AUTO ENGINE REBUILDING NC II – TESDA COURSE MODULE

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TRAINING REGULATIONS FOR AUTO ENGINE REBUILDING NC II

The AUTO ENGINE REBUILDING NC II consists of competencies that a person must achieve to restore defective/worn-out engine parts back to manufacturer’s specifications; inspects, measures and interprets blueprints and repair procedures; sets up and  operates variety of specialized metalworking machines and uses precision measuring instrument in repairing automotive  engine parts.

This Qualification is packaged from the competency map of the Automotive Industry (Service sector)

A student who has achieved this Course in AUTO ENGINE REBUILDING NC II is competent to be:

  • Automotive Engine Rebuilder
  • Machinist

AUTO ENGINE REBUILDING NC II – TRAINING AND REGULATION MODULE

Course Title: AUTO ENGINE REBUILDING
Level: NC II
Nominal Training Duration : 120 Hours

This course is designed to equip individual with operational skills in automotive engine rebuilding which restores  effective/worn-out engine parts back to manufacturer’s specifications; performs the necessary inspections; mensuration, and  interpretation of blueprints and repair procedures; set up and operate variety of specialized metal working machines and uses  precision measuring instruments in repairing automotive engine parts.

This course is also designed to provide basic and common skills to equip individual with operational skills in automotive engine rebuilding.

TRAINEE ENTRY REQUIREMENTS

This section specifies the qualifications of trainees and educational experience. Other requirements like health and physical requirements are also stated. Passing entry written examinations may also be indicated if necessary.

  • With good moral character;
  • Ability to communicate both oral and written; and
  • Physically and mentally fit

COMPETENCIES REQUIRED IN AUTO ENGINE REBUILDING NC II

This units of competency comprising this qualification include Basic, Common, Elective and Core Competencies.

To obtain this course, all units prescribed for this qualification must be achieved.

These units of competency comprising this qualification include the following:

UNIT CODE CORE COMPETENCIES (120 Hours)
ALT723328 Interpret Technical Manual Specification of Engine Components
ALT723329 Disassemble Engine Block and Sub-Assemblies, Checks Tolerances and Components
ALT723330 Disassemble Engine Sub-Assemblies/Cylinder Heads and Check Components
ALT723331 Carry Out Pre-Repair Operations on Engine Components
ALT723332 Inspect Engine Components and Determine Preferred Action
ALT821301 Carry Out Machining Operations
ALT821302 Set, Operate and monitor Specialized Machines
ALT821303 Use and Maintain Measuring Instrument
ALT723333 Assemble Engine Block and Sub Assemblies, Check Tolerances and Carry Out Relevant Testing
ALT723334 Assemble Engine/Cylinder Heads, Check Tolerances and Carry Out Relevant Testing Procedures
UNIT CODE COMMON COMPETENCIES (20 Hours)
ALT723201 Apply Appropriate Sealant/Adhesive
ALT723202 Move and Position Vehicle
ALT311202 Perform Mensuration and Calculation
ALT723203 Read, Interpret and Apply Specifications and Manuals
ALT723204 Use and Apply Lubricant/Coolant
ALT723205 Perform Shop Maintenance
UNIT CODE BASIC COMPETENCIES (18 Hours)
500311105 Participate in workplace communication
500311106 Work in a team environment
500311107 Practice career professionalism
500311108 Practice occupational health and safety procedures

This section gives the details of the contents of the basic, common and core units of competency required in AUTO ENGINE REBUILDING NC II.

CORE COMPETENCIES

UNIT OF COMPETENCY: INTERPRET TECHNICAL MANUAL SPECIFICATION OF ENGINE COMPONENTS
UNIT CODE : ALT723328

This unit identifies the competence required to compare  components to original manufacturer specifications and match in relation to weight, size, and capacity with reference to the technical data.

  1. Carry out interpretation of manual specifications
    • Correct information is accessed and interpreted from appropriate manufacturer specifications
    • Symbols, codes, legends and diagrams interpreted
    • Representations are correctly recognized
    • Parts/systems/components/item represented is correctly identified
    • Information represented is correctly understood
    • Components are prepared for inspection/ measurement.
    • Appropriate measuring instrument and tools are used as prescribed.
    • Measurements are compared against original equipment manufacturer (OEM) specifications
    • Components are adjusted to meet OEM specifications without damage.
    • All interpretation of manual specification are carried out according to industry regulations/guidelines, occupational health and safety (OHS) requirements, and enterprise procedures/policies

UNIT OF COMPETENCY: DISASSEMBLE ENGINE BLOCK AND SUBASSEMBLIES, CHECK TOLERANCES AND COMPONENTS
UNIT CODE: ALT723329

This unit identifies the competence required to disassemble, inspect, evaluate and determine preferred repair action for engine block and sub-assemblies as part of a reconditioning procedure.

