LABORATORY AND METROLOGY/CALIBRATION SERVICES NC III – TESDA COURSE MODULE

TESDA TRAINING REGULATIONS FOR LABORATORY AND METROLOGY/CALIBRATION SERVICES NC III

The TESDA Course in LABORATORY AND METROLOGY/CALIBRATION SERVICES NC III consists of competencies that a person must achieve to perform laboratory and metrology/calibration services work specifically on using comparison and basic measuring devices. It also include competency in measure components using coordinate measuring machines and use graphical techniques and perform simple statistical computations

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

A student who has achieved this TESDA Course in LABORATORY AND METROLOGY/CALIBRATION SERVICES NC III is competent to be:

• Laboratory and Metrology/Calibration Senior Technician

LABORATORY AND METROLOGY/CALIBRATION SERVICES NC III – TRAINING AND REGULATION MODULE

Course Title: LABORATORY AND METROLOGY/CALIBRATION SERVICES
Level: NC III
Nominal Training Duration : 96 Hours

This course is designed to equip individual with competency to perform laboratory and metrology/calibration services work specifically on using comparison and basic measuring devices. It also include competency in measure components using coordinate measuring machines and use graphical techniques and perform simple statistical computations

Basic competencies such as: Lead workplace communication; Lead small teams; Develop and practice negotiation skills; Solve problems related to work activities; Use mathematical concepts and techniques and Use relevant technologies are included.

It also includes common competencies such as: Read, Interpret and Apply Engineering Drawings; Perform Mensuration and Calculation Read; Interpret and Apply Specifications and Manuals and; Perform Shop Maintenance.

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 background in basic mensuration
• Ability to communicate both orally and in writing;
• Physically and mentally fit; and
• Must possess the LABORATORY AND METROLOGY/CALIBRATION SERVICES NC II.

COMPETENCIES REQUIRED IN LABORATORY AND METROLOGY/CALIBRATION SERVICES NC III

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

To obtain this TESDA Course in LABORATORY AND METROLOGY/CALIBRATION SERVICES 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 (56 hours)
ALT315311	Use Comparison and Basic Measuring Devices
ALT315312	Measure Components Using Coordinate Measuring Machines
ALT315313	Use Graphical Techniques and Perform Simple Statistical Computations
UNIT CODE	COMMON COMPETENCIES (20 hours)
ALT742201	Read & Interpret Engineering Drawings
ALT311202	Perform Mensuration and Calculation
ALT723203	Read, Interpret and Apply Specifications and Manuals
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 LABORATORY AND  METROLOGY/CALIBRATION SERVICES NC III

UNIT OF COMPETENCY : USE COMPARISON AND BASIC MEASURING DEVICES
UNIT CODE : ALT315311

This unit covers sorting items using basic comparison measuring equipment, and maintaining the equipment. Measurements are conducted in a production environment or at a work station.

Work is undertaken autonomously or as part of teamwork. All comparative measurements are undertaken to standard operating procedures and to regulatory and legislative requirements

1. Identify job requirements
   • Job sheets or equivalent instructions are interpreted without error and in accordance with company standard operating procedures.
   • Determine what measuring equipment is needed
2. Set comparative measuring devices
   • Measuring equipment is set to specifications using manufacturer guidelines or standard operating procedures and techniques.
3. Use comparison and/or basic measuring devices
   • Basic measuring devices are identified and used to undertake required comparisons or measurements using standard operating procedures.
   • Checking or sorting of items is undertaken using comparison and/or basic measuring device according to standard operating procedures.
   • Measurements are documented and reported as per company standard operating procedures.
4. Maintain comparison and/or basic measuring devices
   • Basic care and storage is maintained according to manufacturers’ standards or standard operating procedures.

UNIT OF COMPETENCY : MEASURE COMPONENTS USING COORDINATE MEASURING MACHINES (CMM)
UNIT CODE : ALT315312

This unit applies where the operator is following established processes, practices and standard operating procedures and is responsible for providing dimensional detail required for adjustment or checking of the manufacturing process. Work is carried out autonomously using predetermined standards of quality and safety. Operators would be expected to have competence in basic setting and adjusting of machines.

