COURSE OF STUDY AUTOMOTIVE TECHNICIAN (P-119-1) MODULE 01: WORKSHOP PRACTICE

Module Synopsis
This module is developed for students to acquire knowledge and skills in workshop practice. At the end of this module trainees will be able to : implement workshop safety and rules conduct fire extinguisher handling conduct first aid treatment arrange workshop tools and equipments conduct bench fitting activities conduct welding metal joining

Module Objectives:
Carry out workshop practice using workshop layout plan, safety signage, fire extinguisher, first aid kit, personal protection equipment (PPE), emergency rescue manual, tools inventory, bench fitting tools and equipment, hand tools set, measuring tools, material for fitting work, technical drawing equipment, project blue print, cutting tool, metal inert gas (MIG) welding machine set and arc welding machine set so that workshop safety rules implemented, fire extinguisher handling and first aid treatment conducted; workshop tools and equipments arranged; layout and marking work piece, material cutting, metal surface filing, metal drilling and tapping, inert gas (MIG) metal joining and arc welding metal joining conducted; in accordance with Standard Operating Procedure.

Module Content
Task No 01.01 01.03 01.05 01.02 01.04 Carry out workshop safety practices Carry out workshop tools maintenance Carry out workshop equipment management Carry out bench fitting activities Carry out basic welding activities

Module Objectives:
Carry out workshop practice using workshop layout plan, safety signage, fire extinguisher, first aid kit, personal protection equipment (PPE), emergency rescue manual, tools inventory, bench fitting tools and equipment, hand tools set, measuring tools, material for fitting work, technical drawing equipment, project blue print, cutting tool, metal inert gas (MIG) welding machine set and arc welding machine set so that workshop safety rules implemented, fire extinguisher handling and first aid treatment conducted; workshop tools and equipments arranged; layout and marking work piece, material cutting, metal surface filing, metal drilling and tapping, inert gas (MIG) metal joining and arc welding metal joining conducted; in accordance with Standard Operating Procedure.

Module Content

STEPS

KNOWLEDGE

PERFORMANCE

HRS

DELIVERY MODE

ASSESSMENT MODE

Module Objectives:
Carry out workshop practice using workshop layout plan, safety signage, fire extinguisher, first aid kit, personal protection equipment (PPE), emergency rescue manual, tools inventory, bench fitting tools and equipment, hand tools set, measuring tools, material for fitting work, technical drawing equipment, project blue print, cutting tool, metal inert gas (MIG) welding machine set and arc welding machine set so that workshop safety rules implemented, fire extinguisher handling and first aid treatment conducted; workshop tools and equipments arranged; layout and marking work piece, material cutting, metal surface filing, metal drilling and tapping, inert gas (MIG) metal joining and arc welding metal joining conducted; in accordance with Standard Operating Procedure.

Module Content
1. Implement workshop safety and rules 1.1 Workshop layout 1.2 Emergency exit, fire extinguisher, and first aid kit location 1.3 Safety signage 1.4 Concept of workshop-5S Organizing Clearing Standardizing Training Discipline 1.5 Basic workshop safety and rules 1.6 Types and purpose of personal protection equipment (PPE) 2 Lecture Knowledge (D) Performance (A/C) Determine workshop layout - emergency exit - fire extinguisher - first aid kit location - safety signage Practice 5S activities organizing clearing standardizing training discipline Practice workshop safety rules Wear workshop personal protection equipment Segregate types of workshop tools and equipment Store workshop tools

1.1 Determine workshop layout 1.2 Determine emergency exit, fire extinguisher, and first aid kit location 1.3 Interpret safety signage 1.4 Practice 5S activities Organizing Clearing

Demonstration and Observation

STEPS

KNOWLEDGE

PERFORMANCE
1.5 Practice workshop safety and rules 1.6 Wear workshop personal protection equipment (PPE) 1.7 Implement workshop housekeeping Attitude / safety Patient when practice 5S

HRS

DELIVERY MODE

ASSESSMENT MODE
Maintain tools and equipment - cleaning - oiling - storage Lay out work piece Use measuring and marking tools Mark work piece Set cutting tools Cut material work piece

STEPS
2. Conduct fire extinguisher handling

KNOWLEDGE
2.1 Purposes and classifications of fire extinguisher Types of fire Types of fire extinguisher 2.2 Procedures to operate fire extinguisher 2.3 Techniques of basic fire fighting

PERFORMANCE

HRS
2

DELIVERY MODE
Lecture

ASSESSMENT MODE
File metal to acquired reference edge File work piece according to blue print Measure work piece according to blue print Drill work piece Ream work piece Tap work piece Operate MIG machine Joint metal sheet with MIG welding Operate arc welding machine Joint metal sheet with arc welding

2.1 Determine types of fire extinguisher 2.2 Operate fire extinguisher Attitude / safety Meticulous when operating fire extinguisher

Demonstration and Observation

STEPS
3. Conduct first aid treatment

KNOWLEDGE
3.1 Types of first aid kit items 3.2 Usage of first aid kit items 3.3 Basic first aid treatment 3.4 Techniques of Cardio Pulmonary Resuscitation (CPR)

PERFORMANCE

HRS
2

DELIVERY MODE
Lecture

ASSESSMENT MODE

3.1 Handle first aid treatment 3.2 Apply Cardio Pulmonary Resuscitation (CPR) techniques Attitude/Safety: Cooperate with other departments Meticulous when conducting first aid treatment

Demonstration and Observation

4. Arrange workshop tools and equipments

4.1 Types of workshop tools and equipments 4.2 Usage of workshop tools and equipment 4.3 Workshop tools equipment inventory system

Lecture

STEPS

KNOWLEDGE
4.4 Procedure of workshop tools and equipments maintenance Inspection Cleaning Oiling Storage

PERFORMANCE

HRS

DELIVERY MODE

ASSESSMENT MODE

4.1 Segregate types of workshop tools and equipments 4.2 Store workshop tools and equipment 4.4 Record tools and equipment movements 4.5 Apply procedure of workshop tools and equipment maintenance Inspection Cleaning Oiling Storage Attitude/Safety: Meticulous when recording tools and equipment movements

Demonstration and Observation

STEPS
5. Conduct layout and marking work piece 5.1 5.2 5.3 5.4

KNOWLEDGE
Types of material Basic technical drawing Basic blue print Methods of laying out work piece 5.5 Types of measuring and marking tools 5.6 Marking work piece according to technical drawing

PERFORMANCE

HRS
2

DELIVERY MODE
Lecture

ASSESSMENT MODE

5.1 Interpret technical drawing 5.2 Interpret blue print 5.3 Lay out work piece 5.4 Use measuring and marking tools 5.5 Mark work piece Attitude/Safety: Handle tools and equipments movement with care Use proper PPE

Demonstration and Observation

STEPS
6. Conduct material cutting

KNOWLEDGE
6.1 Types of cutting tools 6.2 Techniques of using cutting tools 6.3 Procedures of metal cutting 6.4 Methods of metal cutting

PERFORMANCE

HRS
2

DELIVERY MODE
Lecture

ASSESSMENT MODE

6.1 Choose cutting tools 6.2 Set cutting tools 6.3 Cut material work piece Attitude/Safety: Wear PPE 7. Conduct metal surface filing 7.1 Reference edge 7.2 Types of file 7.3 Techniques of filing 7.1 Choose reference edge 7.2 Use measuring tool 7.3 Choose file 7.4 File metal to acquired reference edge 7.5 File work piece according to blue print 7.6 Measure work piece according to blue print Attitude/Safety: Wear PPE Meticulous when filing reference edge

Demonstration and Observation

3 6

Lecture Demonstration and Observation

STEPS
6. Conduct material cutting

KNOWLEDGE
6.1 Types of cutting tools 6.2 Techniques of using cutting tools 6.3 Procedures of metal cutting 6.4 Methods of metal cutting

PERFORMANCE

HRS
2

DELIVERY MODE
Lecture

ASSESSMENT MODE

6.1 Choose cutting tools 6.2 Set cutting tools 6.3 Cut material work piece Attitude/Safety: Wear PPE

Demonstration and Observation

STEPS
8. Conduct metal drilling and tapping

KNOWLEDGE
8.1 Types of drill bit, reamer and tapping tools 8.2 Techniques of drilling, reaming and tapping

PERFORMANCE

HRS
4

DELIVERY MODE
Lecture

ASSESSMENT MODE

8.1 Choose drill bit, reamer and tapping tools 8.2 Drill work piece 8.3 Ream work piece 8.4 Tap work piece Attitude/Safety: Accuracy when tapping work piece

Demonstration and Observation

10

STEPS
6. Conduct material cutting

KNOWLEDGE
6.1 Types of cutting tools 6.2 Techniques of using cutting tools 6.3 Procedures of metal cutting 6.4 Methods of metal cutting

PERFORMANCE

HRS
2

DELIVERY MODE
Lecture

ASSESSMENT MODE

6.1 Choose cutting tools 6.2 Set cutting tools 6.3 Cut material work piece Attitude/Safety: Wear PPE 9. Conduct inert gas (MIG) metal joining 9.1 Types of metal joint 9.2 Types of welding 9.3 Procedures of setting MIG machine 9.4 Technique of MIG welding 9.1 Distinguish types of metal joint 9.2 Prepare materials for MIG welding process 9.3 Operate MIG machine 9.4 Joint metal sheet with MIG welding Attitude/Safety: Accuracy when welding work piece

Demonstration and Observation

Lecture

Demonstration and Observation

11

STEPS
10. Conduct Arc Welding Metal Joining

KNOWLEDGE
10.1 Procedures of setting arc welding machine 10.2 Procedures of arc welding 10.3 Techniques of arc welding

PERFORMANCE

HRS
4

DELIVERY MODE
Lecture

ASSESSMENT MODE

10.1 Prepare materials for arc welding process 10.2 Operate arc welding machine 10.3 Joint metal sheet with arc welding Attitude/Safety: Use personal protection equipment Handle equipment with care

Demonstration and Observation

Core Abilities
01.04 Analyze information 01.05 Utilize the internet to locate and gather information 01.06 Utilize word processor to process information 04.01 Organize own work activities 04.04 Apply problem solving strategies

Selected References and Audio Visual Materials 12

REFERENCES 1. Anthony E.Schwaller (2004) Total Automotive Technology, 4th Edition-Delmar Learning, New York USA, ISBN: 1-4018-2476-5 2. A.K Chintale, RC Gupta (2007) Product Design and Manufacturing, Prentice-Hall (New Delhi), ISBN: 8120333179/IKB

AUDIO VISUAL MATERIALS

Tools, Equipment and Materials

ITEMS 1. Workshop layout plan 2. Workshop cleaning material 3. Safety signage 4. Fire extinguisher 5. First aid kit 6. Personal protection equipment (PPE) 7. Emergency rescue manual 8. Storage area 9. Tools inventory 10. Lubricant 11. Bench fitting tools and equipments 12. Hand tools set 13. Measuring tools 14. Material for fitting work 15. Technical drawing equipment 16. Workshop equipment 17. Project blue print 18. Files 19. Cutting tool 20. Metal Inert Gas (MIG) welding machine set 21. Arc welding machine set RATIO (Equipment : Trainees) 1:5 As required As required As required 1:5 1:1 1:5 As required 1:5 As required 1:5 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1 1:1

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