work offsets and tool offsets used in the CNC machines.
15. Prepare part programme using G codes and M codes and machine simulation and manufacture
different components on CNC machines.
16. Preventive maintenance of CNC machines.
17. Perform TPM (Total Productive Maintenance), TQM (Total Quality Management) and record
keeping system.

30
 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

31
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

32
 8.2 FINAL ASSESSMENT- ALL INDIA TRADE TEST
(SUMMATIVE ASSESSMENT FOR TWO YEARS TRADE)
SUBJECTS Marks Sessional Full Pass Marks Duration of
Marks Marks Exam.

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.

33
 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]
 On successful completion of the course trainees can opt for CITS course.

Employment opportunities:

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

employed in the following industries:

1. Production & Manufacturing industries involved in manufacturing jigs & fixture.

2. Infrastructure and defence organisations
3. In public sector industries (Central and State) and private industries in India &
abroad involved in manufacturing jigs & fixture.

34
 ANNEXURE – I

TOOLS & EQUIPMENT FOR BASIC TRAINING

INFRASTRUCTURE FOR PROFESSIONAL SKILL & PROFESSIONAL

KNOWLEDGE

TRADE: TOOL AND DIE MAKER (PRESS TOOL, JIGS & FIXTURE)

LIST OF TOOLS & EQUIPMENTS FOR 20 APPRENTICES

A : TRAINEES TOOL KIT:

Sl. Description of Tools Quantity

No.
1 Steel Rule 150 mm English and Metric combined 20 nos.

2 Engineer’s Square 150 mm with knife edge 20 nos.

3 Hacksaw frame adjustable with pistol grip for 200-300 mm blade 20 nos.

4 Centre punch 100 mm 20 nos.

5 Prick punch 150 mm 20 nos.

6 File flat bastard 300 mm 20 nos.

7 File flat 2nd cut 250 mm 20 nos.

8 File flat safe edge 200 mm 20 nos.

9 File triangular smooth 200 mm 20 nos.

B : Tools and Equipments:

Sl. Name of Tools and Equipments Quantity

No.
1 Caliper inside spring type-150 mm 4 nos.
2 Caliper outside spring type-150 mm 4 nos
3 Divider spring type – 150 mm 4 nos.
4 Odd leg caliper firm joint 0- 150 mm 2 nos.
5 Screw driver – 150 mm 1 no.
6 Screw driver – 200 mm 1 no.
8 Centre gauge 550 and 600 2 nos.
9 Oil can 250 ml 1 no.
10 File flat smooth 200 mm 4 nos.
11 File flat smooth with safe edge 200 mm 4 nos.
12 File half round bastard 300 mm 4 nos.