1. Identify job requirements
   • Job sheets or equivalent instructions are interpreted without error and in accordance with company standard operating procedures.
2. Load components
   • Pre-start checks are undertaken to standard operating procedures.
   • Appropriate safety procedures are observed and safety equipment is checked for operation according to job requirements.
   • Appropriate fixture/clamping device are selected according to job requirements.
   • Component and fixtures are loaded and clamped in accordance with standard operating procedures.
3. Validate/calibrate precision measuring equipment
   • Calibration of precision measuring equipment is assessed to manufacturers’ specifications and/or standard operating procedures.
   • Equipment is calibrated according to physical standards using appropriate calibration devices, equipment, techniques based on predetermined procedures.
   • Equipment is recommissioned in accordance with standard operating procedures for precision measuring.
4. Set probes
   • Probe configuration is checked in accordance with 3 Set probes standard operating procedures.
   • Pre-measurement manual hits are taken for manual alignment in accordance with standard operating procedures.
5. Measure components
   • Part program is selected as required, run and verified according to standard operating procedures.
   • Components measurement is performed according to standard operating procedures.
   • Results are interpreted and non-conforming/out of tolerance measurements are identified and reported.
   • Part program is correctly shut down and components are removed according to standard operating procedures.
   • Coordinate measuring machine, accessories and surrounds are left in a clean, safe condition.

UNIT OF COMPETENCY : USE GRAPHICAL TECHNIQUES AND PERFORM SIMPLE STATISTICAL COMPUTATIONS
UNIT CODE : ALT315313

This unit covers interpreting and constructing graphs and charts from given or determined data, and performing basic statistical calculations. Application of the Graphs and charts may be applied to information from competency various work contexts, quality processes, production and market trends and other engineering applications. A range of devices may be used to assist with calculations.

1. Read and construct graphs
   • Complex information is extracted from graphical from given or determined representation.
   • Data is analyzed with respect to emerging trends.
   • Graphs are constructed as required from data and drawn with respect to scale and accepted method.
   • Significant features of graphical representation are understood such as limit lines, gradients (straight line graphs), intercepts, maximum and minimum values.
   • A wide variety of graphs are constructed as required including histograms, control charts, straight line graphs and parabolic graphs.
2. Perform basic statistical computation
   • Mean, median and mode are calculated from given calculations data.
   • Standard deviation is calculated.
   • Application of standard deviation and limits to process improvement techniques is understood.

COMMON COMPETENCIES (AUTOMOTIVE MANUFACTURING)

UNIT TITLE: READ, INTERPRET AND APPLY ENGINEERING DRAWINGS.
UNIT CODE: ALT742201

This unit deals with identifying, interpreting and applying specification from Engineering blue prints or drawings that provides the measurements of the product and pattern that is to be produced.

1. Identify and access engineering drawings/specification
   • Appropriate Engineering drawings are identified and accessed as per job requirements.
   • Version and date of drawing is checked to ensure correct specification and procedure are identified.
2. Interpret drawings
   • Relevant dimensions and sections of the drawings/specifications are located in relation to the work to be conducted
   • Information in the manual are interpreted in accordance to industry practices
3. Apply information in the drawings & specifications
   • Engineering drawing is interpreted according to job requirements
   • Work steps are correctly identified in accordance with the specifications in the drawings.
   • Dimensional data and shape are applied according to the given task
4. Store drawings
   • The drawings and specification are stored properly to ensure prevention of damage, ready access and updating of information when required in accordance with company requirements

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

This unit includes identifying, caring for, handling, using and maintaining 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 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 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 : PERFORM SHOP MAINTENANCE
UNIT CODE : ALT723204

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 supplies/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

