C

Coou
urrsse
eCCu
urrrriiccu
ulla
a

ffo
orr

S
Shho
orrtt T
Teerrm
mCCo
ouurrsse
ess b
baasse
eddo
onn
M
Mood
duulla
arr E
Emmp oy
pllo ya
abblle
eSSk
kiillllss ((M
MEES
S))

iin
n

Plastic Processing Sector

D
DIIR
REEC
CTTO
ORRA
ATTE
EGGE
ENNE
ERRA
ALL O
OFFE
EMMP
PLLO
OYYM
MEEN
NTTA
ANND
DTTR
RAAIIN
NIIN
NGG
M
MIIN
NIIS
STTR
RYYO
OFF LLA
ABBO
OUUR
R&&E
EMMP
PLLO
OYYM
MEEN
NTT
G
GOOV
VEER
RNNM
MEEN
NTTO
OFF IIN
NDDIIA
A

0
 Course Curricula for Short Term Courses based on Modular
Employable Skills (MES) in the Plastic Processing Operator Sector

CONTENTS

1. Background ........................................................................................................... 2
2. Frame Work for Skill Development based on Modular Employable Skills ......... 2
3. Age of Participants ................................................................................................ 3
4. Curriculum Development Process ........................................................................ 3
5. Development of Core Competencies.................................................................... 3
6. Duration of the Programmes................................................................................. 4
7. Pathways to acquire Qualification ........................................................................ 4
8. Methodology ......................................................................................................... 5
9. Instructional Media Packages ............................................................................... 5
10. Assessment .......................................................................................................... 5
11. Certificate .............................................................................................................. 5
12. Course Matrix........................................................................................................ 6
13. Modules .............................................................................................................. 7
14. Basic Fitting & Measurement…………………………………………………………7
15. Basic Electrical Joints & Fitting ……………………………………………………….8
16. Plastic Mould assistant for injection moulding ..... …………………………………..9
17. Plastic mould assistant for Compression moulding .... ……………………………10
18. Plastic mould assistant for Extrusion Moulding…………… .. …………………….11
19. Plastic mould assistant for Blow moulding…… ..... …………………………..……12
20. Auto Plastic mould assistant ( injection moulding)………………………………..13
21. Auto Plastic mould assistant ( compression moulding)……………………… ..... 14
22. Auto Plastic mould assistant ( extrusion moulding)………………………… ....... 15
23. Auto Plastic mould assistant ( blow moulding)……………………………… .... …16
24. List of Expert/Trade Committee Members .......................................................... 19

1
 Skill Development based on Modular Employable Skills (MES)

Background

The need for giving emphasis on the Skill Development, especially for the less
educated, poor and out of school youth has been highlighted in various forums. The skill level
and educational attainment of the work force determines the productivity, income levels as
well as the adaptability of the working class in changing environment. Large percentage of
population in India is living below poverty line. One of the important causes is lower
percentage of skilled persons in the workforce

The skill development at present is taking place mostly in the informal way, i.e. persons
acquire skill at the work-place when they help their parents, relatives and employers etc.
Such persons do not have a formal certificate and thus earn lower wages and are exploited by
employers. They have come through informal system due to socio-economic circumstances
of the family and the compulsions of earning a livelihood rather than attending a formal
course. While their productivity is low, their contribution to the national GDP cannot be
ignored. If the country can create a system of certification which not only recognizes their
skills but also provides education and training in a mode that suits their economic
compulsions, it will not only benefit the workforce to earn a decent living but also contribute to
the national economy by better productivity of this workforce.

Another related problem to be tackled is large number of students drop outs (About
63% of the school students drop out at different stages before reaching Class-X).

Frame work for Skill Development based on ‘Modular Employable Skills (MES)’

Very few opportunities for skill development are available for the above referred groups
(out of school youth & existing workers especially in the informal sector). Most of the existing
Skill Development programmes are long term in nature. Poor and less educated persons can
not afford long term training programmes due to higher entry qualifications, opportunity cost
etc. Therefore, a new frame work for Skill Development for the Informal Sector has been
evolved by the DGET to address to the above mentioned problems. The key features of the
new frame work for skill development are:

› Demand driven Short term training courses based on modular employable skills
decided in consultation with Industry
› Flexible delivery mechanism (part time, weekends, full time)
› Different levels of programmes (Foundation level as well as skill upgradation) to meet
demands of various target groups
› Central Government will facilitate and promote training while Vocational Training (VT)
Providers under the Govt. and Private Sector will provide training
› Optimum utilisation of existing infrastructure to make training cost effective.
› Testing of skills of trainees by independent assessing bodies who would not be involved
in conduct of the training programme, to ensure that it is done impartially.
› Testing & certification of prior learning (skills of persons acquired informally)