  1. Disassemble engine block and sub-assemblies
    • Engine block and sub-assemblies are disassembled without causing damage to any component or system.
    • Engine block and sub-assemblies are disassembled using approved methods and appropriate equipment and tools.
    • Correct information is accessed and interpreted from appropriate manufacturer specifications.
    • Components/system are cleaned in preparation for evaluation
    • All disassembling/cleaning activities are carried out according to industry regulations/guidelines, occupational health and safety procedures and company policies using appropriate tools and equipment.
  2. Inspect/measure/test engine block and sub-assembly components and determine repair procedures
    • Inspection/measurement/testing method is completed without causing damage to any component or system.
    • Correct information is accessed and interpreted from appropriate manufacturer specifications
    • Engine block and sub-assembly components are measured against manufacturer specifications and tolerances.
    • Engine block and sub-assembly components are evaluated against measurements, test and inspections made.
    • Repair requirements are identified and reported according to enterprise policy and procedure.
    • Appropriate workplace documentation is completed and dealt with relevant to inspection/measurements/testing outcomes.
    • All inspection/measurement/testing activities are carried out according to industry regulations/guidelines, occupational health and safety and company policies using appropriate tools and equipment.

UNIT OF COMPETENCY: DISASSEMBLE ENGINE SUB-ASSEMBLIES/CYLINDER HEADS AND CHECK COMPONENTS
UNIT CODE: ALT723330

This unit identifies the competence required to disassemble, inspect, check and determine preferred repair action for engines and/or cylinder heads as a part of a reconditioning procedure.

  1. Disassemble engine subassembly/cylinder head
    • Engine sub-assembly/cylinder head is disassembled without causing damage to any workplace property, equipment or components and in accordance to company standard operating procedures.
    • Engine sub-assembly/cylinder head is disassembled using approved methods and appropriate tools/equipment.
    • Correct information is accessed and interpreted from appropriate manufacturer Manual specifications.
    • Component parts are cleaned using appropriate tools equipment and materials in preparation for evaluation.
  2. Inspect engine sub-assembly / cylinder head components and determine repair procedures.
    • Inspection is completed without causing damage to any workplace property, equipment or components.
    • Correct information is accessed and interpreted from appropriate manufacturer specifications.
    • Engine sub-assembly/cylinder head components are measured against manufacturer specifications and tolerances.
    • Engine sub-assembly/cylinder head components are evaluated against the measurements, tests and inspections made.
    • Repair procedures are reported for engine subassembly/cylinder head components.
    • Actions performed and results achieved relative to this competency element are recorded and dealt with according to company policies and procedures.

UNIT OF COMPETENCY: CARRY OUT PRE-REPAIR OPERATIONS ON ENGINE COMPONENTS
UNIT CODE: ALT723331

This unit identifies the competence required to clean components by chemical or mechanical means and remove component in preparation for either storage or repair.

  1. Clean components prior to repairs and/or storage
    • Cleaning of engine components is achieved without causing damage to any component or system
    • Cleaning agents are used according to cleaning agent manufacturer instructions
    • Component of the engine is cleaned to facilitate inspection, assessment, replacement, repair and/or storage.
    • Used cleaning agents and waste materials are safely disposed of according to company policy and national legislation.
    • Cleaning operations are carried out according to industry regulations/guidelines, occupational health and safety procedures and company policy.
  2. Segregate, tag and store components
    • Components are segregated, tagged and stored without causing damage to any component or system.
    • Correct information is accessed and interpreted from appropriate manufacturing specifications.
    • Components are removed, tagged and stored in accordance with manufacturer specifications and enterprise procedures
    • Removal and storage activities are carried out according to industry standards/guidelines, occupational health and safety and company policy.
    • Report on additional parts required to complete the repair (not listed in quotation) is completed in accordance with company policy.

