AUTOMOTIVE ELECTRICAL ASSEMBLY NC II – TESDA COURSE MODULE

TESDA TRAINING REGULATIONS FOR AUTOMOTIVE ELECTRICAL ASSEMBLY NC II

The AUTOMOTIVE ELECTRICAL ASSEMBLY NC II consists of competencies that a person must achieve to mount/install electrical parts and electronic units to automotive vehicle body in accordance with manufacturer’s specification. It also covers headlight focus aiming operations.

This Qualification is packaged from the competency map of the Automotive Industry (Manufacturing sub-sector)

A student who has achieved this Course in AUTOMOTIVE ELECTRICAL ASSEMBLY NC II is competent to be:

• Automotive Electrical Assembly Technician

AUTOMOTIVE ELECTRICAL ASSEMBLY NC II – TRAINING AND REGULATION MODULE

Course Title: AUTOMOTIVE ELECTRICAL ASSEMBLY
Level: NC II
Nominal Training Duration : 143 Hours

This course is designed to enhance the knowledge, skills and attitudes of an individual in the field of automotive manufacturing in accordance with industry standards. It covers competencies such as: install/fit out electrical parts and electronic units to engine assembly, dash panel instruments, interior, exterior and engine room compartment of automotive vehicle body in accordance with manufacturer’s specification. It also covers competencies to install audio and video systems and perform headlight focus aiming operations.

TRAINEE ENTRY REQUIREMENTS

Trainees or students should possess the following requirements:

• can communicate both oral and written;
• physically and mentally fit;
• with good moral character; and

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.

Note: National Certification in Automotive Servicing NC I can be obtained through direct assessment applying principle of Recognition of Prior Learning (RPL).

COMPETENCIES REQUIRED IN AUTOMOTIVE ELECTRICAL ASSEMBLY NC II

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

To obtain this TESDA course in Automotive Electrical Assembly NC II, all units prescribed for this qualification must be achieved.

These units of competency comprising this qualification include the following:

UNIT CODE	CORE COMPETENCIES (105 Hours)
ALT827301	Install/Fit Out Electrical Parts to Engine Assembly
ALT827302	Install/fit Out Electrical Parts and Electronic Units to Body Interior Compartment
ALT827303	Install/Fit Out Electrical Parts and Electronic Units to Dash Instrument Panel
ALT827304	Install/Fit Out Electrical Parts to Exterior and Engine Compartment
ALT827305	Install/Fit Out Audio and Video Systems
ALT827306	Perform Headlight Focus Aiming Operations
UNIT CODE	COMMON COMPETENCIES (20 Hours)
ALT311202	Perform Mensuration and Calculation
ALT742201	Read, Interpret and Apply engineering Drawings
ALT723202	Move and Position Vehicle
ALT723201	Apply Appropriate Sealant/Adhesive
ALT723205	Perform Shop Maintenance
UNIT CODE	BASIC COMPETENCIES (18 Hours)
500311105	Participate in Workplace Communication
500311106	Work in Team Environment
500311107	Practice Career Professionalism
500311108	Practice Occupational Health and Safety Procedures

CORE COMPETENCIES

This section gives the details of the contents of the core units of competency required in AUTOMOTIVE ELECTRICAL
ASSEMBLY NC II

UNIT OF COMPETENCY : INSTALL/FIT OUT ELECTRICAL PARTS TO ENGINE ASSEMBLY
UNIT CODE : ALT827301

This unit identifies the competence required for the preparation, delivery and installation/fitting out of electrical parts to engine assembly in accordance with company standards.

