Final Matrix For Autobody

VOCATIONAL EDUCATION AND TRAINING AUTHORITY
CURRICULUM FOR AUTOBODY RREPAIR
PREPARED BY:
VETA HQ,
BOX 2849,
DAR ES SALAAM SEPTEMBER, 2008
TABLE OF CONTENTS
TABLE OF CONTENTS .............................................................................................................................. ii
VETA VISION AND MISSION ................................................................................................................... iii
ACKNOWLEDGEMENT ............................................................................................................................. iv
FOREWORD ............................................................................................................................................ v
LIST OF ABBREVIATIONS........................................................................................................................ vi
LIST OF TAC MEMBERS, EXPERTS AND SECRETATIAT .............................................................................viii
DEFINITION OF KEY TERMS ................................................................................................................... ix
1.0. INTRODUCTION ............................................................................................................................... 1
2.0. OBJECTIVES AND FUNCTIONS OF VETA IN RELATION TO VET SYSTEM .............................................. 2
3.0. CURRICULUM STRUCTURE ................................................................................................................ 2
3.1. MEANING OF THE OCCUPATION .................................................................................................... 2
3.2. AIM AND OBJECTIVE OF THE COURSE ............................................................................................ 4
3.3. CODING OF MODULE ..................................................................................................................... 5
3.4. ENTRY REQUIREMENTS ................................................................................................................. 6
3.5. STRUCTURE AND ORGANISATION OF THE COURSE CONTENT ......................................................... 6
3.6. DURATION OF THE COURSE .......................................................................................................... 7
3.7. RELATED SUBJECTS....................................................................................................................... 7
3.8. CROSS-CUTTING SKILLS ................................................................................................................ 7
4.0. LEARNING AND TRAINING METHODOLOGY ..................................................................................... 7
4.1. FIELD ATTACHMENT ...................................................................................................................... 8
5.0. MANAGEMENT OF ASSESSMENT ........................................................................................................ 8
5.1. MODES OF ASSESSMENT ............................................................................................................... 8
5.2. ROLES OF A VOCATIONAL TEACHER IN ASSESSMENT ..................................................................... 8
5.3. ROLES OF A TRAINEE IN ASSESSMENT ........................................................................................... 9
5.4. ASSESSMENT RECORDS ................................................................................................................. 9
6.0. CERTIFICATION AND AWARD ............................................................................................................ 9
6.1. ASSESSMENT CRITERIA ................................................................................................................. 9
6.2. MARKING AND GRADING ............................................................................................................... 9
6.3. PASS LEVELS ................................................................................................................................. 9
7.0. VOCATIONAL TEACHERS’ QUALIFICATIONS ..................................................................................... 10
8.0. MONITORING AND EVALUATION ..................................................................................................... 10
9.0. REFERENCE BOOKS ........................................................................................................................ 11
9.1. BOOKS REQUIRED: ...................................................................................................................... 11
9.2. RECOMMENDED BOOKS .............................................................................................................. 11
10.0. COURSE CONTENT OUTLINES FOR AUTOBODY REPAIR .................................................................. 12
ii
VETA VISION AND MISSION
VETA’s Vision Statement:
“An excellent Vocational Education and Training system that is capable of supporting national social
economic development in a global context”
VETA’s mission statement
“To ensure provision of quality Vocational Education and Training that meets labour market
needs, through effective regulation, coordination, financing and promotion, in collaboration with
stakeholders”
iii
ACKNOWLEDGEMENT
VETA wishes to express its deepest gratitude to all those who participated in the process of
developing this curriculum. Gratitude is due to the experts for their significant contributions in the
preparation of the curriculum.
Special thanks should go to the Trade Advisory Committee members for their valuable advices,
inputs and ultimately their recommendations for the approval of this Curriculum.
Valuable inputs from employers in both formal and informal sectors during labour market surveys
are gratefully acknowledged.
It is worth noting that, so many people were involved in the process whom we could not mention
here, thus VETA would also like to express its sincere appreciation for their contributions in one
way or another for the accomplishment of this work.
For and on behalf of:

VOCATIONAL EDUCATION AND TRAINING AUTHORITY
Leah D. Lukindo
DIRECTOR OF VOCATIONAL EDUCATION AND TRAINING
iv
FOREWORD
Vocational Education and Training (VET) is a fundamental tool for socio-economic development of
the nation. Due to its importance, the 1994 VET Act No. 1 was enacted, not only to ensure VET is
properly financed, promoted and regulated, but also to set a legal framework within which
vocational training should be provided.
The basic aim of providing VET is to impart vocational skills to learners, which match with career
opportunities as supplied by the labour market. Preparing youngsters for the realities of earning a
living is a responsibility shared by many different groups of people both inside and outside the
education sector. All are aware that it is vital to ensure that learners gain the best possible
academic or vocational qualifications, in order to provide them with a realistic chance of
succeeding in today's highly competitive job market in both the formal and informal sectors of the
economy. The quality of training provided should be judged above all by its impact- or potential
impact - on practice. In this context, curriculum is viewed as a very significant instrument for
guiding the entire educational and training process aimed at achieving relevance, credibility,
coherence and portability of VET results. A good curriculum must support learners under the
influence of a training institution, in achieving requisite learning experiences. It must focus on
developing the whole person. Therefore, the VET curriculum integrates both technical and life
skills to enable the learner understand other cross cutting issues. In developing this curriculum
several factors were taken into consideration. Central to them were corporate elements such as
VETA’s vision and mission statements as well as technical aspects such as principles of learning
and instruction, the role played by related subjects such as mathematics, communication skills and
the like in facilitating the process of skills acquisition.
In order to meet rapid technological and socio-economic changes, VETA adopted competency-
based curricula which are in a modular format and individually-paced with flexible entry and exit,
skills and knowledge being broad-based to specialization. Collaboration with the labour market is
seen to be of paramount importance because this collaboration guarantees a dynamic
development and tailoring of vocational education and training in step with the rapidly changing
qualification needs of trade and industry.
The process of developing this curriculum involved a range of experts from the field as well as
practicing vocational teachers and educationalists under the guidance of curriculum development
specialists.
Therefore the Board believes that this curriculum is learner focused, knowledge and experience
based, labour market demands guided and hence it is able to contribute towards national
vocational workforce development in the country.
…………………………………….……… ………………..………………………….
CHAIRPERSON VET BOARD SECRETARY VET BOARD
v
LIST OF ABBREVIATIONS
ABR - Auto-Body Repair

ABS - Anti-Lock brake systems.
AC - Alternating current
AF - Across Flats (bolt size)
AFFF - Aqueous film forming foam (fire fighting)
BSI - British standard instrument
CAD - Computer Aided Design.
CAE - Computer Aided Engineering.
CAM - Computer Aided Manufacturing.
CBET - Competence Based Education and Training
CIM - Computer Integrated Manufacturing.
Cm - Centimeter.
cm3 - Cubic Centimeters
CO - Carbon monoxide
CO - Centigrade.
CO2 - Carbon dioxide
DC - Direct current
DIA - Diameter.
ECU - Electronic Control Unit
HVLP - High Velocity Low Pressure (Spray guns)
ISO - International Organization for Standardization
LHS - Left hand Side
LT - Low tension
m - Metre.
MAG - Metal active gas (welding).
MIG - Metal inert gas (weldings).
mm - Millimeter
Nm - Newton metre
OUS - Occupational Unit Standards
PPE - Personal Protective Equipment
PPE - Personal Protection Equipments (Regulations)
REV/MIN - Revolution per minute.
RHS - Right hand side.
vi
SAE - Society of Automobile Engineers.
STD - Standards.
TDS - Tap Drill Size
TIG - Tungsten Inertgas (welding)
TPI - Threads per Inch.
UCM - Underground Coal Mining
VET - Vocational Education and Training
VETA - Vocational Education and Training Authority
VIN - Vehicle Identification Number
vii
LIST OF TAC MEMBERS, EXPERTS AND SECRETATIAT
TRADE ADVISORY COMMITTEE MEMBERS
1. Mr. Simon Kabolla - Chairperson.

