PRESS MACHINE OPERATION NC I – TESDA COURSE MODULE

TESDA TRAINING REGULATIONS FOR PRESS MACHINE OPERATION NC I COURSE

The TESDA Course in Press Machine Operation NC I consists of competencies that a person must achieve to set up and operate mechanical press to bend, notch, punch, draw, trim sheet metal to drawing specifications.

A student who has achieved this Course in PRESS MACHINE OPERATION NC I is competent to be:

• Press worker

TRAINEE ENTRY REQUIREMENTS

Trainees or students wishing to gain entry into this course in PRESS MACHINE OPERATION NC I should possess the following requirements:

• Must be high school graduate
• With good moral character
• Ability to communicate
• Physically and mentally fit

PRESS MACHINE OPERATION NC I – TRAINING AND REGULATION MODULE

Course Title: PRESS MACHINE OPERATION
Level: NC I
Nominal Training Duration : 294 Hours

This qualification is designed to develop knowledge, desirable attitudes and skills in Press Machine Operation NC I.

It covers the competencies required to perform mechanical press pre-production activities and perform basic mechanical press operations

COMPETENCIES REQUIRED IN PRESS MACHINE OPERATION NC I

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

To obtain this course, all units prescribed for this qualification must be achieved.

These units of competency comprising this qualification include the following:

UNIT CODE	CORE COMPETENCIES (Hours)
MEE722301	Perform press machine setting
MEE722302	Perform mechanical press operation
UNIT CODE	COMMON COMPETENCIES (Hours)
MEE722201	Apply safety practices
MEE722202	Interpret working drawings and sketches
MEE722203	Select and cut workshop materials
MEE722204	Perform shop computations (Basic)
MEE722205	Measure workpiece (Basic)
MEE722211	Perform preventive and corrective maintenance
UNIT CODE	BASIC COMPETENCIES (Hours)
500311101	Receive and respond to workplace communication
500311102	Work with others
500311103	Demonstrate Work Values
500311104	Practice Housekeeping Procedures

This section gives the details of the contents of the units of competency required in PRESS MACHINE OPERATION NC I. 

CORE COMPETENCIES

Core competency units comprising the qualification in PRESS MACHINE OPERATION NC I.

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

This unit covers the skills, knowledge and attitudes required to set press machine, 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 drawing.

1. Set up die and machine
   • Instructions are interpreted correctly and understood.
   • Die and machine is set in accordance with standard operating procedures
   • 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 specifications, 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 BASIC MECHANICAL PRESS OPERATIONS
UNIT CODE: MEE722302

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, piercing/punching, trimming, bending and drawing.

1. Secure job instructions
   • Instructions are correctly interpreted and understood
   • Task requirements are understood including machine selection and settings.
2. Conduct pre-start checks
   • Pre-start checks are undertaken to standard operating procedure
   • Safety procedures are observed and all safety equipment is checked for correct operation
3. Select feed stock materials
   • Materials are selected in accordance with job specifications, fitness for purpose and work order instructions.
   • Materials stocks are checked to ensure availability of sufficient quantities of materials to meet job requirements.
4. Perform 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

COMMON COMPETENCIES

UNIT OF COMPETENCY : APPLY SAFETY PRACTICES
UNIT CODE : MEE722201

This unit covers the competencies required to apply safety practices in the workplace.

1. Identify hazards
   • Hazards are identified correctly in accordance with OHS principles.
   • Safety signs and symbols are identified and adhered to.
2. Use protective clothing and devices
   • Appropriate protective clothing and devices correctly selected and used in accordance with OHS requirements or industry/ company policy.
3. Perform safe handling of tools, equipment and materials
   • Safety procedures for pre-use check and operation of tools and equipment followed in accordance with industry/ company policies.
   • Tools, equipment and materials handled safely in accordance with OHS requirements and industry/ company policies.
4. Perform first aid
   • First aid treatment of injuries are carried out according to recommended procedures.
5. Use fire extinguisher
   • Fire extinguisher selected and operated correctly according to the type of fire.

UNIT OF COMPETENCY : INTERPRET WORKING DRAWINGS And SKETCHES
UNIT CODE : MEE722202

This unit covers the competencies required to read and interpret drawings and sketches.

