METAL STAMPING NC II – TESDA COURSE MODULE

TESDA TRAINING REGULATIONS FOR METAL STAMPING NC II

The Metal Stamping NC II Qualification consists of competencies that a person must achieve to set up, conduct trial run and operate mechanical press; perform mechanical shearing operation which applies to a range of press operations including blanking, cutting-off, piercing/punching, trimming and bending; and perform mechanical press forming operation which applies to a range of press forming operations including piercing/punching, trimming, and forming/drawing.

A student who has achieved this TESDA Course in METAL STAMPING NC II is competent to be:

• Press worker; or
• Metal stamping press operator

METAL STAMPING NC II – TRAINING AND REGULATION MODULE

Course Title: METAL STAMPING NC II
Level: NC II
Nominal Training Duration : 294 Hours

This qualification is designed to develop knowledge, desirable attitudes and skills in Metal Stamping NC II Qualification specifically to set up, conduct trial run and operate mechanical press; perform mechanical shearing operation which applies to a range of press operations including blanking, cutting-off, piercing/punching, trimming and bending; and perform mechanical press forming operation which applies to a range of press forming operations including piercing/punching, trimming, and forming/drawing.

Basic competencies such as: Participate in workplace communication; Work in a team environment; Practice career professionalism; and Practice occupational health and safety 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.

• Must be high school graduate;
• Ability to communicate both orally and in writing; and
• Physically and mentally fit

COMPETENCIES REQUIRED IN METAL STAMPING NC II

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

To obtain this TESDA course in METAL STAMPING 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 (256 Hours)
MEE722301	Perform press machine setting
ALT722309	Perform mechanical shearing operation
ALT722310	Perform mechanical press forming operation
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 (18 Hours)
500311105	Participate in workplace communication
500311106	Work in a team environment
500311107	Practice career professionalism
500311108	Practice occupational health and safety procedures

CORE COMPETENCIES

UNIT OF COMPETENCY : PERFORM PRESS MACHINE SETTING
UNIT CODE : MEE722301

This unit covers the skills, knowledge and attitudes required to set-up press machines, conduct trial run, check the components for conformance to specification and replace worn/damaged tooling/dies. The unit applies to a range of press operations including blanking, cutting-off, piercing/punching, trimming, bending and forming/drawing.

1. Set up die on the press machine
   • Instructions are read, interpreted and understood correctly.
   • Prepare die, die accessories, die attachments, tools, installing bolts, transport and lifting equipment.
   • The die is set on the press machine according to standard operating procedure;
   • Machine accessories/ attachments are selected and installed to meet requirements of the operation.
   • Machine is adjusted to meet specifications and operational requirements.
2. Conduct trial run
   • Trial run is conducted in accordance with prescribed operating procedures
   • First-off samples are measured for compliance with quality standards, and adjustments are made to ensure compliance with specification
   • Safety practices are followed in accordance with OHS requirements
3. Replace worn/damaged tooling or dies
   • Abnormal machine operation is noted and reported to concerned personnel
   • Worn or damaged tooling is identified and reported as required
   • Safety practices are followed in accordance with OHS requirements

UNIT OF COMPETENCY : PERFORM MECHANICAL SHEARING PRESS OPERATIONS
UNIT CODE : ALT722309

This unit covers the skills, knowledge and attitudes required to conduct pre-start checks, select feed stock materials, operate and monitor basic press operations. The unit applies to a range of press operations including blanking, cutting-off, trimming and bending

1. Secure job order, part drawings and instructions
   • Job order and instructions are correctly interpreted and understood.
   • Dimensional and task requirements are understood including machine set up and parameters.
2. Conduct machine settings and set-up checks
   • Pre-start checks are undertaken to standard operating procedure.
   • Templates, stoppers and cutting guides are measured and installed firmly in place.
   • Safety procedures are observed and all safety equipment is checked for correct operation
   • Machine check up results are recorded in accordance with company procedures
3. Select steel feed stock materials
   • Materials are selected in conformance to job order specifications and instructions.
   • Materials stocks are counted to ensure availability of sufficient quantities of materials to meet job requirements
4. Perform shearing press operations
   • Machine is started up safely and correctly in accordance with standard operating procedures.
   • Machine is operated in accordance with job instructions or standard operating procedures.
   • Feed stock are loaded and maintained consistent with production requirements.
   • Machine output is unloaded safely to standard operating procedures.
   • Machine output is handled and stored in a manner not likely to cause damage.
   • Production data is recorded to standard operating procedures.
5. Monitor machine operation
   • Machine operation is monitored for safe and correct operation in accordance with standard operating procedures.
   • Deviations and faults are identified and reported in accordance with standard operating procedures.
   • Safety procedures and work practices are followed in accordance with Occupational Health and Safety (OHS) requirements.
   • Emergency procedures are understood and followed in accordance with standard operating procedures

