AUTOMOTIVE BODY PAINTING/FINISHING NC I – TESDA COURSE MODULE

TRAINING REGULATIONS FOR AUTOMOTIVE BODY PAINTING/FINISHING NC I

The AUTOMOTIVE BODY PAINTING/FINISHING NC I Qualification consists of competencies that a person must achieve to paint or repaint new automotive body panels, which do not have any damage using solid color paints. It also includes competency in polishing the painted panels.

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

A student who has achieved this Course in AUTOMOTIVE BODY PAINTING/FINISHING NC I is competent to be:

• Automotive painter (single stage painting)
• Automotive paint finisher (single stage painting)

AUTOMOTIVE BODY PAINTING/FINISHING NC I – TRAINING AND REGULATION MODULE

Course Title: AUTOMOTIVE BODY PAINTING/FINISHING
Level: NC I
Nominal Training Duration : 120 Hours

This course is designed to enhance the knowledge, skills and attitudes of an individual in the field of automotive body paint refinishing in accordance with industry standards. It covers specialized competencies such as: prepare undamaged surface for painting, apply and remove masking, spray solid color paints, and perform polishing.

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.

• can communicate both oral and written;
• with good moral character; and
• can perform basic mathematical computation.

This list does not include specific institutional requirements such as educational attainment, appropriate work experience, and others that may be required of the trainees by the school or training center delivering the TVET program.

COMPETENCIES REQUIRED IN AUTOMOTIVE BODY PAINTING/FINISHING NC I

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 (60 Hours)
ALT714301	Prepare undamaged surface for painting
ALT714302	Apply and remove masking
ALT714303	Spray solid color paints
ALT714304	Perform polishing
UNIT CODE	COMMON COMPETENCIES (32 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 (28  Hours)
500311101	Received and respond to workplace communication
500311102	Work with others
500311103	Demonstrate work values
500311104	Practice basic housekeeping procedures

CORE COMPETENCIES

This section gives the details of the contents of the core units of competency required in AUTOMOTIVE BODY  PAINTING/FINISHING NC I.

UNIT OF COMPETENCY: PREPARE UNDAMAGED SURFACE FOR PAINTING
UNIT CODE: ALT714301

This unit identifies the competence required to remove surface rust/scale and prepare application of primers, sealers and sealant for painting and refinishing.

1. Remove body accessories
   • All detachable parts from panel/surface to be repainted are removed as per procedure and without damage using required tools, equipment, supplies and materials
   • All detachable parts are placed on secured containers with complete label and identification.
2. Sand Surface
   • Adjacent panels or areas not to be sanded are applied with masking materials.
   • Sanding is performed as per procedure.
   • Sanded area is assessed using visual, touch, gauges assessment methods
   • Dual action or orbital sander is used as per manufacturer operation instruction
3. Clean the spray gun
   • Paint cup is cleaned with thinner before and after use
   • Paint passage is cleaned with back-flush technique
   • Nozzle cap is removed and fluid tip is cleaned
   • Thinner is ensured clear after repetitive back-flush cleaning method
4. Apply primers for strip to metal painting job
   • Cleaning of panel is performed using pressurized air with air dryer to remove sanded particles
   • Degreasing performed as per standard operating procedure
   • Tack cloth is used to wipe off remaining particles
   • Primers mixed according to paint manufacturer specifications
   • Spraying air pressure is maintained as per paint manufacturer specification
   • Spraying distance maintained as per manufacturer specification
   • Flash off time is observed as per paint manufacturer specifications
   • Drying time is observed as per paint manufacturer specifications.
   • Personal protective equipment and devices appropriate to the application processes are worn and used as per specification
5. Apply sealant when replacing with new panel
   • Cleaning and degreasing is performed on the area to be applied with sealant
   • Sealant applicator nozzle is trimmed/cut according to application necessity/requirements
   • Sealant is applied as per procedure
   • Applied sealant is checked and excess sealant is removed and cleaned properly

UNIT OF COMPETENCY : APPLY AND REMOVE MASKING
UNIT CODE : ALT714302

This unit covers the competency required in applying and removing materials in preparation for spray painting.