1. Interpret technical drawing
   • Components, assemblies or objects recognized as required.
   • Dimensions identified as appropriate.
   • Instructions identified and followed as required.
   • Material requirements identified as required.
   • Symbols recognized as appropriate in the drawing.
   • Tolerance, limits and fits identified in the drawing.
2. Prepare freehand sketch of parts
   • Sketch drawn correctly and appropriately.
   • Sketch depicted objects or part appropriately.
   • Dimensions indicated in sketch are clear and correct.
   • Instructions included in sketch are clear and correct.
   • Base line or datum points indicated as required.
3. Interpret details from freehand sketch
   • Components, assemblies or objects recognized as required.
   • Dimensions identified as appropriate.
   • Instructions identified and followed as required.
   • Material requirements identified as required.
   • Symbols recognized as appropriate in the drawing.

UNIT OF COMPETENCY : SELECT AND CUT WORKSHOP MATERIALS
UNIT CODE : MEE722203

This unit covers the skills and knowledge required to select and cut workshop materials.

1. Determine job requirement
   • Plans/ drawings are interpreted to produce component to specification.
   • Sequence of operation is determined to produce component to specification.
2. Select and measure materials
   • Materials are selected according to the requirement of the operation.
   • Materials are measured to required level of accuracy using measuring tools.
   • Measuring tools are used according to manufacturer’s specification.
3. Cut materials
   • Materials are cut according to plans/drawing instruction.
   • Cutting tools/ equipment are used based on manufacturers specification, appropriate techniques or the safety procedure.

UNIT OF COMPETENCY : PERFORM SHOP COMPUTATIONS (BASIC)
UNIT CODE : MEE722204

This unit covers the competencies required to perform
basic calculations using the four fundamental operation.

1. Perform four fundamental operations
   • Simple calculations are performed using four fundamental operations.
2. Perform basic calculations involving fractions and decimals
   • Simple calculations are performed involving fractions and decimals using the four fundamental operations.
   • Decimal are converted into fraction (and vice versa) accurately.
3. Perform basic calculations involving percentages
   • Simple calculations are performed to obtain percentages from information expressed in either fractional or decimal format.
4. Perform basic calculation involving ratio and proportion
   • Simple calculations are performed involving ratio and proportion using whole numbers, fractions and decimals.
5. Perform calculations on algebraic expressions
   • Simple calculations are performed on algebraic expressions using the four fundamental operations.
   • Simple transposition of formulae is carried out to isolate the variable required, involving the four fundamental operations.

UNIT OF COMPETENCY : MEASURE WORKPIECE (BASIC)
UNIT CODE : MEE722205

This unit covers the competencies required to measure workpieces using measuring instruments such as steel rule, Vernier caliper, micrometer, etc.

1. Select and use measuring tools
   • Measuring tools are selected and used according to the level of accuracy required.
   • Measurements taken are accurate to the finest graduation of the selected measuring instrument.
   • Measuring technique used is correct and appropriate to the device used.
2. Clean and store measuring tools
   • Care and storage of devices undertaken to manufacturer’s specifications or standard operating procedures.

UNIT OF COMPETENCY : PERFORM PREVENTIVE AND CORRECTIVE MAINTENANCE
UNIT CODE : MEE722211

This unit covers the knowledge and skills required in performing preventive and corrective maintenance such as inspection and repair of hand tools, cleaning and lubrication of machine parts and changing drive pulley and belts.

1. Perform inspection of machine
   • Machine inspected according to worksite procedures.
   • Status/Report recorded on proforma or reported orally according to worksite procedure.
2. Perform cleaning and lubricating of machine
   • Machines lubricated as per manufacturer’s recommendation using appropriate tools and materials
   • Fluids and lubricants replaced and/or topped up according to prescribed schedule.
3. Perform minor machine repair and adjustments
   • Minor machine repairs performed according to manufacturer’s instruction or worksite procedures.
   • Machine moving parts adjusted to manufacturer’s specifications.
4. Maintain hand tools
   • Cutting tools ground to recommended specifications
   • Hand tools lubricated and stored according to prescribed procedure

BASIC COMPETENCIES

UNIT OF COMPETENCY : RECEIVE AND RESPOND TO WORKPLACE COMMUNICATION
UNIT CODE : 500311101

This unit covers the knowledge, skills and attitudes required to receive, respond and act on verbal and written communication.

