AUTOMOTIVE MECHANICAL ASSEMBLY NC III – TESDA COURSE MODULE

TESDA TRAINING REGULATIONS FOR AUTOMOTIVE MECHANICAL ASSEMBLY NC III

The TESDA Course in AUTOMOTIVE MECHANICAL ASSEMBLY NC III consists of competencies that a person must achieve to rectify assembly faults on assembled mechanical assemblies; rectify faults on mounted/installed brake and fuel system; rectify faults on mounted/installed power drive system; and rectify faults on mounted/installed suspension drive train in accordance with manufacturer’s specification. It also covers competencies of conducting engine hot test that determines the status of an engine for operating inconsistencies or faults.

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

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

• Automotive Electrical Assembly Rectifier

AUTOMOTIVE MECHANICAL ASSEMBLY NC III – TRAINING AND REGULATION MODULE

Course Title: AUTOMOTIVE MECHANICAL ASSEMBLY
Level: NC III
Nominal Training Duration : 480 Hours

This course is designed to enhance the knowledge, skills and attitudes of an individual in the field of automotive mechanical assembly in accordance with industry standards. It covers core competencies such as; conduct engine hot test, rectify assembly faults on assembled mechanical assemblies, rectify faults on mounted/installed brake and fuel system, rectify faults on mounted/installed power drive system and rectify faults on mounted/installed suspension drive train.

This course is also designed to enhance the basic and common knowledge, skills and attitudes of an individual in the field of automotive mechanical assembly.

TRAINEE ENTRY REQUIREMENTS

Trainees or students who would like to enroll in this program must possess the following requirements:

• can communicate both oral and written;
• physically and mentally fit; and
• can perform basic mathematical computation.
• Must possess the Automotive Mechanical Assembly National Certificate (NC) II

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 MECHANICAL ASSEMBLY NC III

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

To obtain this TESDA Course in Automotive Mechanical Assembly NC III, all units prescribed below for this qualification must be achieved.

These units of competency comprising this qualification include the following:

UNIT CODE	CORE COMPETENCIES (440 hours)
ALT827319	Conduct Engine Hot Test
ALT827320	Rectify Assembly Faults on Assembled Mechanical Assemblies
ALT827321	Rectify Faults on Mounted/Installed Brake and Fuel System
ALT827322	Rectify Faults on Mounted/Installed Power Drive System
ALT827323	Rectify Faults on Mounted/Installed Suspension Drive Train
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 (20 hours)
500311109	Lead Workplace Communication
500311110	Lead Small Teams
500311111	Develop and Practice Negotiation skills
500311112	Solve Problems Related to Work Activities
500311113	Use Mathematical Concepts and Techniques
500311114	Use Relevant Technologies

CORE COMPETENCIES

This section gives the details of the contents of the core units of competency required in AUTOMOTIVE MECHANICAL ASSEMBLY NC III

UNIT OF COMPETENCY : CONDUCT ENGINE HOT TEST
UNIT CODE : ALT827319

This unit specifies the competency required to assess the status of an engine for operating inconsistencies or faults by connecting it to all service requirements and running it for a designated duration. The unit includes the transfer of the engine to and from the inspection cradle, the connection and disconnection of services, the completion of computer / keypad aided and manual / sensory testing to specification and the reporting of non-conforming engines. The competency must require testing beyond that involving only computer/keypad aided monitoring systems

1. Plan and prepare for work
   • Planning and preparation of work instruction including plans, specifications, quality requirements and operational details are obtained, confirmed and applied.
   • Occupational health and safety (OH & S) requirements are followed in accordance with company safety policies and procedures.
   • Tools and equipment selected to carry out tasks are consistent with the requirements of the job, checked for serviceability and any faults are rectified or reported prior to commencement.
   • Materials appropriate to the work application are identified, obtained, prepared, safely handled and located ready for use.
   • Working environment considerations are identified and measures to reduce noise, dust and obstacles are applied.
2. Shift engine
   • Engine is transferred from the assembly line to the engine testing area.
   • Engine is located in position ready for hot test procedures.
   • Engine which pass inspection are transferred back to the assembly line.
   • Non-conforming engines are transferred to the rectification area.
3. Perform engine hot test
   • Engine is mounted in the engine testing cradle.
   • Services are connected to the engine simulating normal operating conditions.
   • Engine is brought to hot operating conditions.
   • Computerized / keypad aided and manual/sensory tests are conducted on all operating facets of the engine against designated performance specifications.
   • Minor modifications are carried out in accordance with company procedures and engineering manuals.
   • Engine hot test results including engine faults are recorded and documented
   • Engine designated as conforming or requiring rectification are labeled and prepared for transfer.
4. Clean up
   • Work area is cleared and materials disposed of, reused or recycled in accordance with company requirements.
   • Tools and equipment are cleaned, checked, maintained and stored in accordance with company requirements.