UNIT OF COMPETENCY: INSPECT ENGINE COMPONENTS AND DETERMINE PREFERRED REPAIR ACTION
UNIT CODE: ALT723332

This unit identifies the competency required to carry out an inspection of engine components and decide on the most appropriate repair/replacement methods.

  1. Conduct visual inspection of engine components to determine defects
    • Information is accessed from appropriate sources to gain knowledge of the fault.
    • Vehicle components are isolated/disassembled to permit an accurate inspection for defects.
    • Inspection method for engine components is conducted as per procedure.
  2. Lift and move materials/components/parts
    • Lift and move work is completed without causing damage to any component or system
    • Materials weight is determined correctly utilizing most appropriate techniques
    • Appropriate tools and equipment are selected and used when required
    • Items to be lifted up are checked for hazardous implications
    • Lifting techniques are undertaken wherein types of movement, methods, storage, heights and position are considered
    • Parts/components/materials are placed safely on moving equipment and relocated ensuring safety of personnel and security of parts/components/materials.
    • All activities are carried out in accordance with industry standards/guidelines, occupational health and safety and company policies.
  3. Carry out diagnostic procedures
    • Information and assistance (if necessary) is accessed from appropriate sources in distinguishing between “symptoms” and “causes”.
    • Permission to partly disassemble components is obtained, to accurately inspect and diagnose defects.
    • A diagnosis strategy is developed that can be used to determine a fault within the engine component.
    • Identification of defects and needed repairs are made from test results using appropriate tools and equipment and a plan of action is decided upon to rectify defects
    • All inspections are carried out in accordance to industry regulations/guidelines, occupational health and safety, and company policies
  4. Prepare written repair quotations
    • Quotation is prepared accurately on approved format.
      4.2 Repair quotation is prepared is prepared accurately as
      per enterprise-approved format
      4.4 Customer is consulted as per standard operating
      procedures.
      4.5 Approval to complete repairs is sought as per standard
      operating procedures
      4.6 Quotation is filed as per standard operating procedures.

UNIT OF COMPETENCY: CARRY OUT MACHINING OPERATIONS
UNIT CODE: ALT821301

This unit identifies the competence required to set up and machine components to specifications using lathe, drilling and cutting machines for all mechanical streams

  1. Set up machinery prior to machining
    • Machinery set up is completed without causing damage to any components, system, tools and equipment.
    • Correct information is accessed and interpreted from appropriate manufacturer specifications
    • Material to be machined is positioned and clamped
    • Correct speed and feed is selected to suit materials
    • Personal safety requirement including machine guards are worn and positioned
    • Setting up of components including machine guards are worn and positioned
    • All machinery set up activities are carried out according to industry regulations/guidelines, OHS and enterprise
      policies
  2. Machine components
    • Components are machined without causing damage to any components or system
    • Correct information is accessed and interpreted from appropriate manufacturer specifications
    • Components are measured for size and finish
    • Size and finish are compared with specifications
    • Area is cleaned prior to removal from machine
    • Machining/cutting of components is carried out in accordance with manufacturer current specifications for methods, equipment used and tolerance relative to the component being machined out/cut
    • All machining/cutting activities are carried out according to industry regulations/guidelines, OHS, and enterprise procedures/policies.

UNIT OF COMPETENCY: SET, OPERATE AND MONITOR SPECIALIZED MACHINES
UNIT CODE: ALT821302

This unit identifies the competence required to set, operate and monitor specialized machines used in reconditioning engine and/or vehicle components

  1. Set machines
    • Machines are set without causing damage to any component or system
    • Correct information is accessed and interpreted from appropriate manufacturer specifications
    • Components are measured and repair action determined
    • Components is positioned and clamped
    • Machine is set in accordance with defined procedures
    • Machine is adjusted to meet operational requirements and specifications using appropriate measuring equipment
    • Tools and accessories are selected according to job specifications
    • Worn-out or damaged tool is identified and changed/sharpened
    •  All setting activities are carried out according to industry regulations/guidelines, OHS requirements and enterprise procedures/policies
  2. Operate and monitor machine
    • Machine is operated and monitored without damage to any component or system
    • Correct information is accessed and interpreted from appropriate manufacturer specifications
    • Machine is operated in accordance with enterprise procedures
    • Components are checked with appropriate instruments to ensure compliance to specifications
    • Sharpness of tools is monitored and tools are sharpened or replaced to meet requirements when necessary
    • Finished products is checked for alignment, tolerance and finish
    • All machining operations are carried out according to industry regulations/guidelines, OHS, and enterprise procedures/policies

UNIT OF COMPETENCY: USE AND MAINTAIN MEASURING INSTRUMENT
UNIT CODE: ALT821303

This unit identifies the competence required to measure components or sections using non-specialist instrument and maintain the measuring instrument.