2
The Short Term courses would be based on ‘Modular Employable Skills (MES)’.
The concept for the MES is :
‰ Identification of ‘minimum skills set’ which is sufficient to get an employment in the labour
market.
‰ It allows skills upgradation, multiskilling, multi entry and exit, vertical mobility and life long
learning opportunities in a flexible manner.
‰ It also allows recognition of prior learning (certification of skills acquired informally)
effectively.
‰ The modules in a sector when grouped together could lead to a qualification equivalent to
National Trade Certificate or higher.
‰ Courses could be available from level 1 to level 3 in different vocations depending upon
the need of the employer organisations.
‰ MES would benefit different target groups like :
o Workers seeking certification of their skills acquired informally
o workers seeking skill upgradation
o early school drop-outs and unemployed
o previously child labour and their familly

Age of participants

The minimum age limit for persons to take part in the scheme is 14 years but there is no
upper age limit.

Curriculum Development Process

Following procedure is used for developing course curricula

• Identification of Employable Skills set in a sector based on division of work in the labour
market.
• Development of training modules corresponding to skills set identified so as to provide
training for specific & fit for purpose
• Organization of modules in to a Course Matrix indicating vertical and horizontal mobility.
The course matrix depicts pictorially relation among various modules, pre requisites for
higher level modules and how one can progress from one level to another.
• Development of detailed curriculum and vetting by a trade committee and by the NCVT

(Close involvement of Employers Organizations, State Governments, experts, vocational

training providers and other stake holders is ensured at each stages).

Development of Core Competencies

Possession of proper attitudes is one of the most important attribute of a competent person.
Without proper attitudes, the performance of a person gets adversely affected. Hence,
systematic efforts will be made to develop attitudes during the training programme.

The trainees deal with men, materials and machines. They handle sophisticated tools and
instruments. Positive attitudes have to be developed in the trainees by properly guiding them
3
and setting up examples of good attitudes by demonstrated behaviors and by the environment
provided during training.

Some important core competencies to be developed are:

1. Safety consciousness and safe working practices

2. Care of equipment and tools
3. Punctuality, discipline and honesty
4. Concern for quality
5. Respect for rules and regulations
6. Concern for health and hygiene
7. Cordial relationship and Cooperation with co-workers and team Work
8. Positive attitude and behavior
9. Responsibility and accountability
10. Learn continously
11. Communication Skills
12. Concern for environment and waste disposal
Following competencies should also be developed during level-II and higher courses:
1. Ability for planning, organizing and coordinating
2. Creative thinking, problem solving and decision making
3. Leadership
4. Ability to bear stress
5. Negotiation

Duration of the Programmes

Time taken to gain the qualification will vary according to the pathway taken and will be kept
very flexible for persons with different backgrounds and experience. Duration has been
prescribed in hours in the curriculum of individual module, which are based on the content and
requirements of a MES Module. However, some persons may take more time than the
prescribed time. They should be provided reasonable time to complete the course.

Pathways to acquire Qualification:

Access to the qualification could be through:

ƒ An approved training programme; Or

ƒ A combination of an approved training programme plus recognition of prior
learning including credit transfer; Or
ƒ The recognition of prior learning that provides evidence of the achievement of the
competencies for the qualification.

4
Methodology
The training methods to be used should be appropriate to the development of competencies.
The focus of the programme is on “performing” and not on “Knowing”. Lecturing will be
restricted to the minimum necessary and emphasis to be given for ‘hands on training’.

The training methods will be individual centered to make each person a competent one.
Opportunities for individual work will be provided. The learning process will be continuously
monitored and feedback will be provided on individual basis.

Demonstrations using different models, audio visual aids and equipment will be used
intensively.

Instructional Media Packages

In order to maintain quality of training uniformly all over the country, instructional media
packages (IMPs) will be developed by the National Instructional Media Institute (NIMI),
Chennai.

Assessment

DGE&T will appoint assessing bodies to assess the competencies of the trained persons.
The assessing body will be an independent agency, which will not be involved in conducting
the training programmes. This, in turn, will ensure quality of training and credibility of the
scheme. Keeping in view the target of providing training/testing of one million persons through
out the country and to avoid monopoly, more than one assessing bodies will be appointed for
a sector or an area.