1. Obtain materials/parts for job.
   • Materials/parts list is read and interpreted to establish requirements for the job.
   • Parts/materials are picked by matching part numbers and stacked in the warehouse bin/container and floor stack areas.
   • Parts/materials are delivered to respective point of fit to ensure smooth and continuous production.
2. Select and use tools and equipment
   • Tools and equipment are selected to meet job requirements.
   • Tools and equipment are checked to ensure they are in good working order.
   • Appropriate lifting hangers/gears are selected and used in accordance with OH&S requirements.
3. Load and unload engine into assembly jigs
   • Engine is matched to the jigging equipment reference to part numbers and codes.
   • Engine is securely clamped to prevent movement and distortion during the assembly operation as specified in the standard operation sheet
4. Select and use hardware parts
   • Hardware parts are identified and selected to meet the job requirements as stated in the materials/parts list.
   • Hardware parts are fitted in the required number to the designated positions stated in the materials/parts list and associated engineering manuals.
5. Mount/install electrical parts
   • Materials/parts list and engineering drawings are correctly read and interpreted.
   • Parts are matched with the materials/parts list for the particular requirements for the job.
   • Parts are positioned and secured into engine assembly as per the relevant drawings and standard operation sheet.
   • Specified nuts, bolts and screws are tensioned to the specified torque requirements stated in the engineering manuals and standard operating sheet
   • Identified faults are recorded, reported and rectified/scrapped in accordance with company procedures.
6. Route service lines
   • Materials/parts list and engineering manuals are correctly read and interpreted.
   • Appropriate hardware parts are selected and used according to specifications.
   • Service lines are routed, tied and clipped to specification.
   • Workflow and production output are recorded and maintained.

UNIT OF COMPETENCY : INSTALL / FIT OUT ELECTRICAL PARTS AND ELECTRONIC UNITS TO BODY INTERIOR COMPARTMENT
UNIT CODE : ALT827302

This unit identifies the competence required for the preparation, delivery and installation/fitting out of electrical parts and electronic units to body interior compartment in accordance with company standards.

1. Obtain materials / parts for job.
   • Materials/parts list is read and interpreted to establish requirements for the job.
   • Parts and electronic units are picked by matching part numbers and stacked in the warehouse bin/container and floor stack areas.
   • Parts/materials are delivered to respective point of fit to ensure smooth and continuous production.
2. Select and use tools and equipment
   • Tools and equipment are selected to meet job requirements.
   • Tools and equipment are checked to ensure they are in good working order.
3. Select and use hardware parts
   • Hardware parts are identified and selected to meet the job requirements as stated in the materials/parts list.
   • Hardware parts are fitted in the required number to the designated positions stated in the materials/parts list and engineering manuals.
4. Mount/install parts and electronic units
   • Materials/parts list and engineering drawings are correctly read and interpreted.
   • Parts and electronic units are matched with the materials/parts list for the particular requirements of the job.
   • Parts and electronic units are positioned and secured into automotive vehicle body as per the relevant drawings/instructions.
   • Specified nuts, bolts and screws are tensioned to the specified torque requirements stated in the engineering manuals and standard operating sheet
   • Identified faults are recorded, reported and rectified/scrapped in accordance with company procedures.
5. Route service lines
   • Materials/parts list and engineering manuals are correctly read and interpreted.
   • Appropriate hardware parts are selected and used according to specifications.
   • Service lines are routed, tied and clipped to specification.
   • Workflow and production output are recorded and maintained.

UNIT OF COMPETENCY: INSTALL / FIT OUT ELECTRICAL PARTS AND ELECTRONIC UNITS TO DASH PANEL INSTRUMENT
UNIT CODE : ALT827303

This unit identifies the competence required for the preparation, delivery and installation/fitting out of electrical parts and electronic units to dash panel instrument. It also includes the fitting out of electrical parts to steering wheel column in accordance with company standards.