35
13 File half round smooth 250 mm 4 nos.
14 File triangular bastard 250 mm 4 nos.
15 File triangular smooth 200 mm 4 nos.
16 File round bastard 250 mm 4 nos.
17 File square bastard 300 mm 4 nos.
18 File square smooth 250 mm 4 nos.
19 Knife edge file 150 mm 4 nos.
20 Needle file assorted (12 nos.) 150 mm 4 sets
21 File card 4 nos.
22 Scraper flat 250 mm 4 nos.
23 Hammer Ball Peen 0.5 kg with handle 4 nos.
24 Hammer Cross Peen 0.75 kg with handle 4 nos.
25 Chisel cold flat 18 x 150 mm 4 nos.
26 Chisel Cross Cut 10 x 3 x 200 mm 4 nos.
27 Chisel Half Round 10 x 250 mm 4 nos.
28 Chisel diamond point 10 x 200 mm 4 nos.
29 Scribing block universal 300 mm 2 nos.
30 Cast Iron Surface plate 300 x 300 mm 1 no.
31 Granite Surface plate 600 x 600 x 80 mm 1 no
32 Tap extractor 3 mm to 12 mm x 1.5 mm (ezzy out) 1 set
33 Screw extractor sizes 1 to 8 1 set
34 Taps and dies metric 5 mm to 12 mm complete set in a box 2 sets
35 Twist Drill with St. Shank Ø 5 to Ø 12 mm in steps of 0.5 mm 1 set
36 Twist Drill St. Shank Ø 8 mm to Ø 12 mm in steps of 2 mm 1 set
37 Taper shank drills Ø 6 mm to Ø 20 mm in steps of 1 mm 1 set
38 D.E spanners 3-4 , 6-8, 10-12, 13-14, 15-16, 18-19, 20-22, 24-26 ( 8 2 sets
spanners)
39 Letter punch 5 mm set 1 set
40 Number punch 5 mm set 1 set
41 Drill chuck 12 mm capacity with key 1 no.
42 Allen key metric 3 to 12 mm set 2 sets
43 Centre drills 3, 4,5 mm 2 each
44 Parallel hand reamer 6 mm to 12 mm in steps of 1 mm 1 set
45 Star dresser 2 nos.
46 Diamond dresser with holder 2 nos.
47 Safety goggles (Personal Protective Equipments) 4 nos.
48 Demagnetizer 1 no.
49 Snips 200 mm blade 1 no.
50 Workbench 240 cm x 120 cm x 75 cm with 150 mm vice 4 nos.
(Each bench fitted with 4 vices)
51 Bench Vice 150 mm 16 nos.
52 Steel lockers for 16 trainees (Pigeon Cup Board) 2 nos.
53 Steel cupboard 180 cm x 60 cm x 45 cm 6 nos.
54 Metal rack 180 cm x 60 cm x 45 cm 1 nos.
55 Fire extinguisher 2 nos.
56 Fire buckets with stand 4 nos.
57 Feeler gauge 0.05 mm to 0.3 mm by 0.05 and 0.4 mm to 1 mm by 0.1 1 set
mm (13 leaves)
58 Metric Screw pitch gauge-Range 0.4 -6 mm pitch 600 (21 leaves) 1 set
59 Radius gauge 1 - 3 mm by 0. 25 mm and 3.5-7mm by 0.5 mm (34 1 no.

36
 leaves)
60 Vernier height gauge - Range 300 mm, with 0.02 mm least count 1 no.
61 Universal vernier caliper-Range 200 mm, with 0.02 mm least count 2 nos.
62 Dial vernier caliper 0-200 mm, with 0.02 mm least count 1 no.
63 Vernier caliper-Range 300 mm Vernier scale 0.02 mm 2 nos.
64 Vernier bevel protractor-Blade range 150 and 300 mm, dial 10 , least 1 no.
count 5’ (min.) with head, Acute Angle attachment
65 Outside micrometer 0-25 mm, with 0.01 mm least count 2 nos.
66 Outside micrometer 25-50 mm, with 0.01 mm least count 1 no.
67 Outside micrometer 50-75mm, with 0.01 mm least count 1 no.
68 Combination square sets-300 mm blade with square head, centre head, 1 set
protractor head
69 Telescopic gauge range 8 -150 mm (6 pcs/set) 1 set
70 Sine bar 150 mm with stopper plate 1 no.
71 Sine table 200 mm length with magnetic bed 1 no.
72 Slip Gauge Box (workshop grade) -87 pieces per set 1 set
73 Gauge block accessories consisting holders, half round jaws, scriber 1 set
point, centre point , triangular straight edge (14 pcs/set)
74 Central square – Size 400 x 250 mm blade 1 no.
75 V-Block-Approx. 32 x 32 x 41 mm with clamping capacity of 25 mm 2 pairs
with clamps
76 V-Block-Approx 65x65x80 mm with clamping capacity of 50 mm 1 pairs
with clamps
77 Magnetic V-Block 100x100x125 mm 2 pairs
78 Angle plate 150 x 150 x 200 mm 1 no.
79 Angle plate-adjustable 250x250x300 mm 1no.
80 Inside micrometer – Range 50-63 mm with std extension rods upto 1 set
200mm..
81 Depth micrometer – Range 0-25 mm, accuracy 0.01 mm with std set of 1set.
extension rod s.
82 Magnetic stand with magnetic base 60 x 47.5 mm and with universal 2 nos.
swivel clamp, dial holding rod (150 mm) scriber
83 Dial test indicator-Lever type- Range 0-0.8 mm –Graduation 0.01mm, 1 nos.
reading 0-50-0 with accessories
84 Dial test indicator – Plunger type-Range 0-10 mm , Graduation 0.01 1 nos.
mm, Reading 0-100 with revolution counter
85 Bore gauge with dial indicator (1 mm range, 0-0.01 mm graduation)- 1 set
Range of bore gauge 18-150 mm
86 Straight edge-Single beveled-Size 150 mm and 250 mm 1 each
87 Tool makers clamp 50 mm & 75 mm 2 nos. each
88 C – clamp- 50 mm & 75 mm 2 nos. each