Certificate
Successful persons will be awarded certificates issued by National Council for Vocational
Training (NCVT).

5
 Course Matrix

Course Module for Plastic Processing

Plastic Mould Plastic Mould Plastic Mould Plastic Mould

asstt for assistant for assistant for assistant for
Level – III Auto Injection Auto Compre- Auto Extrusion Auto Blow
moulding- ssion moulding moulding moulding
PP-AI-III PP- AC-III PP-AE-III PP-AB-III

Plastic Mould Plastic mould Plastic mould Plastic mould

assistant for assistant for assistant for assistant for
Level – II Injection Compression Extrusion Blow
moulding moulding Moulding moulding
PP-AI-II PP-AC-II PP-AE-II PP-AB-II

Basic Fitting and Basic Electrical

Level – I Measurement Joints & fitting
PP-FM-I PP-EJ-I
MODULES

Basic Fitting and Measurement

* Name : Basic Fitting and Measurement

* Sector : Plastic Processing Industries

* Code : PLA101

* Terminal Competency: On Completion of training the trainee will be able to:

a) Use of fitter’s hand tools, marking of job as per drawing, filing, hack
sawing, chipping, drilling, manufacturing of individual components
with in an accuracy of ± 0.1 mm.
(b) Assembly of individual components maintaining interchangeability.

* Duration : 120 hours

* Entry requirement: a) Qualification: V th class.

b) Age: Minimum 14 years.
Course Contents:
Practical Competencies Underpinning Knowledge (Theory)
● Familiarisation with tools and equipment ● Importance of general safety, machine &
used in the trade. electrical safety, shop floor safety observed
● Carry out safe working practices and while working in work shop.
demonstrate the use of safety devices ● Description of different kinds of hand tools
● Marking out of straight and parallel lines used in bench work - bench vice & hack -
with the help of odd leg calipers, steel rule, saw frames, hacksaw blade, marking &
scribing blocks, dividers and hack sawing punching tools, chisels, their types use,
to a given dimension of different types of care and maintenance.
metals of different sections. ● Hammer, punch and chisel-their types and
●Filling flat and square to a given dimension use.
to an accuracy of ±0.1 mm. ● Description of Files- their grades, cuts and
● Chipping flat surface along a marked line. uses.
● Marking and drilling of holes on flat ● Drilling machine and its types - Bench
surface, finding centre of round bar with type, pillar type, radial type, gang and
the help of ‘V’ according to drawing. multi spindle drilling machine.
● Forming external & internal threads with ● Measuring instruments – vernier caliper,
taps & dies. micrometer, height gauges, dial gauge,
● Exercise on measuring instruments such as bevel protector – with its least count
for linear measurement - steel rule, caliper, calculation.
height gauge & for cylindrical diameter – ● Description and use of Taps and Die.
micrometer (inside & outside)
● Exercise on angular measuring instruments
using combination set & vernier bevel
protector.
● Finish different components individually
and assembling them as per drawing
maintaining interchangeability.

7
 Basic Electrical Joints & fitting

* Name : Basic Electrical Joints & fitting

* Sector : Plastic Processing Industries

* Code : PLA102

* Terminal Competency: On Completion of training the trainee will be able to:

(a) Fix and connect electrical accessories such as switches, holders,
fuse, plugs, sockets etc.
(b) Study of simple electrical circuit (series and parallel) and
knowledge
of electrical measuring instrument its function and use.

* Duration : 120 hours

* Entry requirement: a) Qualification: V th class.

b) Age: Minimum 14 years.
*Course Contents:

Practical Competencies Underpinning Knowledge (Theory)

● Demonstration about use of safety ● Safety precaution and first aid for electric
equipments and artificial respiration. shock. Common terms used in electrical
● Use of electrical hand tools. work conductors and insulators.
● Safety precaution about electric joints and ● Electrical Units, insulation and resistance,
electric instruments. ohms law and its application.
● Measurements of electric current, voltage, ● Basic concept about simple electrical
power and energy by using voltmeter, circuit - essential requirements of electrical
ammeter, wattmeter and energy meter. circuit–series and parallel, different types
● Practice in fixing and connecting electrical of resistance, fuses, earthing etc.
accessories such as switches, holders, fuse, ● Types, grades and size of insulated wires
plug and sockets on extension boards. and cables – their proper selection and use.
● Forming a simple electrical circuits (series
and parallel ) measuring insulation
resistance and earth resistance.