1. Remove detachable parts for panel to be painted
   • All detachable parts from panel to be repainted are removed as per procedure and without damage.
   • All detachable parts are placed on secured containers with complete label and identification.
2. Clean and degrease panel for masking
   • Cleaning is performed using pressurized air with air dryer to remove dust particles.
   • Panel is washed with car shampoo and water
   • Degreasing is performed as per company standard operating procedure
3. Apply masking materials
   • Type of masking materials to be used is accurately determined based on the panel to be repainted
   • Masking materials is applied as per masking procedures depending on the panel to be repainted
   • Improperly applied or loose ends masking materials are rechecked and corrected upon applying pressurized air as per company standard operating procedure.
4. Remove masking materials
   • Remove masking materials as per paint job requirements
   • Masking materials removed as per sequence of layers
   • Masking materials are disposed as per company standard operating procedures.

UNIT OF COMPETENCY : SPRAY SOLID COLOR PAINT
UNIT CODE : ALT714303

This unit covers the competency required in spraying solid color paint to metal, plastic and direct gloss fiberglass surfaces. It also involves single stage paint spraying.

1. Clean and degrease panel/vehicle to be repainted
   • Work area is properly cleaned as per recommended paint manufacturer and company standard.
   • Panel/Vehicle to be painted is positioned as per painting requirements
   • Cleaning of panel/vehicle is performed using pressurized air with air dryer to remove sanded particles
   • Degreasing of panel/vehicle is performed as per company standard operating procedure
   • Tack cloth is used to wipe off remaining particles
2. Prepare paint mixture and spray gun
   • Spray gun is set-up as per paint manufacturer specifications
   • Paint mixture is strained using fine paint strainer while transferring mixture to spray gun without spillage
   • Paint mixture is transferred to spray gun at least 70% of paint cup capacity and without spillage.
   • Spray pattern is checked by spray testing on separate test panel
   • Pattern, discharge, volume, air pressure of spray gun is adjusted as per job requirements.
3. Apply solid color paint by spraying
   • Solid color is applied using spray gun following and observing the factors in paint application:
   • Appropriate personal protective devices are used during painting
   • Flash-off time is observed as per paint manufacturer’s specification
   • Drying time is observed as per manufacturer’s specification.
4. Clean the spray gun
   • Paint cup is cleaned with thinner before and after use
   • Paint passage is cleaned with back-flush technique
   • Nozzle cap is removed and fluid tip is cleaned
   • Thinner is ensured clear after repetitive back-flush cleaning method

UNIT OF COMPETENCY : PERFORM POLISHING
UNIT CODE : ALT714304

This unit covers the competency in performing polishing for automotive body painting. It also involves skills in applying masking materials and handling of polishing equipment.

1. Assess painted surface
   • Adequate lighting system is used in assessing painted surface
   • Appropriate repair procedure is accurately determined
   • Appropriate polishing procedure are selected as per selected repair procedure
2. Prepare surface for polishing
   • Workplace is properly cleaned as per polishing compound manufacturer specification
   • Masking materials are applied on necessary areas as per appropriate masking procedure
   • Panel/surface to polished is positioned as per company polishing requirements
3. Polish painted surface
   • Manual hand polishing is applied on surface as per job requirements
   • Sanding is applied on surface as per job requirements
   • Handling of polishing equipment, tools and materials is done as per procedures
   • Polishing is performed as per procedure
   • Polishing compound are applied as per polishing compound manufacturer standard
   • No over-polish or thin paint results
4. Clean the polished surface
   • Adequate tap water for washing and cleaning is used
   • Soft fine cloth or flannel cloth is used for wiping.
   • Surface is wiped-dried and cleaned
5. Install body accessories
   • Safety requirements are observed in installing automotive body parts and accessories
   • All body accessories are installed and are free from dirt
   • Final polished area is assessed before and after installation of body parts and accessories.

COMMON COMPETENCIES

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

This unit covers the outcomes required in the selection, use 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 : 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 before and after servicing.

1. Prepare vehicle for driving
   • Check-up procedures is 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 : PERFORM MENSURATION AND CALCULATION
UNIT CODE : ALT311202

This unit covers the knowledge, skills and attitudes in measuring and calculating using tools and measuring instruments. It also covers care and handling 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 fundamental operation 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 are kept free from corrosion
   • Measuring instruments are not dropped to avoid damage
   • Measuring instruments are cleaned before and after using.

UNIT OF COMPETENCY : READ, INTERPRET AND APPLY SPECIFICATION AND MANUAL
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 : USE AND APPLY LUBRICANTS/COOLANTS
UNIT CODE : ALT723204

This unit covers the outcomes required to select and apply different types of lubricants and coolants in using and maintaining tools, equipment and vehicles.

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/coolants
   • 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 : ALT723305

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

The BASIC COMPETENCIES refer to non-technical skills (knowledge, skills and attitudes) that everybody will need in order to perform satisfactorily at work and in society and are considered portable and transferable irrespective of jobs and industrial settings.

