PAINTING MACHINE OPERATION NC II – TESDA COURSE MODULE

TESDA TRAINING REGULATIONS FOR PAINTING MACHINE OPERATION NC II

The TESDA Course in PAINTING MACHINE OPERATION NC II Qualification consists of competencies that a person must achieve to perform pre-treatment and cathodic electro-deposition process operations; perform gray primer (2nd primer) application procedures; and perform top coat  application procedures in accordance with manufacturer’s specification.

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

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

• Automotive Painting Machine Operator

PAINTING MACHINE OPERATION NC II – TRAINING AND REGULATION MODULE

Course Title: PAINTING MACHINE OPERATION
Level: NC II
Nominal Training Duration : 178 Hours

This course is designed to enhance the knowledge, skills and attitudes of an individual in the field of automotive manufacturing in accordance with industry standards. It covers competencies to perform cathodic electro-deposition process operations; perform gray primer (2nd primer) application procedures; and perform top coat application procedures in accordance with manufacturer’s specification.

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.

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

COMPETENCIES REQUIRED IN PAINTING MACHINE OPERATION NC II

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

To obtain this TESDA course in PAINTING MACHINE OPERATION 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 (140 Hours)
ALT827316	Perform Pre-treatment and Cathodic Electro-deposition Process Operation
ALT827317	Perform Gray Primer (2nd Primer) Application Procedures
ALT827318	Perform Top Coat Application Procedures
UNIT CODE	COMMON COMPETENCIES (20 Hours)
ALT311202	Perform Mensuration and Calculation
ALT742201	Read, Interpret and Apply Engineering Drawings
ALT723202	Move and Position Vehicle
ALT723201	Apply Appropriate Sealant/Adhesive
ALT723205	Perform Shop Maintenance
UNIT CODE	BASIC COMPETENCIES (18 Hours)
500311105	Participate in workplace communication
500311106	Work in a team environment
500311107	Practice career professionalism
500311108	Practice occupational health and safety procedures

CORE COMPETENCIES

UNIT OF COMPETENCY: PERFORM PRE-TREATMENT AND CATHODIC ELECTRODEPOSITION PROCESS (CEDP) OPERATION
UNIT CODE : ALT827316

This unit identifies the knowledge, skills and attitudes required to perform pre-treatment and CEDP operation.

1. Prepare body shell for pretreatment
   • Tools and materials are selected based on the requirements of the job.
   • Body shell is prepared for pre-treatment operation in accordance with company procedures
   • Body shell is inspected to ensure that it’s 100% free from defect and damage.
2. Perform pretreatment operation
   • Degreasing operation is performed in accordance with company standard operating procedures.
   • Phosphating operation is performed in accordance company standard operating procedure.
   • Excess phosphate is rinsed off in accordance with company standard operating procedure
3. Perform cathodic electrodeposition process (CEDP)
   • Cathodic electro-deposition process is performed in accordance company standard operating procedures
   • Painted main body shell is oven-baked in accordance company standard operating procedures.
   • Paint coat is checked to ensure compliance with company paint appearance and thickness requirements

UNIT OF COMPETENCY: PERFORM GRAY PRIMER (2nd Primer) APPLICATION PROCEDURES
UNIT CODE : ALT827317

This unit covers the knowledge, skills and attitudes required in the application of gray primer to ED body shell.

1. Perform underbody coating to the ED body shell.
   • Hand/air tools are selected based on the job requirement
   • Underbody is prepared for undercoating in accordance with company standard operating procedures
   • Undercoating is applied in accordance with company standard operating procedures
   • Vehicle is cleaned after undercoating application in accordance with company standard operating procedures.
   • ED body shell is checked for damage and other paint defects in accordance with company standard operating procedures
   • Corrective measures are undertaken to correct damage and other paint defects.
2. Install floor silencer
   • Floor silencer is selected in accordance with company standard operating procedures
   • Floor silencer is installed in accordance with company standard operating procedures
3. Apply drip and floor sealant
   • Surface is prepared for sealant application in accordance with company standard operating procedures
   • Sealant is applied based on the quality control guidelines and standards
   • Body shell is cleaned and excess sealants are removed in accordance with quality control guidelines and standards
4. Apply gray primer
   • Shell body is inspected for excess sealants and other paint defects in accordance with company standard operating procedures
   • Body shell is cleaned and prepared for gray primer application in accordance with company standard operating procedures.
   • Gray primer is mixed in accordance with standard ratio of paint and solvent
   • Gray primer is applied based on quality control standards of coating and spray patterns
   • Gray primer coat is checked for damage and/or paint defects and corrective measures are undertaken in accordance with company standard operating procedures
5. Bake the painted gray body shell
   • Baking oven equipment are checked and prepared in accordance with standard operating procedures
   • Body shell is baked as per company standard baking procedure
   • Baking temperature and baking time are monitored to ensure that the painted body surfaces are cured to the required hardness stated in the quality control standard
   • Baked gray primer body surfaces are inspected to ensure that they meet the required thickness and appearance as per quality control standard
   • Safety practices are Implemented in the workplace

UNIT OF COMPETENCY: PERFORM TOP COAT APPLICATION PROCEDURES
UNIT CODE : ALT827318

This unit covers the knowledge, skills and attitudes required to apply top coating (final coating) to vehicle body shell.