8
 Plastic Mould Assistant (Injection Molding)

* Name : Plastic Mould Assistant (Injection Molding)

* Sector : Plastic Processing Industries

* Code : PLA203

* Terminal Competency: On Completion of training the person will be able to :

(a) Manually operate plastic processing Injection
Moulding machine.
(b) Help to running maintenance of manually operate Injection
Moulding machine.

* Duration : 120 hours

* Entry requirement : a) Qualification: V th class & MES Modules on Basic Fitting and
Measurement / Basic Electrical Joints & fitting
b) Age : Minimum 14 years.

*Course Contents:

Practical Competencies Underpinning Knowledge (Theory)

● Demonstration about personal, machine ● Importance of safety and general precautions
& electrical safety while working on hand observed in plastic processing work shop.
operated injection Moulding machine. ● Hand operated Plastic processing Injection
● Familiarisation with the mechanical & Molding Machine’s different parts of mould,
electrical system of hand operated construction, their function and moulding
Injection moulding machine and its techniques.
different parts and their respective ● Definition, types, properties and uses of
functions. polymer substance such as wood, plastic,
● Operating and controlling of hand rubber, fibers etc.
operated Injection Moulding Machine in ● Group of plastics - Thermoplastic– its
ideal run observation (IRO) - Fitting of properties use and application.
mould injector, locking and cooling of ● Low and high density polyethylene,
mould, adjusting feed of screw or ram, polypropylene their properties use and
Temperature controlling, fitting and application.
adjusting nozzle, injector pressure and ● Styrene group of plastic ABS, SAN, PVC,
speed). Nylon group, Polycarbonate - properties, uses
● Operating and controlling of hand and application.
operated Injection Moulding Machine in
Trial Run Observation (TRO) using
thermoplastic material as available.
● Operating and controlling of hand
operated Injection Moulding Machine in
Trial Run Observation (TRO) using
thermosetting material as available.
●Oiling, Lubrication and preventive
maintenance of hand operated injection
moulding machine.
Identification and Testing of plastic.

9
 Plastic Mould Assistant (Compression Moulding)

* Name : Plastic Mould Assistant (Compression Moulding)

* Sector : Plastic Processing Industries

* Code : PLA204

* Terminal Competency : On Completion of training person will be able to:

(a) Manually operate plastic processing Compression Moulding
machine.
(b) Help to running maintenance of manually operate Compression
Moulding machine.

* Duration : 120 hours

* Entry requirement: a) Qualification: V th class & MES Modules on Basic Fitting and
Measurement / Basic Electrical Joints & fitting
b) Age : Minimum 14 years.

*Course Contents:
Practical Competencies Underpinning Knowledge (Theory)
● Demonstration about personal, machine & ● Importance of safety and general
electrical safety while working on precautions observed in plastic processing
compression molding machine. work shop.
● Familiarisation with mechanical & electrical ● Hand operated compression moulding
system of hand operated compression machine – its construction, different parts -
moulding machine - different Parts and their their function and moulding technique.
respective functions. ● Thermosetting plastic material phenol
● Operating and controlling of hand operated formaldehyde (PE) urea formaldehyde
compression moulding machine in IRO (UF) melamine formaldehyde (MF)
(movement of platen top or bottom polyester based resin – its various form,
adjustment and control, adjusting pressure in properties, use and application.
terms of per – square area, total tonnage, ● Basic parts of mould and its construction
fitting and heating of modules controlling details.
temperature, checking of bulk factor/ density ● Moulding defects and their remedies.
etc.) ● Identification of plastic
● Operating and controlling of hand operated ● Different plastic testing machines.
compression moulding machine in IRO
using thermoplastic and thermosetting
material as available.
●Oiling, lubricating and preventive
maintenance of hand operated compression
moulding machine.
● Testing method of plastics.

10
 Plastic Mould Assistant (Extrusion Moulding)

* Name of the Module : Plastic Mould Assistant (Extrusion Moulding)

* Sector : Plastic Processing Industries

* Code : PLA205

* Terminal Competency : On Completion of training the trainee will be able to:

(a) Manually operate plastic processing Extrusion Moulding machine.
(b) Help to running maintenance of manually operate Extrusion
Moulding machine.

* Duration : 120 hours

* Entry requirement : a) Qualification: V th class MES Modules on Basic Fitting and

Measurement / Basic Electrical Joints & fitting
b) Age : Minimum 14 years.