UNIT OF COMPETENCY : RECTIFY ASSEMBLY FAULTS ON ASSEMBLED MECHANICAL ASSEMBLIES
UNIT CODE : ALT827320

This unit specifies the competency required to rectify assembly faults on assembled mechanical assemblies, including sealing systems, based on recommendations from the inspection records and report of the fully assembled vehicle. The unit includes location, diagnosis, rectification of the assembly and sealing faults and full re-assembly in an offline environment.

1. Plan and prepare for work
   • Planning and preparation of work instructions, including relevant inspection reports and forms and quality requirements are obtained, confirmed and applied
   • Occupational health and safety (OH & S) requirements are followed in accordance with company safety policies and procedures
   • Tools and equipment selected to carry out tasks are consistent with the requirements of the job, checked for serviceability and any faults are rectified or reported prior to commencement
   • Materials appropriate to the work application are identified, obtained, prepared, safely handled and located ready for use
   • Working environment considerations are identified and measures to reduce noise, dust and obstacles are applied
2. Locate and rectify assembly faults
   • Final report is interpreted and fault located on assembled vehicle
   • Assembly fault is diagnosed and suitable method of correction planned
   • Rectification is applied, depending on the fault and in accordance with engineering manuals
   • Fault is re-diagnosed to assess outcome of rectification and to ensure rework has eliminated the fault and final  adjustments made
   • Documentation is completed outlining nature of problem, work conducted and outcome and appropriate communication is conveyed, in accordance with company requirements
   • Vehicle is returned to production line
3. Locate and rectify sealing system faults
   • Final report is interpreted and faults located on assembled vehicles.
   • Sealing faults are assessed and suitable method of correction planned
   • Rectification is applied, dependent on the fault and in accordance with engineering manuals
   • Faults are water tested to check outcome of rectification and to ensure rework has eliminated the fault and final adjustments made
   • Documentation is completed outlining nature of problem, work conducted and outcome and appropriate communication is conveyed, in accordance with company requirements
   • Vehicle is returned to production sequence
4. Clean up work area
   • Work area is cleared and materials disposed of, reused or recycled in accordance with company requirements
   • Tools and equipment are cleaned, checked, maintained and stored in accordance with company requirements

UNIT OF COMPETENCY : RECTIFY FAULTS ON MOUNTED / INSTALLED BRAKE AND FUEL SYSTEM
UNIT CODE : ALT827321

This unit specifies the competency required to rectify brake and fuel system faults based on recommendations from the inspection records and report of the fully assembled vehicle. The unit includes location, diagnosis and rectification of the faults in an off-line environment.

1. Plan and prepare for work
   • Planning and preparation of work instructions, including relevant inspection reports and forms and quality requirements are obtained, confirmed and applied
   • Occupational health and safety (OH & S) requirements are followed in accordance with company safety policies and procedures
   • Tools and equipment selected to carry out tasks are consistent with the requirements of the job, checked for serviceability and any faults are rectified or reported prior to commencement
   • Materials appropriate to the work application are identified, obtained, prepared, safely handled and located ready for use
   • Working environment considerations are identified and measures to reduce noise, dust and obstacles are applied
2. Diagnose and rectify mechanical fault
   • Inspection report is interpreted and fault is located on assembled vehicle.
   • Mechanical fault is diagnosed and suitable method of correction is planned.
   • Rectification is applied, dependent on the fault and in accordance with engineering manuals
   • Fault is re-diagnosed to assess outcome of rectification and to ensure rework has eliminated the fault and final adjustments made
   • Documentation is completed and communication is conveyed outlining nature of problem, work conducted and outcome, in accordance with company requirements
   • Vehicle is returned to production sequence
3. Clean up work area
   • Work area is cleared and materials disposed of, reused or recycled in accordance with company requirements
   • Tools and equipment are cleaned, checked, maintained and stored in accordance with company requirements

UNIT OF COMPETENCY : RECTIFY FAULT ON MOUNTED / INSTALLED POWER DRIVE SYSTEM
UNIT CODE : ALT827322

This unit specifies the competency required to rectify power drive system faults based on recommendations from the inspection records and report of the fully assembled vehicle. The unit includes location, diagnosis and rectification of the faults in an off-line environment.