1. Perform wet sanding of gray primer body shell
   • Gray primer body shell is inspected and defects to be rectified are labeled as per company standard operating procedures.
   • Vehicle is prepared for wet sanding as per company standard operating procedures
   • Wet sanding is performed using pneumatic polisher as per company standard operating procedures.
   • Vehicle is rinsed and dried as per company standard operating procedures.
2. Apply top coat
   • Tools and equipment are prepared in accordance with job requirements
   • Gray body shell cleaned and prepared for top coat application based on company standard operation procedure
   • Paint is selected and/or mixed based on job requirements and company standard operation procedure
   • Top coat is applied based on the standard number of coating and spray pattern technique provided by the company
   • Applied top coat is checked for compliance with requirements
3. Bake the top coated body shell
   • Top coated body shell is baked to the required hardness and in accordance with company standard operating procedures
   • Top coated body shells are inspected to ensure that they meet the required appearance and thickness as per quality control standard
4. Perform top coat rectification procedures
   • Painting defects are identified and marked to ensure the correct method of repair
   • Painting defects are rectified and baked based on the required standard of the company
   • Repainted surfaces are polished and cleaned to ensure that they show no signs of defects and that they meet the quality standard for paint rectification

COMMON COMPETENCIES (AUTOMOTIVE MANUFACTURING – ASSEMBLY)

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

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

• Air velocity – Air velocity is the speed of air inside the painting spray booth.
• Asphalt undercoat – Asphalt undercoat is the use of seal consisting of a coating of a tar or rubber like material on the underbody of a motor vehicle to retard corrosion.
• Baking oven – The baking oven is the equipment used to dry paint in order to attain the standard paint hardness.
• Cathodic electrodeposition process – The CEDP or Cathodic Electro-Deposition Process is the process of immersing the unit into the ED tank of paint to highly prevent corrosion. It is also done to attain the superior paint coating up to the hidden/innermost portions of the unit.
• De-ionized water – De-ionized water is water that lacks ions, such as cations from sodium, calcium, iron, copper and anions such as chloride and bromide. This means it has been purified from all other ions except H3O+ and OH−, but it may still contain other non-ionic types of impurities such as organic compounds. This type of water is produced using an ion exchange process. De-ionized water is similar to distilled water, in that it is useful for scientific experiments where the presence of impurities may be undesirable.
• Degreasing – Degreasing is the process of removing grease or oil and other foreign matter on the body surface.
• Filter cloth – A filter cloth is the material used to eliminate foreign matter such as dirt on the paint material.
• Floor silencer – The floor silencer is a material used to reduce sound, noise, and underbody vibration of the unit.
• Ford cup # 4 – The Ford Cup # 4 is an instrument used to measure the paint viscosity.
• Lacquer thinner – Lacquer thinner is used to dilute, dissolve and clean up lacquer products. Typically too caustic for oil paints, lacquer thinner is often used for removing inks on metal, and adhesive residue from a variety of surfaces. Lacquer thinner is very strong and rapidly deteriorates many surfaces and fabrics. Always test in a small inconspicuous area before applying too liberally on a large surface.
• Naptha solvent – Naptha Solvent is Any of several highly volatile, flammable liquid mixtures of hydrocarbons distilled from petroleum, coal tar, and natural gas and used as fuel, as solvents, and in making various chemicals.
• Painting – Painting is the process, art, or occupation of coating surfaces with paint for a utilitarian or artistic effect.
• Paint reducer – Paint reducer is used in paint mixing to attain the required viscosity.
• Paint viscosity – Paint Viscosity is the condition or property of paint to be viscous; the resistance of paint to shear forces (and hence to flow).
• Phosphate  application – Phosphate application is done to make phosphate serve as the base for coating and make it an integral part of metal. It also provides adhesion and coating flexibility. It also increases the resistance to corrosion.
• Pneumatic polisher – A pneumatic polisher is an instrument activated by air pressure. It is the hand tool used in wet sanding operation of the gray primer.
• Polishing compound – The polishing compound is the material used to smoothen the paint applied to increase the glossy appearance of the top coat paint.
• Pressure tank – A pressure tank is a closed cylindrical steel container designed to store water under pressure. It is an equipment supplied with air pressure that is designed to contain paint used in painting application.
• Primer paint – Primer Paint is the first or preliminary coat of paint or size applied to a surface.
• Sealer – A sealer seals, as an undercoat of paint or varnish used to size a surface. It is also a kind of sealing material that is used to form a hard coating on a porous surface (as a coat of paint or varnish used to size a surface).
• Spray booth – Spray Booth means a power-ventilated structure that encloses or accommodates a spraying operation so that spray vapour and residue can be controlled and exhausted.
• Spray gun – The spray gun is a an applicator resembling a gun for applying liquid substances (as paint) in the form of a spray
• Thermocouple – A thermocouple is a thermoelectric device used to measure temperatures accurately, especially one consisting of two dissimilar metals joined so that a potential difference generated between the points of contact is a measure of the temperature difference between the points.
• Wet sanding – Wet sanding is a painting process wherein the gray primer is sanded with a pneumatic polisher and water.