  1. Measure dimensions or variables using appropriate instrument
    • Measurement of dimensions and variables are completed without causing damage to any instrument or components
    • Appropriate measuring instrument is selected
    • Relevant measuring techniques are used and results appropriately recorded
    • All measuring activities are carried out according to industry regulations/guidelines OHS & requirements and enterprise/procedures policies
  2. Maintain measuring instrument
    • Maintenance of measuring instrument is achieved without causing damage to any instrument or component
    • Routine care and storage of measuring instrument is undertaken according to manufacture specifications
    • Checking and calibrating of measuring devices is done prior to use.
    • All maintenance activities of measuring instruments are carried out according to industry regulations/guidelines OHS legislation, and enterprise procedures policies

UNIT OF COMPETENCY: ASSEMBLE ENGINES/CYLINDER HEADS, CHECK TOLERANCES AND CARRY OUT RELEVANT TESTING PROCEDURES
UNIT CODE: ALT723333

This unit covers the knowledge skills and attitudes required to assemble engines and/or cylinder heads, check tolerances and carry out relevant testing procedures as part of a reconditioning procedure.

  1. Use appropriate methods to check tolerances
    • Tolerances are checked without causing damage to any workplace property, equipment or components.
    • Correct tolerances are obtained using relevant engine/component manufacturer specifications.
    • Tasks are carried out as per established industry guidelines.
    • Final quality inspection procedure is performed.
  2. Assemble engines/cylinder head.
    • Engine/cylinder head is assembled without causing damage to any workplace property, equipment or components.
    • Assembly is carried out to comply with manufacturer specifications and established industry guidelines.
    • Checking procedure is done according to manufacturer specification.
  3. Carry out relevant test procedures.
    • Test procedures are completed without causing damage to any workplace property, equipment or components.
    • Relevant test procedures are performed using industry approved procedures and equipment.
    • Testing is carried out to comply with manufacturer specifications

UNIT OF COMPETENCY: ASSEMBLE ENGINE BLOCK AND SUBASSEMBLIES, CHECK TOLERANCES AND CARRY
OUT RELEVANT TESTING PROCEDURES
UNIT CODE: ALT723334

This unit covers the knowledge, skills and attitudes required to assemble engine block and sub-assemblies, check tolerances, fit cylinder head(s) and carry out relevant testing and adjustment procedures as part of a re-conditioning procedure.

  1. Use appropriate methods to check tolerances
    • Tolerances are checked without causing damage to any component or system
    • Tolerances are checked based on industry approved procedures/methods, equipment and tools and materials
    • Correct tolerances are obtained using relevant engine/component manufacturer specifications
    • Tasks are carried out to comply within established industry guidelines
    • All checking activities are carried out according to industry regulations/guidelines, occupational health and safety (OHS) and company policies.
  2. Assemble engine block and subassemblies/fit cylinder head(s)
    • Engine block and sub-assemblies are assembled and cylinder head(s) are fitted without causing damage to any component or system
    • Assembly and fitting is carried out to comply with manufacturer specification and established industry guidelines and operating procedure
    • All assembly and fitting activities are carried out according to industry regulations/guidelines, OHS, and industry policies.
    • Inspection of new parts quality, condition, fittings are done as per company standard operating procedures.
  3. Carry out relevant testing and adjustment procedures
    • Test and adjustments are completed without causing damage to any component or system.
    • Testing and adjustment is carried out to comply with manufacturer’s specifications, established industry
      guidelines and standard.
    • Testing and adjusting of tightening torque is carried out and confirmed by the supervisor.

COMMON COMPETENCIES (AUTOMOTIVE)

UNIT OF COMPETENCY: PERFORM MENSURATION AND CALCULATION
UNIT CODE: ALT311202

This unit includes identifying caring, handling and use of measuring instruments.

