TINSMITHING (AUTOMOTIVE MANUFACTURING) NC II – TESDA COURSE MODULE

TESDA TRAINING REGULATIONS FOR TINSMITHING (AUTOMOTIVE MANUFACTURING) NC II

The TESDA Course in TINSMITHING (AUTOMOTIVE MANUFACTURING) NC II consists of competencies that a person must achieve to perform tinsmith operation in an automotive manufacturing work area.

Tinsmithing involves cutting, forming, straightening, and repairing sheet metal surfaces of vehicles. It also includes sanding and grinding the shaped or repaired metal surface and joints of welded or brazed to comply with the required finish. It also includes competencies on welding & brazing 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 TINSMITHING (AUTOMOTIVE MANUFACTURING) NC II is competent to be:

• Tinsmith (Automotive Manufacturing)

TINSMITHING (AUTOMOTIVE MANUFACTURING) NC II – TRAINING AND REGULATION MODULE

Course Title: TINSMITHING (AUTOMOTIVE MANUFACTURING)
Level: NC II
Nominal Training Duration : 126 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 such to perform tinsmith operation which includes welding & brazing in accordance with manufacturer’s specification. It also covers headlight focus aiming operations.

TRAINEE ENTRY REQUIREMENTS

Trainees or students should possess the following requirements:

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

COMPETENCIES REQUIRED IN TINSMITHING (AUTOMOTIVE MANUFACTURING) NC II

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

To obtain this TESDA course in TINSMITHING (AUTOMOTIVE MANUFACTURING) 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 (88 Hours)
ALT827314	Weld and Braze Automotive Body Shell
ALT827315	Perform Tinsmith Operation
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 : WELD AND BRAZE AUTOMOTIVE BODY SHELL
UNIT CODE : ALT827314

This unit covers the skills knowledge and attitudes required to perform welding and brazing operation including repair of defects on automotive body shells.

1. Prepare body shell for welding and brazing operation
   • Tools, equipment and PPEs are selected and prepared in accordance with standard operating procedures.
   • Body shell is checked for compliance with job requirement
   • Corrective measures are undertaken to rectify body shell errors and defects in accordance with standard operating procedures
   • Body shell is prepared based on standard operating procedure
2. Perform welding
   • Areas/Sections for welding are identified based on the standards/ job specification requirements
   • Welding is applied to designated areas/sections based on the standard welding procedure
   • Safety standards are followed in accordance with Occupational Health and Safety (OHS) requirements
3. Perform Brazing
   • Brazing tools, equipment and materials are prepared in accordance with the job requirements
   • Areas/Sections for brazing are identified based on the standards/ job specification requirements
   • Appropriate brazing jigs are installed in accordance with the job requirements
   • Brazing is applied to designated areas/sections based on the company standard
   • Brazed areas are ground and polished to the required finish in accordance with company standards
   • Safety standards are followed in accordance with Occupational Health and Safety (OHS) requirements

UNIT OF COMPETENCY: PERFORM TINSMITH OPERATION
UNIT CODE : ALT827314

This unit covers the skills, knowledge and attitudes required to install skin panels and perform metal finishing operation in automotive manufacturing.

1. Install skin panels
   • Tools and equipment are selected and prepared in accordance with standard operating procedures
   • Skin panels are checked for compliance with the job requirement
   • Skin panels are installed based on company standards procedures
   • Task is performed using appropriate PPE and without incurring damage to the body shell and skin panels
2. Inspect installed skin panels
   • Clearances and alignments of installed skin panels are checked for compliance with work specification
   • Bolt fitting of panel parts is checked based on company standard
   • Corrective measures are undertaken to rectify incorrect clearances and/or misalignment
3. Perform metal finishing operation
   • Inspect the main body shell based on the standard inspection procedure
   • Defects and/or damages are detected and marked or labeled after inspection in accordance with standard company procedures
   • Metal finishing operation is performed based on company standard
   • Finished main body shell is 100% free of any defects and damages

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

• Brazing – Brazing is a method of joining metal parts using nonferrous filler metals with high melting points such as copper, silver, and aluminum alloys. Brazing differs from soldering by using a higher temperature; and unlike welding, the parts are not melted. Brazing is best for dissimilar or thinner metal parts difficult to weld or solder.
• Dent – A dent is a depression in a surface made by pressure or a blow.
• File – The file is any of several hardened steel tools with cutting ridges for forming, smoothing, or reducing especially metallic surfaces.
• Impact gun – An impact gun is a pneumatic tool with attached sockets used to tighten and loosen screws or bolts.
• Jig – A jig is a device for guiding a tool or for holding machine work in place.
• Pry bar – A pry bar is a heavy steel bar, pointed at one end and shaped lie chisel at the other end; used for prying.
• Rubber mallet – The rubber mallet is a tool with a large head, used to strike a surface without damaging it.
• Sander – A sander is a machine having a powered abrasive-covered disk or belt, used for smoothing or polishing surfaces.
• Skin panel parts – Skin panel parts refers to the parts of the vehicle such as hood, trunk lid, LH-RH doors, LH-RH fender.
• Steel brush (wire) – A steel brush is a hard brush wire, providing a high fatigue life and durable cutting action. It is most appropriate for work on steel and iron work pieces, but may also be used on wood, aluminum, brass and copper; however the softer the material to be brushed, the more likely that a steel wire brush will cut into the material and remove base material in addition to the targeted coating or contamination.
• Tinsmith operation – Tinsmith operation is a part of the body shop section wherein the additional welding process, brazing application, sin panel installation, dent and other metal damages rectification are performed.
• Welding – Welding is the process of joining metals by applying heat, sometimes with pressure and sometimes with an intermediate or filler metal having a high melting point. It is the process of fastening two pieces of metal together by softening with heat and applying pressure.