* Course Contents:

Practical Competencies Underpinning Knowledge (Theory)

● Demonstration about personal, machine & ● Importance of safety and general
electrical safety while working on hand precautions observed in plastic processing
operated extrusion molding machine. work shop.
● Familiarisation with mechanical & electrical ● Hand operated Eaxtrusion machine – its
system of Extrusion machine and its construction, different parts - their function
different parts and their respective functions. and moulding technique.
● Operating of hand operated Extrusion ● Knowledge of multilayer extrusion.
machine in IRO (Changing and cleaning of ● Thermoplastic- polybutylene terephthalate
screws in extruder, adjusting and (PBT), polyethylene terephthalate (PET)-
controlling temperature, adjusting screen their description, properties and
pack arrangement, adjusting variable speed, use in hand operated extrusion moulding
setting and adjusting die head for profile and process.
film etc.) ● Polyester resin- its properties and use.
● Operating and controlling of hand operated ● Expxy resin- its properties and use.
Extrusion Machine in (TRO) using ● Printing technique involved in pipe.
thermoplastic and thermosetting material ● Preventive maintenance, oiling and
as available. lubrication of hand operated extrusion
● Oiling, lubricating and preventive machine.
maintenance of hand operated extrusion
moulding machine.
● Identification and testing of plastic.

11
 Plastic Mould Assistant (Blow Moulding)

* Name of the Module : Plastic Mould Assistant (Blow Moulding)

* Sector : Plastic Processing Industries

* Code : PLA206

* Terminal Competency: On Completion of training the trainee will be able to:

(a) Manually operate plastic processing Blow Moulding machine.
(b) Help to running maintenance of manually operate Blow Moulding
machine.

* Duration : 120 hours

* Entry requirement : a) Qualification: V th class & MES Modules on Basic Fitting

and Measurement / Basic Electrical Joints & fitting
b) Age : Minimum 14 years.

* Course Contents :

Practical Competencies Underpinning Knowledge (Theory)

● Demonstration about personal, machine & ● Importance of safety and general
electrical safety while working on hand precautions observed in plastic processing
operated blow molding machine. work shop.
● Familiarization with mechanical & Electrical ● Hand operated Blow moulding machine –
system of Blow- Molding Machine and its its construction, different parts - their
different parts and their respective functions. function and moulding technique.
● Operating and controlling of hand operated ● Polymer - their properties, use and
Blow-Molding Machine in IRO(Setting of application of LDPE,HDPE,PET, PC.
die, adjusting mandrel, controlling and ● Foamed plastic - its properties, use and
adjusting thickness uniformity). application.
● Operating and controlling of hand operated ● Knowledge of multilayer extrusion blow
Blow-Molding Machine in TRO using moulding, extrusion stretch blow moulding,
thermoplastic and thermosetting material press blow moulding for squeezable
as available. container.
● Preventive maintenance of hand operated ● Preventive maintenance, oiling and
blow-molding machine-oiling and lubrication of hand operated Blow
Lubrication. Moulding Machine.
● Testing of mechanical properties-operating ● Foamed plastic- its properties, use and
testing machine to determine tensile impact, application.
elongation and compressive strength. ● Thermoforming – its properties and use.
● Cup flow testing identification of various ● Concept of different testing machines and
plastic in relation to properties. their use for testing and quality control
with respect to manufacturing parameters.

12
 Auto Plastic Mould Assistant (Injection Molding)

* Name : Auto Plastic Mould Assistant (Injection Molding)

* Sector : Plastic Processing Industries

* Code : PLA307

* Terminal Competency: On Completion of training the trainee will be able to:

(a) Operate plastic processing auto injection Moulding machine.
(b) Help to running maintenance of auto injection Moulding machine.

* Duration : 120 hours

* Entry requirement: a) Qualification: V th class + MES Modules on Basic Fitting and

Measurement / Basic Electrical Joints & fitting /Plastic Mould Assistant
(Injection Molding)/Plastic Mould Assistant (Compression
Moulding)/Plastic Mould Assistant (Extrusion Moulding)/Plastic Mould
Assistant (Blow Moulding)
b) Age : Minimum 14 years.