2. Mr. Haji Mwiru - Member.
3. Mr. Kedmon Mapunda - Member.
4. Eng. Stembridge Rushatila - Member.
5. Mr. Simon X. Ngowi - Member.
6. Prof. Patrick Makungu - Member.
7. Mrs Leah Lukindo - Secretary.
EXPERTS
1. Mr. W.M. Gideme - Dar es Salaam Institute of

Technology
2. Eng. Stembridge M. Rushatila - Tanzania Electrical, Mechanical and
Electronics Services Agency
(TEMESA) - Kilimanjaro
SECRETARIAT
1. Mrs. Rehema M. Binamungu - Curriculum Development Specialist

2. Mrs. Stella M. Ndimubenya - Curriculum Development Specialist
viii
DEFINITION OF KEY TERMS
Competence: The ability to use knowledge, understanding, practical and thinking skills
to perform effectively to the workplace standards required in employment.
Occupational Standards: Specific requirements of competences people are expected

to demonstrate in a particular occupational area, including knowledge and relevant
attitudes. They also act as performance tool of assessment of the pre – scribed
outcomes.
Performance criteria: indicate the expected end results or outcome in form of

evaluative statements.
Standard: it is a set of statement, which if proved true under working conditions,

means that an individual is meeting an expected level and type of performance
Assessment: The process of collecting evidence and making judgments on whether

competency has been achieved, or whether specific skills and knowledge have been
achieved that will lead to the attainment of competency.
Element: A sub- unit (step), which reflects learning sequence with the aim of achieving
broad learning objectives of a unit.
Unit: A statement of broad learning objectives, which pre- scribe the requirements of a
standard in form of practical skills, knowledge and appropriate attitudes
Underpinning Knowledge: This is essential knowledge needed in order to

demonstrate competences that are associated in performing a given task.
Circumstantial knowledge: Detailed knowledge, which allows the decision-making in

regard to different circumstances and cross cutting issues.
ix
1.0. INTRODUCTION
The Vocational Education and Training Authority (VETA) is a body corporate established by
the Vocational Education and Training Act No. 1 of 1994. VETA was established with an
overall responsibility for ensuring the provision of required skills for effective socio economic
development in both, the formal and informal sectors. The Act was passed with a focus on
making the training system more flexible, cost effective and responsive to the demands of
the labour market.
In order to ensure that the flexibility of the training system is enhanced, VETA has adopted
a Competence Based Education and Training (CBET) approach. The approach is flexible in
responding to demands of the labour market and at the same time it puts emphasis on
performance at the standards set by the labour market.
The implementation of the CBET approach becomes more effective if the curriculum content
is reflecting the work place skills requirements. This pre - requisite has been adhered to in
developing this curriculum as the process started by conducting labour market surveys.
Furthermore, technical inputs were drawn from experts in the field, trainers, and curriculum
development experts.
To ensure that vocational education and training contributes to learners’ employability,

personal and social development, the curriculum content has been designed in such a way
that it covers the technical aspects in terms of the required skills and knowledge; as well as
attitudinal aspects in relation to cross cutting aspects such as entrepreneurship,
environmental and HIV/AIDS issues. These have been integrated so as to produce graduates
who can face the challenges of the world of work in a holistic manner.
In this document important information concerning the curriculum for underground coal
mining operations, has been provided. It includes general objectives and functions of VETA,
the curriculum structure, learning and training methodologies, management of assessment
certification and award system, required qualifications for vocational teachers to be eligible
to teach the course, and monitoring and evaluation modalities. The course content is also
provided.
1
2.0. OBJECTIVES AND FUNCTIONS OF VETA IN RELATION TO VET SYSTEM
(a) To establish a vocational and training system including both basic and specialised
training to meet the needs of formal and informal sectors of the economy.
(b) To satisfy the demand of the labour market for employees with trade skills in order
to improve production and productivity of the economy.
(c) To foster and promote entrepreneurial values and skills, as an integral part of all
training programs.
(d) To promote on- the - job training in the industry for both apprenticeship training
and for skills up – dating and upgrading.
(e) To raise the quality of vocational education and training being provided.
(f) To promote or provide vocational education and training according to needs, within
the framework of overall national socio – economic development plans and policies.
(g) To promote access to vocational education and training for disadvantaged groups.
(h) To promote and to provide tailor – made course programs and

in – service training in order to improve the performance both of quality and
productivity of the national economy.
(i) To provide a dual vocational education and training system, combining broad basic
training, gradual specialisation and practical experiences from work, and
(j) To promote a flexible training approach and appropriate teaching methodologies.
3.0. CURRICULUM STRUCTURE
3.1. MEANING OF THE OCCUPATION