1. Follow routine spoken messages
   • Required information is gathered by listening attentively and correctly interpreting or understanding information/instructions
   • Instructions/information are properly recorded
   • Instructions are acted upon immediately in accordance with information received
   • Clarification is sought from workplace supervisor on all occasions when any instruction/information is not clear
2. Perform workplace duties following written notices
   • Written notices and instructions are read and interpreted correctly in accordance with organizational guidelines
   • Routine written instruction are followed in sequence
   • Feedback is given to workplace supervisor based on the instructions/information received

UNIT OF COMPETENCY : WORK WITH OTHERS
UNIT CODE : 500311102

This unit covers the skills, knowledge and attitudes required to develop workplace relationship and contribute in workplace activities.

1. Develop effective workplace relationship
   • Duties and responsibilities are done in a positive manner to promote cooperation and good relationship
   • Assistance is sought from workgroup when difficulties arise and addressed through discussions
   • Feedback provided by others in the team is encouraged, acknowledged and acted upon
   • Differences in personal values and beliefs are respected and acknowledged in the development
2. Contribute to work group activities
   • Support is provided to team members to ensure workgroup goals are met
   • Constructive contributions to workgroup goals and tasks are made according to organizational requirements
   • Information relevant to work is shared with team members to ensure designated goals are met

UNIT OF COMPETENCY : DEMONSTRATE WORK VALUES
UNIT CODE : 500311103

This unit covers the knowledge, skills, and attitude in demonstrating proper work values.

1. Define the purpose of work
   • One’s unique sense of purpose for working and the why’s of work are identified, reflected on and clearly defined for one’s development as a person and as a member of society.
   • Personal mission is in harmony with company’s values
2. Apply work values/ethics
   • Work values/ethics/concepts are classified and reaffirmed in accordance with the transparent company ethical standards, policies and guidelines.
   • Work practices are undertaken in compliance with industry work ethical standards, organizational policy and guidelines
   • Personal behavior and relationships with co-workers and/or clients are conducted in accordance with ethical standards, policy and guidelines.
   • Company resources are used in accordance with transparent company ethical standard, policies and guidelines.
3. Deal with ethical problems
   • Company ethical standards, organizational policy and guidelines on the prevention and reporting of unethical conduct are accessed and applied in accordance with transparent company ethical standard, policies and guidelines.
   • Work incidents/situations are reported and/or resolved in accordance with company protocol/guidelines.
   • Resolution and/or referral of ethical problems identified are used as learning opportunities.
4. Maintain integrity of conduct in the workplace
   • Personal work practices and values are demonstrated consistently with acceptable ethical conduct and company’s core values.
   • Instructions to co-workers are provided based on ethical, lawful and reasonable directives.
   • Company values/practices are shared with co-workers using appropriate behavior and language.

UNIT OF COMPETENCY : PRACTICE HOUSEKEEPING PROCEDURES
UNIT CODE : 500311104

This unit covers the knowledge, skills and attitudes required to apply the basic housekeeping procedures.

1. Sort and remove unnecessary items
   • Reusable, recyclable materials are sorted in accordance with company/office procedures
   • Unnecessary items are removed and disposed of in accordance with company or office procedures
2. Arrange items
   • Items are arranged in accordance with company/office housekeeping procedures
   • Work area is arranged according to job requirements
   • Activities are prioritized based on instructions.
   • Items are provided with clear and visible identification marks based on procedure
   • Safety equipment and evacuation passages are kept clear and accessible based on instructions
3. Maintain work area, tools and equipment
   • Cleanliness and orderliness of work area is maintained in accordance with company/office procedures
   • Tools and equipment are cleaned in accordance with manufacturer’s instructions/manual
   • Minor repairs are performed on tools and equipment in accordance with manufacturer’s instruction/manual
   • Defective tools and equipment are reported to immediate supervisor
4. Follow standardized work process and procedures
   • Materials for common use are maintained in designated area based on procedures
   • Work is performed according to standard work procedures
   • Abnormal incidents are reported to immediate supervisor
5. Perform work spontaneously
   • Work is performed as per instruction
   • Company and office decorum are followed and complied with
   • Work is performed in accordance with occupational health and safety (OHS) 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