UNIT OF COMPETENCY : RECEIVE AND RESPOND TO WORKPLACE COMMUNICATION
UNIT CODE : 500311101

This unit covers the knowledge, skills and attitudes required to receive, respond and act on verbal and written communication.

1. Follow routine spoken messages
   • Required information is gathered by listening attentively and correctly interpreting or understanding information/instructions
   • Instructions/information are properly recorded
   • Instructions are acted upon immediately in accordance with information received
   • Clarification is sought from workplace supervisor on all occasions when any instruction/information is not clear
2. Perform workplace duties following written notices
   • Written notices and instructions are read and interpreted correctly in accordance with organizational guidelines
   • Routine written instruction are followed in sequence
   • Feedback is given to workplace supervisor based on the instructions/information received

UNIT OF COMPETENCY : WORK WITH OTHERS
UNIT CODE : 500311102

This unit covers the skills, knowledge and attitudes required to develop workplace relationship and contribute in workplace activities.

1. Develop effective workplace relationship
   • Duties and responsibilities are done in a positive manner to promote cooperation and good relationship
   • Assistance is sought from workgroup when difficulties arise and addressed through discussions
   • Feedback provided by others in the team is encouraged, acknowledged and acted upon
   • Differences in personal values and beliefs are respected and acknowledged in the development
2. Contribute to work group activities
   • Support is provided to team members to ensure workgroup goals are met
   • Constructive contributions to workgroup goals and tasks are made according to organizational requirements
   • Information relevant to work is shared with team members to ensure designated goals are met

UNIT OF COMPETENCY : DEMONSTRATE WORK VALUES
UNIT CODE : 500311103

This unit covers the knowledge, skills, and attitude in demonstrating proper work values.

1. Define the purpose of work
   • One’s unique sense of purpose for working and the why’s of work are identified, reflected on and clearly defined for one’s development as a person and as a member of society.
   • Personal mission is in harmony with company’s values
2. Apply work values/ethics
   • Work values/ethics/concepts are classified and reaffirmed in accordance with the transparent company ethical standards, policies and guidelines.
   • Work practices are undertaken in compliance with industry work ethical standards, organizational policy and guidelines
   • Personal behavior and relationships with co-workers and/or clients are conducted in accordance with ethical standards, policy and guidelines.
   • Company resources are used in accordance with transparent company ethical standard, policies and guidelines.
3. Deal with ethical problems
   • Company ethical standards, organizational policy and guidelines on the prevention and reporting of unethical conduct are accessed and applied in accordance with transparent company ethical standard, policies and guidelines.
   • Work incidents/situations are reported and/or resolved in accordance with company protocol/guidelines.
   • Resolution and/or referral of ethical problems identified are used as learning opportunities.
4. Maintain integrity of conduct in the workplace
   • Personal work practices and values are demonstrated consistently with acceptable ethical conduct and company’s core values.
   • Instructions to co-workers are provided based on ethical, lawful and reasonable directives.
   • Company values/practices are shared with co-workers using appropriate behavior and language.

UNIT OF COMPETENCY : PRACTICE HOUSEKEEPING PROCEDURES
UNIT CODE : 500311104

This unit covers the knowledge, skills and attitudes required to apply the basic housekeeping procedures.

1. Sort and remove unnecessary items
   • Reusable, recyclable materials are sorted in accordance with company/office procedures
   • Unnecessary items are removed and disposed of in accordance with company or office procedures
2. Arrange items
   • Items are arranged in accordance with company/office housekeeping procedures
   • Work area is arranged according to job requirements
   • Activities are prioritized based on instructions.
   • Items are provided with clear and visible identification marks based on procedure
   • Safety equipment and evacuation passages are kept clear and accessible based on instructions
3. Maintain work area, tools and equipment
   • Cleanliness and orderliness of work area is maintained in accordance with company/office procedures
   • Tools and equipment are cleaned in accordance with manufacturer’s instructions/manual
   • Minor repairs are performed on tools and equipment in accordance with manufacturer’s instruction/manual
   • Defective tools and equipment are reported to immediate supervisor
4. Follow standardized work process and procedures
   • Materials for common use are maintained in designated area based on procedures
   • Work is performed according to standard work procedures
   • Abnormal incidents are reported to immediate supervisor
5. Perform work spontaneously
   • Work is performed as per instruction
   • Company and office decorum are followed and complied with
   • Work is performed in accordance with occupational health and safety (OHS) requirements