Auto-Body Repair is putting back into attractive shape the motor vehicle
bodies after distortion due to metal corrosion, accident, deterioration and any
deformation caused on vehicle body at the effect of use.
Auto-body Repair is an occupation which deals with repair, fabricate and
installation of vehicle body parts. Also it contains the performance of chassis
or frame, body alignment and painting on vehicle bodies.
2
Mainly this is an ability to work on current vehicle models or restoring vintage
or classic cars.
General competencies of the occupation

General competencies required in this occupation include the ability to:
(a) Set the working environment.
(b) Fabricate variety shapes.
(c) Perform bench work processes.
(d) Inspect vehicle body for alignment and damage.
(e) Repair rusted body panel.
(f) Straighten body panel.
(g) Weld metals.
(h) Filling metal surfaces.
(i) Cut different metals.
(j) Align Body, frame or chassis.
(k) Dismantle body panels.
(l) Fix the attachments and panels.
(m) Fit wind screen and vent glasses.
(n) Sanding body surfaces.
(o) Put body filer.
(p) Spray paint.
(q) Estimate body materials.
(r) Fix interior body parts.
(s) Arrange the workshop.
(t) Service auto-body equipment.
(u) Effect proper workshop administration and procedures.
(v) Supervise subordinates and impart knowledge.
(w) Report to superior on job related matters.
Employment opportunities for the occupation

(a) Public sector.
- Government ministries/departments.
- Training Institutions.
- Parastatal Organizations.
- Industries.
Mining.
3
Farming.
Building and constructions.
Railways.
Factories.
Aviations.
Automotive.
Transport.
Shipping.
(b) Private sector

- Self employment.
- Private companies.
- Production industries.
3.2. AIM AND OBJECTIVE OF THE COURSE

Aim: The aims for this course is to provide with knowledge correct attitude
and practical skills those who would become auto-body repairs, so they can
be employed or self employ themselves to the highly demanding field of
automobile.
Objectives:
At the end of the course, the trainee should be able to:
(a) Observe Health & Safety requirements at the workplace.
(b) Perform bench work.
(c) Perform sheet metal forming.
(d) Perform welding.
(e) Perform metal fabrication.
(f) Straighten accidented auto-body and frame.
(g) Repair body dent.
(h) Perform plastic filling.
(i) Perform sanding.
(j) Perform spray painting.
(k) Supervise auto-body shop operations.
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3.3. CODING OF MODULE
LEVEL I
MODULES MODULE TITLES
CODES
ABR 101 Maintaining workshop safety, equipment and tools.
ABR 102 Performing bench work.
ABR 103 Performing sheet metal work.
ABR 104 Performing soft and hard soldering on vehicle panels.
ABR 105 Performing vehicle general check-up.
ABR 106 Performing gas welding and cutting on body panels.
ABR 107 Performing arc welding and cutting on vehicle frames.
ABR 108 Performing straightening of body panels
LEVEL II

CODES
ABR 201 Performing gas welding on auto-body panels.
ABR 202 Performing repair of accidented body panel.
ABR 203 Performing vehicle body panel straightening.
ABR 204 Performing resistance welding on panels.
ABR 205 Performing straightening of bent body frame.
ABR 206 Performing of repair of rusted body part.
ABR 207 Performing alignment of car body panels.
ABR 208 Performing thick metal cutting gas welding.
ABR 209 Performing car body plastic filling.
ABR 210 Performing painting on a plate or panel.
5
LEVEL III
CODES
ABR 301 Performing spray painting on vehicle body or panels.
ABR 302 Performing arc welding on various vehicle body parts.
ABR 303 Performing gas welding on vehicle body brackets.
ABR 304 Performing fabrication of vehicle body components.
ABR 305 Performing installation of vehicle body components.
ABR 306 Performing vehicle frames welding.
ABR 307 Managing auto-body shop.
3.4. ENTRY REQUIREMENTS