1. Plan and prepare for work
   • Planning and preparation of work instructions, including relevant inspection reports and forms and quality requirements are obtained, confirmed and applied
   • Occupational health and safety (OH & S) requirements are followed in accordance with company safety policies and procedures
   • Tools and equipment selected to carry out tasks are consistent with the requirements of the job, checked for serviceability and any faults are rectified or reported prior to commencement
   • Materials appropriate to the work application are identified, obtained, prepared, safely handled and located ready for use
   • Working environment considerations are identified and measures to reduce noise, dust and obstacles are applied
2. Diagnose and rectify mechanical fault
   • Inspection report is interpreted and fault is located on assembled vehicle
   • Mechanical fault is diagnosed and suitable method of correction is planned.
   • Rectification is applied, dependent on the fault and in accordance with engineering manuals
   • Fault is re-diagnosed to assess outcome of rectification and to ensure rework has eliminated the fault and final adjustments made
   • Documentation is completed and communication is conveyed outlining nature of problem, work conducted and outcome, in accordance with company requirements
   • Vehicle is returned to production sequence
3. Clean up
   • Work area is cleared and materials disposed of, reused or recycled in accordance with company requirements
   • Tools and equipment are cleaned, checked, maintained and stored in accordance with company requirements

COMMON COMPETENCIES

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 instrument. It also covers caring for and handling of measuring instrument.

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 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 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 : 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 : LEAD WORKPLACE COMMUNICATION
UNIT CODE : 500311109

This unit covers the knowledge, skills and attitudes required to lead in the dissemination and discussion of ideas, information and issues in the workplace.

1. Communicate information about workplace processes
   • Appropriate communication method is selected
   • Multiple operations involving several topics areas are communicated accordingly
   • Questions are used to gain extra information
   • Correct sources of information are identified
   • Information is selected and organized correctly
   • Verbal and written reporting is undertaken when required
   • Communication skills are maintained in all situations
2. Lead workplace discussions
   • Response to workplace issues are sought
   • Response to workplace issues are provided immediately
   • Constructive contributions are made to workplace discussions on such issues as production, quality and safety
   • Goals/objectives and action plan undertaken in the workplace are communicated
3. Identify and communicate issues arising in the workplace
   • Issues and problems are identified as they arise
   • Information regarding problems and issues are organized coherently to ensure clear and effective communication
   • Dialogue is initiated with appropriate personnel
   • Communication problems and issues are raised as they arise

UNIT OF COMPETENCY : LEAD SMALL TEAMS
UNIT CODE : 500311110

This unit covers the knowledge, skills and attitudes to lead small teams including setting and maintaining team and individual performance standards.

1. Provide team leadership
   • Work requirements are identified and presented to team members
   • Reasons for instructions and requirements are communicated to team members
   • Team members’ queries and concerns are recognized, discussed and dealt with
2. Assign responsibilities
   • Duties, and responsibilities are allocated having regard to the skills, knowledge and aptitude required to properly undertake the assigned task and according to company policy
   • Duties are allocated having regard to individual preference, domestic and personal considerations, whenever possible
3. Set performance expectations for team members
   • Performance expectations are established based on client needs and according to assignment requirements
   • Performance expectations are based on individual team members duties and area of responsibility
   • Performance expectations are discussed and disseminated to individual team members
4. Supervised team performance
   • Monitoring of performance takes place against defined performance criteria and/or assignment instructions and corrective action taken if required
   • Team members are provided with feedback, positive support and advice on strategies to overcome any deficiencies
   • Performance issues which cannot be rectified or addressed within the team are referenced to appropriate personnel according to employer policy
   • Team members are kept informed of any changes in the priority allocated to assignments or tasks which might impact on client/customer needs and satisfaction
   • Team operations are monitored to ensure that employer/client needs and requirements are met
   • Follow-up communication is provided on all issues affecting the team
   • All relevant documentation is completed in accordance with company procedures

UNIT OF COMPETENCY : DEVELOP AND PRACTICE NEGOTIATION SKILLS
UNIT CODE : 500311111

This unit covers the skills, knowledge and attitudes required to collect information in order to negotiate to a desired outcome and participate in the negotiation.

