MOLDMAKING NC II – TESDA COURSE MODULE

TESDA TRAINING REGULATIONS FOR MOLDMAKING NC II

The TESDA Course in MOLDMAKING NC II consists of competencies that a person must achieve to be able to machine parts using a variety of machining equipment and tools on plain carbon steel, heat resistant steel and other metals and alloy using different machining processes; perform precision assembly and testing complex engineering components and mechanical assemblies in a production, manufacturing environment. It also includes minor maintenance of equipment being used.

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

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

• Mold Maker

MOLDMAKING NC II – TRAINING AND REGULATION MODULE

Course Title: MOLDMAKING
Level: NC II
Nominal Training Duration : 106 Hours

This course is designed to enhance the knowledge, skills and attitudes of an individual to be able to machine parts using a variety of machining equipment and tools on plain carbon steel, heat resistant steel and other metals and alloy using different machining processes; perform precision assembly and testing complex engineering components and mechanical assemblies in a production, manufacturing environment. It also includes minor maintenance of equipment being used.

This course is also designed to enhance the basic and common knowledge, skills and attitudes of an individual in the field of foundry-pattern making.

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 experience in basic machining
• Ability to communicate both orally and in writing; and
• Physically and mentally fit

COMPETENCIES REQUIRED IN MOLDMAKING NC II

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

To obtain this TESDA course in MOLDMAKING 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 (68 Hours)
ALT722307	Machine Parts
ALT722308	Perform Precision Assembly
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 : MACHINE PARTS
UNIT CODE : ALT722307

This unit covers the competency required to use a range of equipment to machine parts

1. Determine job requirements
   • Drawings, job sheets or equivalent instructions are interpreted and understood
   • Workpiece materials are identified and prepared based on the specification listed.
   • Tools and equipment are selected and prepared in accordance with the requirements of the job.
   • Measuring equipment is calibrated to ensure accurate measurement within the tolerances specified.
2. Prepare machine for operation
   • Workpiece is set in accordance with standard operating procedures or manufacturer’s instruction
   • Cutting tools are selected and set based on the job specification
   • Machine controls are preset or adjusted to job specification.
   • Minor maintenance is carried out in accordance with company policy.
   • Measuring equipment is calibrated to ensure accurate measurement within the tolerances specified.
   • Machine speed and feed controls are adjusted in accordance with the specifications to suit the type of metal/alloy being machined
   • Machine is set in accordance with company or manufacturer procedures.
3. Machine Parts
   • Parts are machined and finished to specification using the appropriate machining process.
   • Parts are checked for tolerances specified in the standard operating procedures and to minimize waste.
   • Identified faults and defects are rectified in accordance with enterprise quality control standards to minimize wastage.
   • Machined parts are washed, inspected and dried to ensure they are cleaned and contain no waste in cavities or chambers.
   • Production schedule is maintained and recorded in accordance with company procedures
   • Safe working procedures are implemented in accordance with company procedures

UNIT OF COMPETENCY: PERFORM PRECISION ASSEMBLY
UNIT CODE : ALT722308

This unit covers assembling and testing complex engineering components and mechanical assemblies in a production, manufacturing environment.

1. Read and understand drawings, job sheets and specifications
   • Drawings, job instructions and specifications are interpreted and task requirements understood including settings in accordance with workplace procedures
   • Components/sub-assemblies are checked against specifications in the drawing, job sheet, assembly list or equivalent instructions.
   • Tools, equipment and components/sub-assemblies are selected to meet job requirements
   • Fitting requirements and sequential assembly planning are carried out where applicable.
2. Assemble components
   • Defective or faulty components/sub-assemblies are identified and processed according to standard operating procedure.
   • Components/sub-assemblies is correctly prepared for assembly.
   • Techniques and principles appropriate to the job requirements are applied in assembly activity.
   • Records/inputs are accurately maintained or processed.
   • Components of mold are fitted to ensure correct positioning and conformance with specifications.
   • Mold is tested to ensure that components interface/ interact according to operational specifications.
   • First-off sample products are evaluated and compared with standard of acceptance
3. Perform final adjustments
   • Final adjustments are performed on assembly to ensure alignment with operational specifications.
   • Faults are identified for rework or, where the fault is outside the scope of the workstation, processed according to standard operating procedure.
   • The assembly is correctly marked/tagged according to standard operating procedure.
   • Components and/or mold assembly are handled and stored according to standard operating procedures and in a manner least likely to cause damage.
   • Procedures are undertaken in response to emergency in accordance with workplace 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

• Machining – mechanical method used to precisely shape a work-piece by removing some of the work-piece material with tools having sharp and geometrically precise cutting edge
• Drilling – Making holes using rotary end cutting tool
• Milling – Removing metal using a milling cutter
• Turning – Removing material by facing a cutting tool against the surface of a rotating work piece. The tool may or may not be moved toward or along the axis of rotation while it cuts away material.
• Tapping – cutting internal thread with a tap
• Reaming – Enlarging a hole to desired size. The tool used is called a reamer
• Spot Facing – Machining a flat seat for a bolt head
• Counter bore – Drilling or boring a flat bottom hole often concentric with other holes
• Boring – A machining method using single point or multiple point tools to make holes other than drilling or enlarging a hole
• Planing – Producing flat surface on a metal by linear reciprocal motion of work and the table to which it is attached relative to a stationary cutting tool
• Shaping – Producing flat surface using simple point tool. The work piece is held in a vise or fixture
• Carbide tools – Cutting or forming tools usually made from Tungsten, titanium, niobium or a combination of them in a matrix of cobalt nickel or other metals
• Clearance – The gap or space between two mating parts.
• Interference – The difference in lateral dimension at room temperature between two mating components before assembly