  1. Select measuring instruments
    • Object or component to be measured is identified
    • Correct specifications are obtained from relevant source
    • Appropriate measuring instrument is selected according to job requirements
  2. Carry out measurements and calculation
    • Measuring tools are selected in line with job requirements
    • Accurate measurements are obtained to job
    • Calculation needed to complete work tasks are performed using the four basic process of addition (+), subtraction (-), multiplication (x) and division (/).
    • Calculations involving fractions, percentages and mixed numbers are used to complete workplace tasks.
    • Numerical computation is self-checked and corrected for accuracy
    • Instruments are read to the limit of accuracy of the tool.
  3. Maintain measuring instruments
    • Measuring instruments must kept free from corrosion
    • Measuring instruments not dropped to avoid damage
    • Measuring instruments cleaned before and after using.

UNIT TITLE: READ, INTERPRET AND APPLY SPECIFICATION AND MANUALS.
UNIT CODE: ALT723203

This unit deals with identifying, interpreting and applying  service specification manuals, maintenance procedure manuals and periodic maintenance manual.

  1. Identify and access manual/specification
    • Appropriate manuals are identified and accessed as per job requirements.
    • Version and date of manual is checked to ensure correct specification and procedure are identified.
  2. Interpret manuals
    • Relevant sections, chapters of manuals/specifications are located in relations to the work to be conducted
    • Information and procedure in the manual are interpreted in accordance to industry practices
  3. Apply information in manual
    • Manual is interpreted according to job requirements
    • Work steps are correctly identified in accordance with manufacturer specification
    • Manual data is applied according to the given task
    • All correct sequencing and adjustments are interpreted in accordance with information contained on the manual or specifications
  4. Store manuals
    • Manual or specification are stored appropriately to ensure prevention of damage, ready access and updating of information when required in accordance with company requirements

UNIT OF COMPETENCY: MOVE AND POSITION VEHICLE
UNIT CODE: ALT723202

This competency unit covers the knowledge, skills and attitude needed to move and position vehicle in a workshop.

  1. Prepare vehicle for driving
    • Correct check-up procedures performed based on vehicle manufacturer standard
  2. Move and position vehicle
    • Select vehicle to be moved or re-position.
    • Drive the vehicle to appropriate location
    • Park vehicle following parking safety techniques and procedure
  3. Check the vehicle
    • Vehicle position is checked as per required
    • Vehicle is checked for external damages

UNIT OF COMPETENCY: APPLY APPROPRIATE SEALANT/ADHESIVE
UNIT CODE: ALT723201

This competency unit covers the selection and application of sealant/adhesives.

  1. Identify appropriate Sealant/adhesive
    • Sealant/adhesive selected in line with job requirements and manufacturer’s specification
    • Sealant/adhesive checking is performed to ensure that product is fit for use.
  2. Prepare surface for Sealant/adhesive
    • Surface materials are identified as per construction
    • Surface is cleaned and free of moisture, dust and other foreign matters to ensure maximum adhesion or seal.
  3. Apply sealant/adhesive evenly
    • Sealant/adhesive is applied evenly on the surface in line with manufacturer’s specification
    • Excess sealant/adhesive is removed by sanding or scrapping
    • Tools and equipment used to apply sealant/adhesive are appropriate to job requirements
    • Safety are observed and PPE are worn in accordance with industry SOP
    • Hazards associated with the use of sealant and adhesives are identified.
  4. Store/Dispose of sealant/adhesive
    • Sealant/adhesive are stored as per prescribed procedure
    • Waste are disposed as per workshop SOP

UNIT OF COMPETENCY: USE AND APPLY LUBRICANTS/COOLANT
UNIT CODE: ALT723204

This unit identifies the competencies required to select and apply different types of lubricants.

  1. Identify types of lubricants/ coolant
    • Correct information on lubrication schedule is accessed and interpreted from appropriate manufacturers specifications manuals
    • Type and quantity of lubricants/coolant is identified as per job requirements
  2. Use and apply lubricants/coolant
    • Correct procedure for change of lubricant is identified following manufacturer’s specification or manual
    • Correct tools and equipment are selected and used in line with job requirements
    • Existing lubricants is removed and replaced with specified types and quantity of new materials in line with manufacturer’s specification
    • Safe procedure and use of PPE is observed when removing or replacing lubricant
    • Used lubricants are disposed in accordance with environmental guidelines
    • Work is checked in line with company SOP.
  3. Perform housekeeping activities
    • Tools, equipment and materials are properly stored as per company SOP
    • Workplace is free from waste materials