C : Cutting Tools:

Sl. Name of Tools and Equipments Quantity

No.
1 Side and face milling cutter Ø 100 x 10 X Ø 25 mm 2 nos.
2 Side and face cutter Ø 80 x 10 X Ø 27 mm 2 nos.
3 Cylindrical milling cutter Ø 63 x 70 x Ø 27 mm 2 nos.
4 Slitting Saw cutter Ø 75 x 3 X Ø 27 mm 2 nos.

37
5 Slitting Saw cutter Ø 100 x 6 X Ø 27 mm 2 nos.
6 Single angle cutter Ø 75 x 16 x Ø 27mm - 600 2 nos.
7 Single angle cutter Ø 75 x 20 x Ø 27 - 450 2 nos
8 Equal angle cutter Ø75x 30 x Ø 27 - 900 2 nos
9 Shell End Mill Ø 50 x 36 x Ø 22 (preferably inserted tip type) 2 nos.
10 Shell End Mill Ø 75 mm x 50 x Ø 22 (preferably inserted tip type) 2 nos.
11 Parallel shank end mills Ø6, Ø10 and Ø 16 are (double fluted), Ø 20 4 nos. each
mm & Ø 25mm (four fluted)
12 ‘T’ slot cutter with parallel shank- Ø 17.5 x 8 mm width x dia. of 2 nos.
shank 8 mm
13 Concave Milling cutter Ø 63 x 6 radius x Ø 27 mm 1 nos.
14 Convex Milling cutter Ø 63 x 6 radius x Ø 27 mm 1 nos.
15 Disc type form milling cutter (involutes form -2 module, 20° pressure 1 set
angle)
16 Tool holder (straight) to suit 6, 8 mm sq. bit size 2 nos. each
17 Parting tool holders to suit 3 and 4 mm thick tool blade. 2 nos.
18 Boring bars with holders to accommodate 4, 6 and 8 mm HSS tool bits 3 each
19 Knurling tool (straight & diamond) 2 nos. each
20 Tool bits, inserts, carbide tool bits, reamers, special counter bore, As required
counter sink tools(CNC tooling setup)

D : General Machinery & Installation:

(Note: The specifications given under “General Machinery & Installation” can be purchased to
the nearest size according to the availability in the Indian Market.)

Sl. Name of Tools and Equipments Qty.

No.
1. Sensitive drilling machine - capacity 12 mm Motorized –with drill chuck and 1No.
key etc.
2. Pillar/column type Drilling machine – 25 mm capacity-motorized with drill 1No.
chuck & key etc.

3. Radial Drill machine to drill up to 32 mm diameter. 1No.

4. Power hacksaw machine to accommodate 21” or more length blade. 1no.
5. Double ended Pedestal Grinder with 178 mm wheels(one fine and one rough 1 no.
wheel)
6. SS and SC centre lathe (all geared) with centre height 150 mm and centre 3 sets.
distance 1000 mm along with 3 jaws, 4 jaw chuck, auto feed system, taper
turning attachment, coolant pump, safety guard, dog carriers, face plate and
machine light arrangement.
7. Shearing machine (lever type)hand operated complete with 300 mm blade 1 no.
length
8. Welding Equipment (It is not required if Welding Trade is available in the 2 set.
Institute) Latest welding kits in Die making

38
 (i) Transformer welding set 300 amps-continuous welding current with all 1 set
accessories and electrode holder
(ii) Welding cable to carry 400 amps 50 meter with flexible rubber cover. 12 nos.
(iii) Lugs for cable 2 nos.
(iv) Earth clamps 1 set
(v) Arc welding table (all metal top) 122cm x 12 cm x 60 cm with positioner 1 no.
(vi) Oxy-acetylene gas welding set-equipment with hoses, regulator and other 1 set
accessories
(vii) Gas welding table with positioner 6 nos.
(viii) Welding torch tips of different sizes 1 no
(ix) Gas lighter 2 nos.
(x) Trolley for gas cylinders 2 pairs
(xi) Chipping hammer 2 nos.
(xii) Gloves (Leather) 1 set
(xiii) Leather apron 2 nos.
(xiv) Welding torches 5 to 10 nozzles 4 pair
(xv) Spindle key for cylinder valve 2 nos.
(xvi) Welding goggles 10 sets
(xvii) Welding helmets with coloured glass 2 nos.
(xviii) Tip cleaner 1 no.
9. Universal Milling Machine - 2 no
Longitudinal traverse 700 - 800 mm
Cross traverse 300 - 400 mm
Vertical traverse 200 - 350 mm
Swivel of table on either side 450
Speed range rpm 30 to 1800
With universal dividing head, circular table, long arbors,
slab arbor, slotting attachment, vertical indexing head, etc.
10. Horizontal and Vertical milling machine 2 Nos. each
Table
Length x width 1350x310 mm
Longitudinal traverse 700 - 800 mm
Cross traverse 200 - 265 mm
Vertical traverse 300 - 400 mm
Speed range rpm 20 to 1800
11. Hydraulic Surface Grinding Machine 2 Nos.
Table
Clamping area 600 x 178 mm
Grinding area 400 x 200 mm
Distance table-centre of spindle 400 - 500 mm
Table speed 1-25 m/min.
With standard accessories like dust extractor with
water separator, balancing device, table-mounted Radius-tangent wheel
dresser, wheel flanges, etc.
12. Tool and Cutter Grinder 1No.
Largest diameter of cutter that can be ground 10-100 mm
Max. admit between centers 230 mm
Max. length of cutting edges ground 120 mm
With standard equipment like adaptor bushes, cutter head holder
assembly, adaptors, extension spindle, flanges fro grinding wheel, etc.
13. Universal cylindrical Grinding Machine 1No.

39
 Max. dia ground (effective) 250 mm
Max. grinding length 300 mm
Height of centre 130 mm
Max. distance between centers 340 mm
With special accessories like face plate, steady,
radius and face dressers, find hand feed attachment etc.
14. Pantograph / Engraving 3D machine 1set.
Working area (rectangle) 320 x 145 mm
Max. height of work 380 mm
Work table traverse:
Longitudinal x Transverse 160 x300 mm
Work clamping area 360x200 mm
With attachment like index head, roll engraving attachment,
type template holders, circular table, raised and sunk letters etc.
15. Fly press 5 ton capacity 1No.
16. Muffle furnace – heating chamber 300 x 300 x 450 mm for 10500 C 1No.
Quenching tank-600 x600 x 600 mm
17. Rockwell hardness testing machine with standard accessories 1No.
18. Wire EDM with CAM software 1 No.
19. CAD/CAM software(Standard/latest available in the market) 4 set
20. Desktop computers with latest configuration suitable for CAD/CAM software 5 sets
with necessary furniture
21. Spark Erosion EDM (Optional) 1No.
22. CNC vertical milling machine (Optional) 1 no
23. CNC lathe (optional) 1 no
24. Co-ordinate measuring machine (Optional) 01
25. Profile projector (Optional) 01
26. Unit height master (Optional) 01
27. Polishing kits (Optional) 1 set
28. Hydraulic press 16T with all safety measures (Optional) 01

Note: Any institute not having the optional machines may tie up with an industry having
the above machine for exposure.

40
 INFRASTRUCTURE FOR WORKSHOP CALCULATION & SCIENCE AND
ENGINEERING DRAWING

TRADE: TOOL AND DIE MAKER (PRESS TOOL, JIGS & FIXTURE)

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 Nos.
2. Set square celluloid 45⁰ (250 X 1.5 mm) 20 Nos.
3. Set square celluloid 30⁰-60⁰ (250 X 1.5 mm) 20 Nos.
4. Mini drafter 20 Nos.
5. Drawing board (700mm x500 mm) IS: 1444 20 Nos.

B : FURNITURE REQUIRED
Sl. Quantity
Name of the items
No. (indicative)
1 Drawing Board 20 Nos.
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

41
 ANNEXURE – II

INFRASTRUCTURE FOR ON-JOB TRAINING

TRADE: TOOL AND DIE MAKER (PRESS TOOL, JIGS & FIXTURE)

For Batch of 20 APPRENTICES

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.

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 ANNEXURE-III

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.

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