1. Plan negotiations
   • Information on preparing for negotiation is identified and included in the plan
   • Information on creating non verbal environments for positive negotiating is identified and included in the plan
   • Information on active listening is identified and included in the plan
   • Information on different questioning techniques is identified and included in the plan
   • Information is checked to ensure it is correct and up-to- date
2. Participate in negotiations
   • Criteria for successful outcome are agreed upon by all parties
   • Desired outcome of all parties are considered
   • Appropriate language is used throughout the negotiation
   • A variety of questioning techniques are used
   • The issues and processes are documented and agreed upon by all parties
   • Possible solutions are discussed and their viability assessed
   • Areas for agreement are confirmed and recorded
   • Follow-up action is agreed upon by all parties

UNIT OF COMPETENCY : SOLVE PROBLEMS RELATED TO WORK ACTIVITIES
UNIT CODE : 500311112

This unit of covers the knowledge, skills and attitudes required to solve problems in the workplace including the application of problem solving techniques and to determine and resolve the root cause of problems.

1. Identify the problem
   • Variances are identified from normal operating parameters; and product quality
   • Extent, cause and nature are of the problem are defined through observation, investigation and analytical techniques
   • Problems are clearly stated and specified
2. Determine fundamental causes of the problem
   • Possible causes are identified based on experience and the use of problem solving tools / analytical techniques.
   • Possible cause statements are developed based on findings
   • Fundamental causes are identified per results of investigation conducted
3. Determine corrective action
   • All possible options are considered for resolution of the problem
   • Strengths and weaknesses of possible options are considered
   • Corrective actions are determined to resolve the problem and possible future causes
   • Action plans are developed identifying measurable objectives, resource needs and timelines in accordance with safety and operating procedures
4. Provide recommendation/s to manager
   • Report on recommendations are prepared
   • Recommendations are presented to appropriate personnel.
   • Recommendations are followed-up, if required

UNIT OF COMPETENCY : USE MATHEMATICAL CONCEPTS AND TECHNIQUES
UNIT CODE : 500311113

This unit covers the knowledge, skills and attitudes required in the application of mathematical concepts and techniques.

1. Identify mathematical tools and techniques to solve problem
   • Problem areas are identified based on given condition
   • Mathematical techniques are selected based on the given problem
2. Apply mathematical procedure/solution
   • Mathematical techniques are applied based on the problem identified
   • Mathematical computations are performed to the level of accuracy required for the problem
   • Results of mathematical computation is determined and verified based on job requirements
3. Analyze results
   • Result of application is reviewed based on expected and required specifications and outcome
   • Appropriate action is applied in case of error

UNIT OF COMPETENCY : USE RELEVANT TECHNOLOGIES
UNIT CODE : 500311114

This unit of competency covers the knowledge, skills, and attitude required in selecting, sourcing and applying appropriate and affordable technologies in the workplace.

1. Study/select appropriate technology
   • Usage of different technologies is determined based on job requirements
   • Appropriate technology is selected as per work specification
2. Apply relevant technology
   • Relevant technology is effectively used in carrying out function
   • Applicable software and hardware are used as per task requirement
   • Management concepts are observed and practiced as per established industry practices
3. Maintain/enhance relevant technology
   • Maintenance of technology is applied in accordance with the industry standard operating procedure, manufacturer’s operating guidelines and occupational health and safety procedure to ensure its operative ability
   • Updating of technology is maintained through continuing education or training in accordance with job requirement
   • Technology failure/ defect is immediately reported to the concern/responsible person or section for appropriate action

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 Mechanical Assembly Technician – Refers to an all around auto mechanical assembly man that can perform all mechanical assembly works from assembling of mechanical 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
• Mechanical Assemblies – Type of construction in which different and related parts/components are converted into sub-assembly form.
• Hardware Parts – Refers to bolts, nuts, screws, washers and other small parts
• Catalytic Converter – 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
• Intake Manifold – Tubing attached to the engine through which the air/fuel mixture reaches the cylinder.
• Master Cylinder – The liquid-filled cylinder in the hydraulic brake system or clutch, where hydraulic pressure is developed when depresses a foot pedal.
• Power Steering column – Steering that has been designed to make the wheel move more easily than in a manual steering system. Hydraulic assists the process utilizing hydraulic fluid. The fluid increases pressure in the power steering pump and aids in the movement of the steering mechanism. This fluid, called power steering fluid, is what is replaced at regular intervals to keep steering soft and comfortable.
• 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.