The minimum entry qualifications in the course are
Level I
- Ordinary Level Secondary School Education
OR
Level II
- Transcript of Vocational Training level I in Auto-Body Repair.
Level III
- Basic Vocational Certificate Level II in Auto-Body fields.
3.5. STRUCTURE AND ORGANISATION OF THE COURSE CONTENT

The course content is presented in a matrix form whereby the following
components are indicated.
1. Module number
2. Module title
3. Unit number
4. Unit title
5. Performance criteria
6. Elements
7. Training requirements
8. Training duration of a module.
6
3.6. DURATION OF THE COURSE
Contact hours for institutional training and field attachment are as follows:
Core modules Level I 780 hours, Level II 740 hours and Level III 960
hours.
Field attachment……………………………………….………………………………….
Related subjects…………………………………….……………………………………..
Cross cutting skills………………………………..……………………………….……..
Total hours for institution training are…..………………………………………..
Total hours for the course are………………………..………………………………
3.7. RELATED SUBJECTS

Related subjects:
Communication Skills.
Engineering Mathematics.
Engineering Science.
Computer Applications with CAD.
English language.
Technical drawing.
3.8. CROSS-CUTTING SKILLS

Entrepreneurship Skills
Occupation Health and Safety.
Life Skills.
Preventive Maintenance
4.0. LEARNING AND TRAINING METHODOLOGY
Learning and training methodology in CBET is based upon philosophy of learning

through application, and learners’ competent performance should focus on three
domains i.e. cognitive, affective and psychomotor skills. Therefore, a variety of
learning and teaching methods will be applied in delivering the curricular content.
Normally, the vocational teacher functions as a facilitator hence learning and training
is learner centred. Learning and training however will include institutional and
industrial based training (field attachment). Field attachment will be part of training.
Its assessment modalities will be managed by using a logbook comprising
occupational areas to be covered.
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4.1. FIELD ATTACHMENT
It is suggested that the period of field attachment be 6 months during which
the vocational teachers will visit the trainees at least once every two months
to ascertain the learning and training performances.
There will be a logbook for each trainee suggesting areas to be covered and
the actual areas covered. The industry to which the trainee is attached shall
provide a supervisor to guide and assess him/her in the day-to-day activities.
5.0 MANAGEMENT OF ASSESSMENT

In a competence – based assessment system, the purpose of assessment is to collect
sufficient evidence that the individuals can perform to specified standards in a
specific role.
5.1. MODES OF ASSESSMENT

In implementing CBET, testing and assessment shall be conducted in two ways;
internal and external assessment according to assessment guidelines.
Internal Assessment
This is a continuous or formative assessment which is conducted by a
vocational teacher. Each unit has to be assessed and the trainee has to meet a
required standard before she/he can proceed to the next unit.
Final Assessment
Final assessment is a quality assurance process conducted by a licensed
external assessor before the learner is awarded a certificate of competence.
Validation of Assessment
Validation of final assessment is conducted by licensed experts from the
industry in the relevant field with the objective of validating final assessment
and the process of learning.
5.2. ROLES OF A VOCATIONAL TEACHER IN ASSESSMENT

In CBET, the teacher is an assessor in continuous assessment and responsible
for completing the log sheets and transfer the grade attained by a
trainee to a log book. The vocational teacher therefore should make sure
that the log book is endorsed accordingly.
8
5.3. ROLES OF A TRAINEE IN ASSESSMENT
The trainee is responsible for identifying her/his own strengths and weaknesses
i.e. She/he will conduct self assessment under the guidance of a teacher or
assessor. The trainee is also responsible for endorsing the results for the
continuous and final assessment.
5.4. ASSESSMENT RECORDS

Progress reports for every individual trainee should be recorded in the log
sheets and logbook as evidence that will be used to support claims of
achievement. The vocational teacher has a duty to keep and maintain records
of a trainee.
6.0 CERTIFICATION AND AWARD

A Professional Certificate within the National Vocational Award (NVA) will be awarded
to the trainee upon successful completion of training.
It is proposed that certification be awarded as Auto-body repair Artisan Certificate in
Automotive sector.
6.1. ASSESSMENT CRITERIA