DIFINITION OF TERMS

• Basecoat – The foundation paint layer of the basecoat / clearcoat automotive finish. Specifically the layer of densely pigmented paint (color) applied over the primer coat.
• D.A. Polisher/ Sander – Dual Action rotates with a double elliptical movement
• Degreasing – The removal from the substrate of contaminants which would otherwise give rise to surface defects and performance failures. e.g. poor adhesion
• Drying – The process of change of a coating from the liquid to the solid state by evaporation of solvent, chemical reaction of the binding medium, or a combination of these processes. When drying takes place during exposure to air at normal temperatures, it is called ‘air-drying’; if it can be accelerated by the application of a moderate degree of heat it is called ‘Force-drying’ (or Low-bake), as distinct from High-bake.
  Alternate Term(s): Binder, Air-drying, Force-drying, Stoving, Lowbake, High-bake
• Fish Eye – Complications which occur during repainting when paint is repelled from a spot due to the presence of grease, oil or silicone on the paint surface
• Flash-off Time – Dwell time for solvent to evaporate from the paint surface
• Masking – Temporary covering of areas not to be painted
• Metallic Paint – A type of automotive finish which contains metallic flakes that produce a glittery appearance
  A term used for finishes incorporating fine metallic particles,
  usually aluminum, in the paint.
• Mica – A naturally occurring mineral, based on silica, which after treatment, is used as an effect pigment in coatings. Their special property is that light falling on a mica particle, depending on the angle of illumination, reflects the light with a change in colour. Because of this they are sometimes referred to as pearls.
  Alternate Term(s): Pearl
• Mottling – Paint color appears streaked, with light and dark areas. Cause, heavier film thickness in some areas that in others. Excessive wetting of some areas when painted. Uneven disbursement of the metallic in the paint.
• Orange Peel – The nubby rough appearance of paint; looks much like the texture of an orange skin, surface lacks clarity or reflected image. Caused by paint applied too dry, resulting in poor flow-out.
• Overspray – Substance such as paint mist that settles out of the air onto automobile surface appearing as tiny specks.
• Paint Film Thickness – Measure of the amount of paint on the vehicle. Also known as film builds, and is measured in millimeters or thousandths of an inch.
• Polishing – Term is often used to describe the action of using a machine to buffer wheel a vehicle.
• Primers – Material applied to the surface to seal, fill scratches and improve adhesion of paint.
• Putty – A plastic material with a high mineral filler content – used for filling deep holes or wide gaps.
• Sanding – An abrasive process used to level a coated surface prior to the application of a further coat.
  Alternate Term(s): Flatting
• Sealer/Sealant – A protective product applied by hand or machine to an automotive paint, which coats, seals and protects the surface. Normally contains silicones to maximize durability.
• Skinning –  The formation of a thin tough film on the surface of a liquid paints film. Usually due to reaction with the air or to rapid solvent loss.
• Solid Color – A coating, which contains colored pigments only, i.e., does not contain pigments such as aluminum and micas.
• Spray Gun – A typical painter will use a high-pressure spray gun to apply coatings. High-pressure guns are powered by compressed air. The purpose of the gun is to turn the liquid paint into a mist (atomize) and propel the paint toward the surface to be painted. When the wet mist contacts the surface, some of it sticks and some of it bounces off of the surface. Under ideal conditions, only about 30% of the paint sprayed stick or is transferred to the surface using a high pressure spray gun. This is termed transfer efficiency; high-pressure spray guns have a maximum transfer efficiency of 30%. This means that if a gallon of paint can coat 300 square feet, it will only coat 90 square feet if applied with a high-pressure spray gun.
• Tack cloth – Cotton fabric, such as cheesecloth, lightly impregnated with a resin, used to remove dust from a surface after rubbing down and prior to further painting. Tack rags should be stored in an airtight container to conserve their tackiness.
• Thinner – A blend of volatile organic solvents added to the paint to reduce it to the correct viscosity for application
• Three-Stage Color – A topcoat colour, which consists of 3, parts, a basecoat, a midcoat and a clear.
  Alternate Term(s): Tri-coat
• VIN (Vehicle Identification Number) – Acronym for Vehicle Identification Number. This is a unique number that identifies your vehicle. Although its primary purpose is to identify your vehicle, it often contains important information concerning the equipment and options that were installed on your vehicle at the factory. This information allows the Repair Center to order the correct parts for your vehicle. Any professional estimate or Repair Order will have this number on it
• Wet Sanding – A procedure of simultaneously sanding and rinsing an automotive finish to remove imperfections. Regarded as complicated and should only be attempted by professionals.