*Course Contents:

Practical Competencies Underpinning Knowledge (Theory)

● Demonstration about personal, machine, ● Importance of safety and general precautions
electrical & hydraulic safety while observed in plastic processing work shop.
working on semi-auto & auto injection ● Types of semi-automatic & automatic Injection
Moulding machine. Molding Machine their different parts,
● Familiarisation with the mechanical, construction and their function and moulding
electrical and hydraulic system of techniques.
semi automatic & automatic Injection ●Nomenclature of moulds - its types and
moulding machine and its different parts material.
and their respective functions. ● Importance of pre-drying of plastic materials.
● Operating and controlling of semi ● Setting of mould, process parameters.
automatic Injection Moulding Machine to ● Operational requirement of annealing, stress
produce components in different moulds, relieving, warp age control.
cycle time, process parameter & study in
IRO.
● Operating and controlling of automatic
Injection Moulding Machine – its process
sequence, ejector stroke, tie-bar distance
platen sizes, mould clamping
arrangements.
● Idle Run Observation (IRO) & study of
injection unit, clamping system, start up
& shut-down procedure, types of nozzle
& hydraulic system.
●Oiling, Lubrication and preventive
maintenance of semi automatic automatic
injection moulding machine.

13
 Auto Plastic Mould Assistant (Compression Moulding)

* Name : Auto Plastic Mould Assistant (Compression Moulding)

* Sector : Plastic Processing Industries

* Code : PLA308

* Terminal Competency : On Completion of training the trainee will be able to:

(a) Operate plastic processing Compression Moulding machine.
(b) Help to running maintenance of Compression Moulding machine.

* Duration : 120 hours

* Entry requirement : a) Qualification: V th class + MES Modules on Basic Fitting and

Measurement / Basic Electrical Joints & fitting / Plastic Mould
Assistant (Injection Molding)/Plastic Mould Assistant (Compression
Moulding)/Plastic Mould Assistant (Extrusion Moulding)/Plastic Mould
Assistant (Blow Moulding)
b) Age : Minimum 14 years.

*Course Contents:
Practical Competencies Underpinning Knowledge (Theory)
● Demonstration about personal, machine, ● Importance of safety and general
electrical & hydraulic safety while working precautions observed in plastic processing
on semi automatic & automatic compression work shop.
molding machine. ● Types of semiautomatic & automatic
● Familiarisation with mechanical, electrical compression moulding machine – its
and hydraulic system of semi automatic & construction, different parts - their function
automatic compression moulding machine – and moulding technique.
different Parts and their respective functions. ● Types of transfer mouldsits function,
● IRO of automatic compression Moulding limitation, advantages.
Machine parts, mould loading / unloading, ● Principle of compression moulding of
setting up process and its process variables. thermoplastic and thermoforming.
● Operating and controlling of compression ● Roto moulding machine and its process.
moulding machine in IRO using
thermoplastic and thermoforming material
as available.
● IRO of Roto Moulding Machine mould
loading / unloading, setting up process.
● Oiling, lubricating and preventive
maintenance of compression moulding &
roto moulding machine.
● Testing method of plastics.

14
 Auto plastic Mould Assistant (Extrusion Moulding)

* Name : Auto plastic Mould Assistant (Extrusion Moulding)

* Sector : Plastic Processing Industries

* Code : PLA309

* Terminal Competency: On Completion of training the trainee will be able to:

(a) Operate plastic processing Extrusion Moulding machine.
(b) Help to running maintenance of Extrusion Moulding machine.

* Duration : 120 hours

* Entry requirement : a) Qualification: V th class + MES Modules on Basic Fitting and

Measurement / Basic Electrical Joints & fitting / Plastic Mould
Assistant (Injection Molding)/Plastic Mould Assistant (Compression
Moulding)/Plastic Mould Assistant (Extrusion Moulding)/Plastic Mould
Assistant (Blow Moulding)
b) Age : Minimum 14 years.

* Course Contents:

Practical Competencies Underpinning Knowledge (Theory)

● Demonstration about personal, machine, ● Importance of safety and general
electrical & hydraulic safety while working precautions observed in plastic processing
on semi automatic & automatic extrusion work shop.
molding machine. ● Types of semi automatic & automatic
● Familiarisation with mechanical, electrical extrusion machine – its construction,
and hydraulic system of semi automatic & different parts & their function.
automatic extrusion machine and its different ● Fundamental knowledge of semi automatic
parts and their respective functions. & autometic extrusion process.
● Operating of semi automatic & automatic ● Fundamental knowledge about extrusion
Extrusion machine in IRO (Setting process moulding materials, its behavior.
parameters, screw speed, nip roller speed, ● Simple method of identification of plastic
wider speed, blow ratio, control of cooling materials.
bubble & air pressure). ● Basic knowledge about extrusion coating
● Practice of die setting on the machine, sizing materials, its pretreatment and surface
techniques, procedure for parameter setting treatment.
& operation practice to produce pipes. ● Basic knowledge about processing
● Practice of operating machines to produce parameter, defects, cause and remedies of
different size of pipes. trouble shooting for extrusion moulding
● Oiling, lubricating and preventive process.
maintenance of semi automatic & automatic ● Simple techniques of reprocessing of plastic
extrusion machines. waste.
● Identification and testing of plastic.