UNIT OF COMPETENCY : PERFORM MECHANICAL PRESS FORMING OPERATIONS
UNIT CODE : ALT722310

This unit covers the skills, knowledge and attitudes required to conduct pre-start checks, select feed stock materials, operate and monitor forming press operations. The unit applies to a range of press forming operations including piercing/punching, trimming, and forming/drawing.

1. Secure job order, part drawings and instructions
   • Job order and instructions are correctly interpreted and understood
   • Dimensional and task requirements are understood including machine set up and parameters.
2. Conduct machine settings and set-up checks
   • Prior to machine start up, checks are carried out according to standard operating procedure.
   • Dies are checked for proper set-up, centering, clamping and stability.
   • Safety procedures are observed and all safety equipment is checked for correct operation
   • Machine check up results are recorded in accordance with workplace procedures
3. Inspect delivered steel feed stock materials
   • Delivered steel materials are inspected to assure conformance to job order specifications and instructions.
   • Materials stocks are counted to ensure availability of sufficient quantities of materials to meet job requirements.
4. Perform press operations
   • Inspect condition of die, clamping devices and machine set up before press machine is started up safely and correctly in accordance with standard operating procedures.
   • Machine is operated in accordance with job instructions or standard operating procedures.
   • Steel feed stock are loaded and maintained consistent with production requirements.
   • Machine output is inspected and unloaded safely to standard operating procedures.
   • Machine output is handled and stored in a manner not likely to cause damage.
   • Production data is recorded to standard operating procedure
5. Monitor machine operation
   • Machine operation is monitored for safe and correct operation in accordance with standard operating procedures.
   • Deviations and faults are identified and reported in accordance with standard operating procedures.
   • Safety procedures and work practices are followed in accordance with Occupational Health and Safety (OHS) requirements.
   • Emergency procedures are understood and followed in accordance with standard operating procedures

COMMON COMPETENCIES (AUTOMOTIVE MANUFACTURING)

UNIT OF COMPETENCY : 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 : 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 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

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 : DEVELOP CAREER AND LIFE DECISIONSUNIT 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

• Press – A machine by which pressure is applied to a workpiece to cut, pierce, bend or shape it
• Die – A tool used to impart shapes to or to form impressions on sheet metal
• Blanking – A press operation wherein metal sheets are cut into shapes by striking with a punch
• Bending – A press operation that involves forming a metal part into a curved or angular shape, or the stretching or flanging of it along a curved path
• Drawing – A press operation that forces plastic deformation of metal in a die to form recessed parts or cuplike shapes
• Drawing die – A die that forms sheet metal into cuplike, wrinkle-free shapes
• Feed stock – The raw material furnished to a press machine to form or shape the metal
• Trimming – Removing excess materials from drawn or blanked part
• Punching – A piece removed from a sheet metal or other material by a punch press
• Ram – A plunger, weight or other guided structure for exerting pressure by impact
• Shearing – Shearing is a metalworking process which cuts stock without the formation of chips or the use of burning or melting. Strictly speaking, if the cutting blades are straight the process is called shearing; if the cutting blades are curved then they are shearing-type operations.

  The most commonly sheared materials are in the form of sheet metal or plates, however rods can also be sheared. Shearing-type operations include: blanking, piercing, roll slitting, and trimming.

• Piercing – Piercing is a shearing process where a punch and die are used to create a hole in sheet metal or a plate. The process and machinery are usually the same as that used in blanking, except that the piece being punched out is scrap in the piercing process.

  There are many specialized types of piercing: lancing, perforating, notching, nibbling, shaving, cutoff, and dinking.