They will be derived from performance criteria in occupational unit standards.
6.2. MARKING AND GRADING

The emphasis in CBET is on performing to the required standards in
workplaces, therefore, the grades descriptions shall focus on performance
levels as follows:
A: 90 - 100: Exemplary performance
B: 70 - 89: Performance to the required standard
C: 50 - 69: Needs more training
D: Below 50: Poor performance
Trainees achieving grade A and B will be eligible for final assessment.
A trainee with grade C will need to repeat the course and assessment. A
trainee with grade D will need to be guided to opt for other opportunities.
6.3. PASS LEVELS
Continuous assessment marks shall be combined with final assessment marks

to determine one’s grade for award.
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A candidate who does not pass continuous assessment and field attachment
at a minimum of 70% (B) shall not qualify for final assessment.
The pass mark of related subjects and cross-cutting skills shall be

70%. A trainee is allowed to carry over modules to another level if
not passed.
The total pass mark for practical and theory shall be 70% (B).
Practical shall carry two thirds (2/3) of the pass mark while theory
shall be one third (1/3) of the same.
Notwithstanding a candidate who qualifies for final assessment shall not be

awarded a certificate unless she/he scores B in the final assessment.
7.0 VOCATIONAL TEACHERS’ QUALIFICATIONS

The minimum qualifications of a Vocational Teacher to conduct this course are:
Full technical Certificate in Automobile/Mechanical Engineering with not less than
two years of auto-body repair works supervision from recognized workshop or
Ordinary level diploma in automobile engineering with the experience not less
than two years of auto-body repair works supervision from recognized workshop.
Certificate/or diploma in teaching.
Basic Vocational level III who has at least five years of experience in the field
plus Teaching or Instructor course.
8.0. MONITORING AND EVALUATION
Implementation of the curriculum will be continuously monitored and summatively

evaluated i.e. At the end of the course.
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9.0. REFERENCE BOOKS
9.1. Books Required:

[1] W.A. Livesey & A. Robinson,(2006), The repair of Vehicle Bodies, Fifth
Edition, Published by Elsevier Ltd.
ISBN: 13:978-0-7506-6753-1.
[2] Maurice W. Cuming, (1976), The Theory and practical of Personal

management, 4th Edition, Publisher Heineman London.
[3] Robert Scharff & James E. Duffy, Motor Auto-Body Repair, 3rd Edition.
[4] Chapman W.A.J. (2003), Workshop Technology Part 1, 5th Edition,

Publisher: Electrical Butterwerth Heineman Linacre House, Jordan hill,
Oxford OX28DP,
ISBN: 0-7131-3269-8
9.2. Recommended books
[1] V.A.W. Hiller and Peter Crombes, (2005), Fundamentals of Motor Vehicle
Technology, 5th Edition, Book 1 and 2, Publisher: Nelson Thorne A. Wotters
Kluwer Business.
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10.0 COURSE CONTENT OUTLINES FOR AUTOBODY REPAIR
LEVEL: I
MODULE NUMBER: 1 MODULE TITLE: MAINTAINING WORKSHOP SAFETY, EQUIPMENT AND TOOLS
UNIT NO: 1 UNIT TITLE: MAINTAIN WORKSHOP SAFETY DURATION: 16 HOURS.
PERFORMANCE ELEMENTS COMPETENCE ASSESSMENT
CRITERIA TRAINING
PROCESS PRODUCT UNDERPINNING REQUIREMENTS
ASSESSMENT ASSESSMENT KNOWLEDGE
ASSESSMENT
A person who has 1. Maintain workshop The trainee should The workshop Detailed knowledge of: This unit can be achieved at
achieved this unit safety rules. be able to: contained with Method used: a work place or training
should be able to 2. Maintain workshop See or sense the safety gears The trainee should explain institutions.
apply and maintain maintenance. alarming danger. conform to how to maintain personal The following safety gears,
safety according to 3. Maintain personal Remove unwanted industrial and and workshop safety. equipment and tools should
the given rules and safety. remnants in the workshop rules and Principles: The trainee be available:
regulations. 4. