Automotive Clutch Operator (Multiskilled)

SYLLABUS OF SEMESTERSYSTEM
FORTHE ROLE OF
Automotive Clutch Operator
(Multiskilled)
Under
High Employment Potential
Courses through Flexi MOUs
(One Year/TwoSemesters)
Designed in
2015
By
Government of India
Ministry of Labour & Employment (DGE&T)
FORMAT
1. Cover Page
2. Title
3. General Information
4. Week wise contents ofTT and TP(Intabular form)
5. Tools and Equipment list- broadspecification
6. List ofthe consumable
7. Trade testingand certification
8. Further learningoptions
9. List ofTrade Committee Members
GENERAL INFORMATION
1.Name of theCourse
Certificate Course inAutomobile Clutch
Manufacturing - Multiskilled
2.N.C.O.CodeNo.
3.Qualification PackCode No.
4.DurationofTraining
One Year (Two semesters)
5.EntryQualification
10thstd
Age –Above 18 Yrs
20 Trainees (TwoBatches-eachbatchof 10Trainees)
6.UnitStrength
7.Space Norms
8.PowerNorms
a) Class room:30sqm.
b) Workshop:80 sqm.
a) Class room: 1kw (6000lumen)
b) Workshop:2kw (30,000lumen)
9.Job Role:
Atthe endof course thetrainee willbe able to: Describe Automobile Clutches
 Perform press operations
 Carry out Blanking ,piercing ,Drawing and Coining
 Perform die-casting
 Perform machining operations
 Load the component
 Unload the components and carry out inspection/visual using measuring instruments
and gauges
 Interpret Engineering drawings.
 Carry out Shot blasting ,Trimming and Deburring
 Perform Preventive Maintenance.
 Carryout Plasma ,Progressive and TIG welding
 Carryout Heat treatment and Glueing
 Carryout Assembly Operation for Dry and Wet clutch.
 Follow best practices pertaining to Quality Inspection.
 Communicate effectively
 Maintain health and safety at workplace
 Handle different types of fire extinguisher
 Follow proper housekeeping practices .
 Adhere to companys Policies and Procedures.
 Apply the principles of 5S ,5T in the work area
10.Instructor’sQualification
Graduate in Mechanical Engineering at least2years
post qualification
11.Instructor’s/Trainer’s Qualification
(a) AcademicQualification:
(i) Graduate in Mechanical Engineering
Or
(ii) Diploma in Mechanical Engineering
(b) TechnicalQualification:
(i) For Graduate Degree holders in Mechanical
Engineering, at least 2 years post qualification
experience in Automobile industries (Clutch
Manufacturing preferred)
OR
(ii) For Diploma holders in Mechanical Engineering
at least 4years post qualification experiencein
Automobile industries (Clutch Manufacturing
preferred)
(c)DesirableQualification:
N/A
Syllabus for the role of Automobile Clutch Manufacturing - Multiskilled
First Semester (Semester Code No – ACM:SEM-I)
Duration: Six Months
Syllabus for TP01and TT01
Week wise contentIndex ofFirst Semester
Sl.
No.
1.
Week
No.
1&2
Contents Heading
Practical
Theory
Communication Skills, Time
Management,Policies and Procedures,
Team work,Computing skills.
ACM-100
Workplace skills
Health & Safety-identify the hazards,
application of first aid
ACM-200
Health & Safety
Duration
2 Week
2.
3&4
3.
5&6
4.
7, 8 & 9
5.
10 & 11
6.
12, 13, 14 & 15
Study and interpretation of engineering
drawing
7.
16, 17, 18 & 19
Turning, Drilling, Broaching, Facing,
Chamfering, Grooving, Threading, Grinding
8.
1 to 19
9.
20, 21, 22 & 23
Revision
4 Weeks
10.
24 & 25
Examination
2 Weeks
2 Week
ACM-300
CLUTCHES
2 Week
Blanking, Drawing, Piercing,
Deburring/restrike, coining.
ACM-400
Press shop
3 Week
Melting of raw materials, casting,
Trimming, Deburring, Shot blast
ACM-500
Die casting
2 Week
ACM-600
Engineering drawing
4 Weeks
ACM-700
Machining
4 Weeks
Types of clutches
OJT /Projectwork/Site Visit
19
Weeks
Syllabus for the role of Automobile Clutch Manufacturing - Multiskilled
First Semester (SemesterCode No – ACM:SEM-I)
Duration:Six Months
Syllabus for TP01and TT01
Week
No.
1&2
TradePractical
ACM-100
Workplace skills:
Activities pertaining to:
 Communication skills
 Time Management
 Teambuilding skills
 Team work
 Computing skills
TradeTheory






3&4
ACM-200

Health & Safety

Activities pertaining to:

Study of work place to identify the
hazards and suggest mitigation
application of first aid, Identification
of Hazardous waste and disposal as
per the norms , Activities pertaining
to electrical safety block out tag out
procedures







Basic communication skills (Importance
of communication, verbal
communication and non verbal
communication)
Policies and procedures
Managing time effectively through
planning
Behaviour skills (attitude problem
solving thinking skills confident building)
Workplace Ethics.
Computing skills
(Introduction,Computer and its
applications, Basics of Opertaing
system, Basic operations of word
processing Basics of excel work sheet
Basics of computer network, meaning of
world wide web).
Introduction to Occupational safety and
health and its importances at workplace
Hazards Identification and avoidance of
accidence
Introduction of personal protective
equipment
Do’s and don’ts during the process
Fire extinguisher
safety guidelines
Housekeeping activities
MSDS
Disposal procedure of waste material
Response to emergencies examples
Power failure, fire and system failure





Introduction to clutches
Principles of Clutch
Single Plate Clutch
Multiplate Clutch
Types of clutch
o Centrifugal clutch.
o Semi-centrifugal clutch.
o Hydraulic clutch
o Positive clutch.
o Vacuum clutch.
o Electromagnetic clutch
7, 8 & 9 ACM-400
Press shop:
OJT- Automobile industry
Practice operation of various types of
press to produce various components of
clutch meeting the quality and
productivity norms
Practice Blanking, Drawing ,Piercing
Deburring/restrike ,Coining










Introduction to press tools
Application of press tools
Press working Terminology
Theory of shearing
Operations of CNC Machines
Blanking Process and its tools and dies
DrawingProcess and its tools and dies
PiercingProcess and its tools and dies
Deburring/restrike
Coining Process
10 & 11 ACM-500
Die casting:
OJT- Automobile industry
Practice Weighing of raw
materials, Melting, casting,
Trimming,Deburring,Shot blasting.



Introduction to Die casting Machine
Property of material such as AL and Zn
Die casting defects such as part unfilled,
blow holes, air bubbles, Part dent, Heat
mark and scratches
Melting
Casting
After Mould operations
o Trimming
o Deburring
o Shot blasting
5&6
ACM-300
Clutches
Identification of parts of clutches of
dry and wet clutches for both 2 and 4
wheeler
Identification of various types of
clutches



12, 13, 14 ACM-600
& 15


Engineering drawing:

Study and interpretation of
engineering drawing, Prepartion
of engineering drawing.
16, 17, 18 ACM-700
& 19
Machining Operation:
OJT- Automobile industry
Practice Turning , Drilling,
Broaching, Facing, Chamfering,
Grooving, Threading, Grinding



•








Reading of drawing
Types and formats of engineering
drawing
Graphic language and machinist
engineering drawing
Dimensioning
Isometric and orthographic projections
sectional views and shop floor drawing
Introduction to cnc machines
Cutting tools& Equipments.
Turning Operation
DrillingOperation
BroachingOperation
FacingOperation
ChamferingOperation
GroovingOperation
ThreadingOperation
Grinding Operation
All weeks – 1 to 19
Site visit/OJT /Practical’s
Week 20, 21,
22 & 23
Week 24 & 25
Revision
Examination
Syllabus for the role of Automobile Clutch Manufacturing - Multiskilled
Second Semester (Semester Code No – ACM: SEM-II)
Duration: Six Months
Syllabus for TP02and TT02
Week wise content Index of Second Semester
Sl.
No.
Contents Heading
Week No
Practical
Theory
Duration
ACM-800
Basic machine
maintenance
2 Weeks
1.
1&2
Preventive Maintenance ,Machine
Breakdown.
2.
3&4
EWPS
ACM-900
EWPS Skills
2 Weeks
3.
5, 6, 7 & 8
Plasma welding, Progressive welding and
Tig welding
ACM-1000
Welding
4 Weeks
ACM-1100
Heat treatment
3 Weeks
ACM-1200
Glueing
3 Weeks
4.
5.
9, 10 11
Alkaline chemicals, cooling,
quenching Tempering, Induction
hardening
Raw materials, mixing ratios of the
raw materials, shot blasting, making
12, 13 & 14 of pre bonds, finishing of pre bonds,
grinding of pre bonds, Air bleaching,
Curing Ranking
6.
15, 16 & 17 Assembly of dry clutch and wet clutch for 2
wheeler and four wheeler
ACM-1300
Assembly
3 Weeks
ACM-1400
Quality
2 Weeks
7.
18 & 19
8.
1 to 19
Site visit /OJT /Project work
19 Weeks
9.
20, 21, 22 &
23
Revision
4 Weeks
10.
24 & 25
Examination
2 Weeks
Quality System,Measuring Instruments
Syllabus for the role of Automobile Clutch Manufacturing - Multiskilled
Second Semester (Semester Code No – ACM: SEM-II)
Duration: Six Months
Syllabus for TP02 and TT02
Week
No.
Week
1&2
Week 3 & 4
Trade Practical
ACM-800
Basic Machine Maintenance
Practice Preventive maintenance
 Applying grease
 Checking the oil level
 Checking for loose parts
 Replacing the worn parts
ACM-900
EWPS
Activities pertaining to:
 Work guide lines
 Reading instructions on
machines
 EMS, 5S and 5T
Trade Theory












Purpose of Maintenance
Principle Objectives in
Maintenance
Types of Maintenance
Preventive Maintenance
Advantages of preventive
maintenance
Introduction to engineering work
place skills
Work guide lines
Reading instructions on machines
EMS and 5T
Purpose of house keeping
Practice of good house keeping
Principle of 5S in house keeping
SEIRI SEITON SEISO SEIKETSU
SHITSUKE
Week 5, 6, 7 ACM-1000
&8
Welding
OJT- Automobile industry

Practice plasma ,Progressive and Tig
welding
Practice welding inspection

Week 9, 10 & ACM-1100
11
Heat Treatment
OJT - Automobile industry



















Practice heat treating of automobile 
components
Practice Oil and Water Quenching
Practice induction hardening

Practice arranging of materials for
heat treatment




Introduction to welding machines
Types of welding
Welding principle
Welding power sources
Step involved in the preparation of
base metal for welding
Welding consumables
Welding metallurgy
Plasma Welding
Progressive Welding
Tig Welding
Safety guidelines during welding
Welding defects
Introduction to heat treatment
Types of heat treatment
Advantages and disadvantages of
heat treatment
Imporving work ability and other
property such as machinability
forgeability stress relief magnetic
property microstructure realinement
Imporving mechanical property such
as wear resistance fatigue and
strength
Pre washing of components
Post washing of components
Tempering
Applications of heat treatment
Week 12,
13 & 14
ACM-1200
Glueing
OJT - Automobile industry
 Practice weighing of chemicals
 Practice mixing of chemicals
 Practice shot blasting
 Practice pressing of pre bond
with the bush
 Practice grinding of pre bond to
required accuracy
 Practice Air bleaching
 Practice Curing Ranking
Week 15, 16 ACM-1300
& 17
Assembly
OJT- Automobile industry
 Practice assembly of dry
clutch for 2 wheeler and 4
wheeler
 Practice assembly of wet
clutch for 2 wheeler and 4
wheeler
















Introduction to Glueing
Chemicals used in Glueing and their
ratios
Shot blasting and its uses
Pre bonds
Joining of components using glue
Grinding
Air bleaching
Curing Ranking
Introduction to assembly line
Tools used in assembly line
Parts of wet clutch for 2 ad 4
wheeler
Parts of dry clutch for2 and 4
wheeler
Gauges used in assembly line
Rivetting Machines
Go and NO Go Gauges
Balancing machines
Week 18 & 19 ACM-1400
Quality
OJT- Automobile Industry
 Practice usage of dial gauge,
height gauge, vernier calliper,
micrometre, Bore gauge, bevel
protractor and balancing
machine to test the accuracy of
the automobile components
 Visual inspection of raw
material for rusting, scaling and
corrosion






Quality management system
Introduction to metrology
Importance of Inspection in
Industry
Quality requirements
Quality tools
Measuring Instruments like Dial
gauge, Height gauge venier
calliper, screw gauge, Balancing
machine, Leak tester, One out
check machine
1 to 19
Site visit /OJT/Practical’s
20, 21, 22
& 23
24 & 25
Revision
Examination
LIST OF TOOLS&EQUIPMENT
SL NO
Items
Quantity
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Hand tools
Hammer
Adjustable Spanner
Allen key
Needle File Set
Centre punch set
Try square
Stainless steel
Rule tape
Ball peen hammer
Cross peen hammer
Screw driver set
Straight peen hammer
Digital verniercaliper
V ernier Gear Tooth Caliper
Bevel protractor
Balance Checker
Height gauge
Micrometer
Try square
Tap
Dies
Reamers
Pliers
PPE
Aprons
Ear plugs
Slitting saw cutter (100*4*27)mm
Side & face cutter 150*10*27 mm & 100*15*27 mm
Collet Chuck (for vertical milling) collet 10 and 12mm
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
30
31
32
33
34
35
36
39
40
41
42
43
44
45
46
47
48
Leak tester
Broaching tool
Drill bits
Surface plate 4 0 0 MM*4 0 0 MM GRADE 1
Vee Block
Dial T est Indicator w it h m ag net i c g auge
Radius Gauge Metric Set
First aid kit(triangular bandages also)
Fire extinguisher
Riveting machines
Central Grinding Machines
Bore Gauge
CNC Turning Machine
CNC Welding Machine
Die-Casting Machine
300T / 400T Press Machines
Manual Lever Weight Measurement Machine
1
1
1 set
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Note: The above quantity given is for one batch (20 Trainees) out of which 4 will be grouped into 5teams.
LIST OF CONSUMABLES
SL.NO
2
Materials
Cotton waste
Bucket
Quantity
1 kg
2
3
Water
500 litres tank
4
Coolants
Die lube coolant-10 litres
1
Trade Testing and Certification
As per the NCVT norms
Further Learning Options
Upon successful completion of this Course the candidate will be eligible for attending the
advanced Courses in Automobile Clutch Manufacturing.
List of Trade Committee Members
Sl.No
1
2
3
4
5
6
7
NAME&DESIGNATIONS
/SHRI
REPRESENTING
ORGANIZATION
REMARKS