15
 Auto Plastic Mould Assistant (Blow Moulding)

* Name : Auto Plastic Mould Assistant (Blow Moulding)

* Sector : Plastic Processing Industries

* Code : PLA310

* Terminal Competency: On Completion of training the trainee will be able to:

(a) Operator plastic processing Blow Moulding machine.
(b) Help to running maintenance of Blow Moulding machine.

* Duration : 120 hours

* Entry requirement : a) Qualification: V th class MES Modules on Basic Fitting and

Measurement / Basic Electrical Joints & fitting / Plastic Mould
Assistant (Injection Molding)/Plastic Mould Assistant (Compression
Moulding)/Plastic Mould Assistant (Extrusion Moulding)/Plastic Mould
Assistant (Blow Moulding)

b) Age : Minimum 14 years.

* Course Contents:

Practical Competencies Underpinning Knowledge (Theory)

● Demonstration about personal, machine, ● Importance of safety and general
electrical & hydraulic safety while working precautions observed in plastic processing
on blow molding machine. work shop.
● Familiarization with mechanical, Electrical ● Fundamental knowledge of Semi
and hydraulic system of semi automatic & automating and automatic Blow moulding
automatic blow- molding machine and its machine – its construction, different parts -
different parts and their respective functions. their function and moulding technique.
● Operating and controlling of semi automatic ● Fundamental knowledge of extruded
& automatic Blow-Molding Machine in IRO multilayer, die and press Blow moulding
(Setting of dies, mould, cycle time and machine – its construction, different parts -
process parameter). their function and moulding technique.
● Operating & practice of removing & fix the ● Fundamental knowledge of multilayer
parison die to produce correct type of extrusion blow moulding, extrusion stretch
blowing system. blow moulding, press blow moulding for
● Operating and practice of single stage, two squeezable container.
stage blow moulding process. ● Basic knowledge of blow moulds,
● Operation and practice of multilayer blow materials, temperature control during blow
moulding process. moulding process.
● Operation and practice of dip and press ● Basic knowledge about processing
moulding process . parameter, defects, cause and remedies of
trouble shooting for blow moulding
process.

16
● List of Tools (For a batch of 16 trainees)

Sr Name of the Tools & Equipment Quantity for Trainees Total

No. Instructor

1. Rule steel 15 cm with metric graduations. 1 16 17

2. Try square 10 cm blade. 1 16 17
3. Outside spring caliper.15 cm 1 16 17
4. Inside spring caliper 15 cm 1 16 17
5. Divider 15 cm spring. 1 16 17
6. Scriber 15 cm. 1 16 17
7. Punch Centre 10 cm. 1 16 17
8. Screw driver 15 cm. 1 16 17
9. Chisel cold 10. 1 16 17
10. Hammer ball pein 0.45 kg with handle. 1 16 17
11. Hammer ball pein 0.22 kg with handle. 1 16 17
12. File flat 25 cm second cut. 1 16 17
13. File flat 25 cm smooth. 1 16 17
14. File half round 2nd cut 15 cm. 1 16 17
15. Hacksaw frame adjustable 20-30 cm. 1 16 17
16. Safety goggles. 1 16 17
17. Dot slot punch. 1 16 17

Instruments & General Shop Outfit per Unit

1. Plate surface 45 cm * 45 cm 2
2. Marking table 91 * 91 * 122 cm height 1
3. Portable hand drill (electric) 0 to 6 mm 2
4. Drill brace hand o to 12 mm 2
5. Drill twist S/S 1.5 to 12 mm by 0.4 mm 1 set.
6. Drill twist S/S 8 mm to 15 mm by ½ mm 1 set.
7. Taps and dies complete set in box B.S.F. 1
8. Taps and dies complete set in box (Metric) 1
9. Micrometer 25-50 mm outside 3
10. Vernier caliper 20 cm 1
11. Vice Bench 12 cm jaw 16
12. Bench working L:240 cm * W:120 cm * H:75 cm 4
13. Lockers with 8 drawers (standard size) 2
14. Almirah 180 CM * 90 cm * 30 cm 2
15. Metal rack 182 cm * 182 cm * 45 cm 1
16. Black Board 1
17. Fire extinguisher (For 4 units) 2
18. Fire buckets 2
19. Hand hammer 1 kg with handle 2
20. Rule wooden 4 fold 600 mm 2
21. Saw tennon 250 mm 2
22. C-Clamps ( 100 mm,150 mm and 200 mm ) 2 each
23. Drill Machine hand 6 mm cap 2
24. Rawal plug tool and kit 2 sets
25. Ammeter 1 ma to 500 ma DC 10
26. Ammeter 0 to 1 Amp. DC 10
27. Volt Meter 0-300 V A.C. 10 Nos.
28. A.C. Ammeter 0.5 & 0.25 Amp. 5 each