UNIT OF COMPETENCY: PERFORM SHOP MAINTENANCE
UNIT CODE: ALT723307

This unit deals with inspecting and cleaning of work area including tools, equipment and facilities. Storage and checking of tools/ equipment and disposal of used materials are also incorporated in this competency

  1. Inspect/clean tools and work area
    • Cleaning solvent used as per workshop/tools cleaning requirement
    • Work area is checked and cleaned
    • Wet surface/spot in work area is wiped and dried
  2. Store/arrange tools and shop equipment
    • Tools/equipment are checked and stored in their respective shelves/location
    • Corresponding labels are posted and visible
    • Tools are safely secured and logged in the records
  3. Dispose wastes/used lubricants
    • Containers for used lubricants are visibly labeled
    • Wastes/used lubricants are disposed as per workshop SOP
  4. Report damaged tools/equipment
    • Complete inventory of tools/equipment is maintained
    • Damaged tools/equipment/facilities are identified and repair recommendation is given
    • Reports prepared has no error/discrepancy

BASIC COMPETENCIES

UNIT OF COMPETENCY : PARTICIPATE IN WORKPLACE COMMUNICATION
UNIT CODE : 500311105

This unit covers the knowledge, skills and attitudes required to gather, interpret and convey information in response to workplace requirements.

  1. Obtain and convey workplace information
    • Specific and relevant information is accessed from appropriate sources
    • Effective questioning, active listening and speaking skills are used together and convey information
    • Appropriate medium is used to transfer information and ideas
    • Appropriate non- verbal communication is used
    • Appropriate lines of communication with supervisors and colleagues are identified and followed
    • Defined workplace procedures for the location and storage of information are used
    • Personal interaction is carried out clearly and concisely
  2. Participate in workplace meetings and discussions
    • Team meetings are at ended on time
    • Own opinions are clear expressed and those of others are listened to without interruption
    • Meeting inputs are consistent with the meeting purpose and established protocols
    • Workplace interactions are conducted in a courteous manner
    • Questions about simple routine workplace procedures and matters concerning working conditions of employment are asked and responded to.
    • Meetings outcomes are interpreted and implemented
  3. Complete relevant work related documents
    • Range of forms relating to conditions of employment are completed accurately and legibly
    • Workplace data is recorded on standard workplace forms and documents
    • Basic mathematical processes are used for routine calculations
    • Errors in recording information on forms/documents are identified and properly acted upon
    • Reporting requirements to supervisor are completed according to organizational guidelines

UNIT OF COMPETENCY : WORK IN TEAM ENVIRONMENT
UNIT CODE : 500311106

This unit covers the skills, knowledge and attitudes to identify role and responsibility as a member of a team.

  1. Describe team role and scope
    • The role and objective of the team is identified from available sources of information
    • Team parameters, reporting relationships and responsibilities are identified from team discussions and appropriate external sources.
  2. Identify own role and responsibility within team
    • Individual role and responsibilities within the team environment are identified.
    • Roles and responsibility of other team members are identified and recognized.
    • Reporting relationships within team and external to team are identified.
  3. Work as a team member
    • Effective and appropriate forms of communications used and interactions undertaken with team members who contribute to known team activities and objectives.
    • Effective and appropriate contributions made to complement team activities and objectives, based on individual skills and competencies and workplace context.
    • Observed protocols in reporting using standard operating procedures.
    • Contribute to the development of team work plans based on an understanding of team’s role and objectives and individual competencies of the members.

UNIT OF COMPETENCY : PRACTICE CAREER PROFESSIONALISM
UNIT CODE : 500311107

This unit covers the knowledge, skills and attitudes in promoting career growth and advancement.

  1. Integrate personal objectives with organizational goals
    • Personal growth and work plans are pursued towards improving the qualifications set for the profession
    • Intra- and interpersonal relationships is are maintained in the course of managing oneself based on performance evaluation
    • Commitment to the organization and its goal is demonstrated in the performance of duties
  2. Set and meet work priorities
    • Competing demands are prioritized to achieve personal, team and organizational goals and objectives.
    • Resources are utilized efficiently and effectively to manage work priorities and commitments
    • Practices along economic use and maintenance of equipment and facilities are followed as per established procedures
  3. Maintain professional growth and development
    • Trainings and career opportunities are identified and availed of based on job requirements
    • Recognitions are sought/received and demonstrated as proof of career advancement
    • Licenses and/or certifications relevant to job and career are obtained and renewed

UNIT OF COMPETENCY : PRACTICE  OCCUPATIONAL HEALTH AND SAFETY PROCEDURES
UNIT CODE : 500311108

This unit covers the outcomes required to comply with regulatory and organizational requirements for occupational health and safety.