1. Obtain materials / parts for job.
   • Materials/parts list is read and interpreted to establish requirements for the job.
   • Parts and electronic units are picked by matching part numbers that are stacked in warehouse bin/container and floor stack areas.
   • Parts and electronic unit and materials are delivered to respective point of fit to ensure smooth and continuous production.
2. Select and use tools and equipment
   • Tools and equipment are selected to meet job requirements.
   • Tools and equipment are checked to ensure they are in good working order.
3. Select and use hardware parts
   • Hardware parts are identified and selected to meet the job requirements as stated in the materials/parts list.
   • Hardware parts are fitted in the required number to the designated positions stated in the materials/parts list and engineering manuals.
4. Mount/install parts and electronic units
   • Materials/parts list and engineering manuals are correctly read and interpreted.
   • Parts and electronic units are matched with the materials/parts list for the particular requirements of the job.
   • Parts and electronic units are positioned and secured into dash panel of an automotive vehicle body as per the relevant drawings/instructions.
   • Specified nuts, bolts and screws are tensioned to the specified torque requirements stated in the engineering manuals and standard operation sheet
   • Identified faults are recorded, reported and rectified/scrapped in accordance with company procedures.
5. Route service lines
   • Materials/parts list and engineering manuals are correctly read and interpreted.
   • Appropriate hardware parts are selected and used according to specifications.
   • Service lines are routed, tied and clipped to specification.
   • Workflow and production output are recorded and maintained.

UNIT OF COMPETENCY : INSTALL/ FIT OUT ELECTRICAL PARTS TO EXTERIOR AND ENGINE ROOM COMPARTMENT
UNIT CODE : ALT827304

This unit identifies the competence required for the preparation, delivery and installation/fitting out of electrical parts to exterior and engine room compartment of automotive vehicle body in accordance with company standards.

1. Obtain parts for job.
   • Materials/parts list is read and interpreted to establish requirements for the job.
   • Parts and materials are picked by matching part numbers and stacked in the warehouse bin/container and floor stack areas.
   • Parts/components and materials are delivered to respective point of fit to ensure smooth and continuous production.
2. Select and use tools and equipment
   • Tools and equipment are selected to meet job requirements.
   • Tools and equipment are checked to ensure they are in good working order.
3. Select and use hardware parts
   • Hardware parts are identified and selected to meet the job requirements as stated in the materials/parts list.
   • Hardware parts are fitted in the required number to the designated positions stated in the materials/parts list and engineering manuals.
4. Mount/install electrical parts
   • Materials/parts list and engineering drawings are correctly read and interpreted.
   • Parts are matched with the materials/parts list for the particular requirements of the job.
   • Parts are positioned and secured into automotive vehicle body as per the relevant drawings/instructions.
   • Specified nuts, bolts and screws are tensioned to the specified torque requirements stated in the engineering manuals and standard operating sheet.
   • Identified faults are recorded, reported and rectified/scrapped in accordance with company procedures.
5. Route service lines
   • Materials/parts list and engineering manuals are correctly read and interpreted.
   • Appropriate hardware parts are selected and used according to specifications.
   • Service lines are routed, tied and clipped to specification.
   • Workflow and production output are recorded and maintained.

UNIT OF COMPETENCY : INSTALL/ FIT OUT AUDIO AND VIDEO SYSTEMS
UNIT CODE : ALT827305

This unit identifies the competence required for the preparation, delivery and installation/fitting out of audio and video systems to automotive vehicle body in accordance with company standards.

1. Obtain parts for job.
   • Materials/parts list is read and interpreted to establish requirements for the job.
   • Parts/electronic units and materials are picked by matching part numbers and stacked in the warehouse bin/container and floor stack areas.
   • Parts/components and materials are delivered to respective point of fit to ensure smooth and continuous production.
2. Select and use tools and equipment
   • Tools and equipment are selected to meet job requirements.
   • Tools and equipment are checked to ensure they are in good working order.
3. Select and use hardware parts
   • Hardware parts are identified and selected to meet the job requirements as stated in the materials/parts list.
   • Hardware parts are fitted in the required number to the designated positions stated in the materials/parts list and associated engineering manuals.
4. Mount/install electrical parts and electronic units
   • Materials/parts list and engineering drawings are correctly read and interpreted.
   • Parts and electronic units are matched with the materials/parts list for the particular requirements of the job.
   • Parts and electronic units are positioned and secured into automotive vehicle body as per the relevant drawings/instructions.
   • Specified nuts, bolts and screws are tensioned to the specified torque requirements stated in the engineering manuals and standard operating sheet.
   • Identified faults are recorded, reported and rectified/scrapped in accordance with company procedures.
5. Route service lines
   • Materials/parts list and engineering manuals are correctly read and interpreted.
   • Appropriate hardware parts are selected and used according to specifications.
   • Service lines are routed, tied and clipped to specification.
   • Workflow and production output are recorded and maintained.