• Accuracy – Accuracy designates the degree of agreement of the measured size with its true magnitude as expressed in standard units of measurement.
• Caliper gauges – Caliper gauges are measuring device with jaws establish the length to be measured by positive contact. One of the jaws is integral with the graduated beam, the other has markings to indicate the corresponding scale position.
• Dial indicators – Dial indicators are instruments used to accurately measure a small distance. These may be used to check the variation in tolerance during the inspection process of a machined part, measure the deflection of a beam or ring under laboratory conditions, as well as many other situations where a small measurement needs to be registered or indicated.
• Diffraction gratings – Diffraction gratings are transparent plates, usually made of glass, having a large number of equally  Spaced parallel lines.
  5. DMC (Dimensional Mark-up Language) – DMC (Dimensional Mark-up Language) is the release and ongoing development and testing a global language for metrology systems interfaces.
• Gauge blocks – Gauge blocks are precision ground and lapped measuring standards. They are used as references for the setting of measuring equipment such as micrometers, sine bars, dial indicators (when used in an inspection role).
• Line graduated master scales – Line graduated master scales is the basis for the operation of optical instruments for absolute length measurements.
• Line graduated rules – Line graduated rules are available in widely different degrees of accuracy to suit diverse requirements for plain length measuring tools.
• Metrology – Metrology designates the science of all measurements that are made by comparing the dimensionally measurable conditions of solids, or of diverse physical phenomena to generally accepted units of measurement. It is a branch of technology concerned with the measurement of geometrically defined dimensions of technical parts.
• Micrometer – Micrometer is a measuring device using rotation of the threaded spindle causes controlled advance of the spindle’s contact face relative to an integral reference face.
• Precision – Precision expresses the degree of repeatability of the measuring process. It designates how closely identical values are obtained when repeating the same measurement at various intervals, or duplicating them by means of different instruments.
• Random errors – Random errors are statistical fluctuations (in either direction) in the measured data due to the precision limitations of the measurement device.
• Sine bar – Sine bar is a hardened, precision ground body with two precision ground cylinders fixed at the ends. The distance between the centers of the cylinders is precisely controlled, and the top of the bar is parallel to a line through the centers of the two rollers.
• Standard deviation Standard deviation is the measure of the dispersion of a set of data from its mean. The more spread apart the data is, the higher the deviation.
• Tolerance – Tolerance is the allowable variance from a nominal value established by design engineers that is deemed non harmful to the functioning of the product.
• Coordinate measuring machine – A ‘coordinate measuring machine’ (CMM) is a device for measuring the physical geometrical characteristics of an object. This machine may be manually controlled by an operator or it may be computer controlled. Measurements are defined by a probe attached to the third moving axis of this machine. This probe touches the part of interest and allows collecting discrete points on the object’s surface.
• Go/No Go Device – A Go-No Go gauge (or Go/no go) refers to an inspection tool used to check a workpiece against its allowed tolerances. Its name derives from its use: the gauge itself has two tests; the check involves the workpiece’s having to pass one test (Go) and ‘fail’ the other (No Go).

  It is an integral part of the quality process that is used in the manufacturing industry to ensure interchangeability of parts between processes, or even between different manufacturers. A Go NoGo gauge is a measuring tool that does not return a size in the conventional sense, but instead returns a state. The state is either acceptable (the part is within tolerance and may be used) or it is unacceptable (and must be rejected).

  They are well suited for use in the production area of the factory as they require little skill or interpretation to use effectively and have few, if any, moving parts to be damaged in the often hostile production environment.

• Probe – A very common probe was made by soldering a hard ball to the end of a shaft. This was ideal for measuring a whole range of flat, cylindrical or spherical surfaces. Other probes were ground to specific shapes, for example a quadrant, to enable measurement of special features. These probes were physically held against the workpiece with the position in space being read from a 3-Axis digital readout (DRO) or, in more advanced systems, being logged into a computer by means of a footswitch or similar device. Measurements taken by this contact method were often unreliable as machines were moved by hand and each machine operator applied different amounts of pressure on the probe or adopted differing techniques for the measurement.