  1. Identify hazards and risks
    • Safety regulations and workplace safety and hazard control practices and procedures are clarified and explained based on organization procedures
    • Hazards/risks in the workplace and their corresponding indicators are identified to minimize or eliminate risk to co-workers, workplace and environment in accordance with organization procedures
    • Contingency measures during workplace accidents, fire and other emergencies are recognized and established in accordance with organization procedures
  2. Evaluate hazards and risks
    • Terms of maximum tolerable limits which when exceeded will result in harm or damage are identified based on threshold limit values (TLV)
    • Effects of the hazards are determined
    • OHS issues and/or concerns and identified safety hazards are reported to designated personnel in accordance with workplace requirements and relevant workplace OHS legislation
  3. Control hazards and risks
    • Occupational Health and Safety (OHS) procedures for controlling hazards/risks in workplace are consistently
      followed
    • Procedures for dealing with workplace accidents, fire and emergencies are followed in accordance with organization OHS policies
    • Personal protective equipment (PPE) is correctly used in accordance with organization OHS procedures and practices
    • Appropriate assistance is provided in the event of a workplace emergency in accordance with established organization protocol
  4. Maintain OHS awareness
    • Emergency-related drills and trainings are participated in as per established organization guidelines and procedures
    • OHS personal records are completed and updated in accordance with workplace requirements

DIFINITION OF TERMS

  • Babbit – A metal used to line bearing; consisting of tin, antimony, copper and other metals
  • Bore Out – To increase the engine cylinder diameter by boring it larger, requires the fitting of oversize piston.
  • Calibrate – To check or correct the initial setting of a test instrument.
  • Cold Welding – Process of repairing a crack in a metal by drilling a hole through the crack, threading the hole, and screwing in a section of threaded rod to form a seal.
  • Crankpins – Part of the crankshaft to which the connecting rod is attached. Also called the crank throw or connecting rod journal.
  • Dynamic Unbalance – Results when there are two weights in separate planes that will set up separate forces which causes the crankshaft to rock or twist on an axis perpendicular tot he axis of rotation.
  • Guide Sleeve – A tubular sleeve put on a connecting rod bolt before the rod is removed from the block to prevent scratching of the crankpins by the bolt threads.
  • Honing – The process of restoring the cylinder into a straight, round shape and smooth surface by machining to remove only a small amount of metal or to obtain the desired cylinder finished after re-boring.
  • Journals – The part of the rotating shaft which turns in a bearing.
  • Kinetic unbalance – Unbalanced state that tends to throw the mass outward due to the centrifugal force and cause a bending or flexing of the crankshaft.
  • Line Boring Using a special boring machine, centered on the original center of the cylinder-block main bearing bores, to re-bore the crankcase into alignment.
  • Machining – The process of using a machine to remove metal from a metal part.
  • Magna Flux – A process that uses an electromagnet and special magnet powder to detect surface and subsurface cracks in iron and steel.
  • Re-bore – To increase the diameter of a cylinder.
  • Re-boring – Reconditioning process by cutting or grinding some amount of metals from the cylinder surface to fit the nearest oversize piston.
  • Re-sleeving – Restoring the cylinder condition into standard diameter by removing the worn sleeves and replacing them with new ones.
  • Rod Small End – The end of the connecting rod through which the piston pin passes to connect the piston tot he connecting rod.
  • Rod Big End – The end of the connecting rod that attached around the crankpins.
  • Specifications – Information provided by the manufacturer for each engine and its components, operation, clearances. Also the service procedure to be followed for a system to operate properly.
  • Static Unbalance – Condition at which when the crankshaft placed on knife-edges and rotated will come to rest always on the heaviest part at the bottom.
  • Tolerance – The range of variation in a given dimension.
  • Valve seat Insert – A metal ring installed in the cylinder head to act as a valve seat.

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