UNIT OF COMPETENCY: PERFORM HEADLIGHT FOCUS AIMING OPERATIONS
UNIT CODE : ALT827306

This unit identifies the competence required to perform headlight focus aiming operations within the motor vehicle assembly Industry.

1. Prepare for the job
   • Work specification is read and interpreted to determine alignment process.
   • Tools and equipment are determined and selected to meet requirements for the job.
2. Perform headlight focus aiming operations
   • Headlight alignment equipment information is accessed and interpreted from manufacturer specifications.
   • Headlight alignment procedures are undertaken in accordance with company procedures.
   • Adjustments are undertaken in accordance with the vehicle and equipment manufacturer’s specifications.
   • Headlight alignment procedures are carried out and documentation completed in accordance with company procedures/policies.

COMMON COMPETENCIES

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 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.
4. 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 OF COMPETENCY : READ, INTERPRET AND APPLY ENGINEERING DRAWINGS.
UNIT CODE : ALT742201

This unit deals with identifying, interpreting and applying automotive mechanical assembly engineering manuals / specifications in accordance with requirements of the job.

1. Identify and access engineering manuals / specifications
   • 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-positioned.
   • Drive the vehicle to appropriate location
   • Park vehicle following parking safety techniques and procedure
3. Check 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 is 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 application
   • 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 : PERFORM SHOP MAINTENANCE
UNIT CODE : ALT723205

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 : 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

DEFINITION OF TERMS

• Automotive Vehicles – These are motor vehicles whose gross vehicle weight is equal or less than 3,500 kgs. Powered by a gas or diesel engine. It could be a passenger car or a light utility vehicle
• Automotive Electrical Assembly Technician – Refers to an all around auto electrical assembly man that can perform all electrical assembly works from assembling of electrical assemblies to mounting and installation to automotive vehicle body.
• Adhesives – Substance used to hold gasket in place during assembly. It also maintains a tight seal by filling in small irregularities on a surface and prevents gasket from shifting due to vibration.
• Point of Fit – Refers to the assembly area where parts / materials / assemblies are used or consumed
• Electronics – Electrical assemblies, circuit and system that use electronic devices such as transistors and diodes
• Hardware Parts – Refers to bolts, nuts, screws, washers and other small parts
• Catalytic Converter Emission – The control device fitted in the exhaust system of an internal combustion engine. The converter reduces the toxicity of products of combustion by catalytic re-combination
• Assembly Manuals – Reference manuals with illustration or drawings of parts/components and its direction on how they are mounted or installed on the automotive vehicle or certain assemblies.
• Quality Inspection Manuals – Reference manuals with explanation on what quality standards have to be maintained in the conduct of assembling automotive vehicle
• Work Order – A work order is a form of instruction that is broadcasted either by manual or by electronic system by preceding stations to the next stations regarding on what model sequence to produce on a timely-structured manner.
• Job Requirements – Refers to specific specifications of model/variant to be assembled.
• Standard Operation Sheet – Is a listing of process elements arrange according to the assembly sequence for a given job requirements
• Fuel Injection – An electronic system that increases the performance ad fuel economy because it monitors engine conditions and provides the correct air/fuel mixture based on the engine’s demand. It injects fuel directly into the cylinder head enabling more precise control over the quantity used.
• Jigs/fixtures – Kind of equipment that is used for sub-assembly operations in order to meet the desired dimensions and outcome of a certain assembly.