17
29. Magger 500 volts 1
30. Electric switches, fuses, holders, lamps, teak wood As required.
boards, plug sockets, solder, flux, wires and cables,
battens, round blicks and other consumables.

• Machinery

1. Drilling Machine Pilar Sensitive 0-20 mm cap. With swivel 1

table motorized with chuck & key.
2. Grinding machine (General purpose) D.E. pedestal with 1
20 cm dia. Wheels rough & smooth with twist drill grinding
attachment.
3. 30 mm extruder with downstream lines such as film pipe with 1
re-processing unit to process PVC,IDP & RDP.
4. Auto Injection Moulding Machine 40 T Cap. 1
5. Hand operated injection moulding machines
(a) 13 grams capacity 1
(b) 30 grams capacity 1
(c) 60 grams capacity 1
6. Hand operated compression moulding machines 40 T Cap. 1
7. Automatic compression press 100 T cap. with moulds. 1
8. Pipe extrusion machine 1
9. Hand operated Blow Moulding Machine ---
(a) 1 litre capacity 1
(b) 3 litre capacity 1
10. Full automatic double stage blow moulding machine 1
with multilayer extrusion with accessories
11. Test Equipment (Tensile, MFI, Hardness, Izod, Impact 1 set
identifying unit etc. )
12. Accessories & moulds including scrap grinder 1 set
13. Hand operated compression moulding machine 60 ton cap. 1 No.
14. Preheater 12 trays of 25 kgs. capacity. 1 No.

18
 List of Expert/Trade Committee Members

CURRICULUM DEVELOPMENT FOR SHORT TERM COURSES BASED ON

MODULAR EMPLOYABLE SKILLS

SECTOR/AREA: Plastic Processing

MEMBERS OF THE TRADE COMMITTEE

1. SHRI KETAN V. PAREKH, DIRECTOR,
NATIONAL PLASTIC INDUSTRIES LTD., ANDHERI, MUMBAI
2. SHRI YASHWANT R. JUNNARKAR , GENERAL MANAGER ( TECHNICAL),
PRINCE PLASTICS INTERNATIONAL PVT. LTD., ANDHERI, MUMBAI
3. SHRI CHETAN SHAH, MANAGING DIRECTOR,
ZOOM DEVELOPERS PVT. LTD., ANDHERI , MUMBAI
4. SHRI GIRISH NITSURE, MANAGER ,
ZOOM DEVELOPERS PVT. LTD., ANDHERI , MUMBAI
5. SHRI SUNIL CHOUDHURY,
RAMA PACKAGING INDUSTRIES, MAHIM ( W), MUMBAI
6. PROF. M. A. SHENOY,
UNIVERSITY DEPTT OF CHEMICAL TECHNOLOGY, MATUNGA, MUMBAI
7. DR. MAHANAWAR,
UNIVERSITY DEPTT OF CHEMICAL TECHNOLOGY, MATUNGA, MUMBAI
8. PROF. G. G. PATWARDHANE,
DEPTT OF PLASTIC ENGINEERING, VILLE PARLE ( W), MUMBAI
9. PROF. D. M. KARAD,
DEPTT. OF PLASTIC ENGINEERING, VILLE PARLE ( W), MUMBAI,
10. DR. A. N. SANGHVI, PRINCIPAL,
SHRI BHAGUBHAI MAFATLAL POLYTECHNIC, VILE PARLE ( W),MUMBAI
11. MR. D. R. PATEL, BORIVILLI(W), MUMBAI
12. SHRI. MOULIK MODI,
A.J. AUTO PVT. LTD., ANDHERI ( E), MUMBAI
13. Shri Dinesh Nijhawan, Joint Director, DGET

File name : MES - ppo Aug 2007

19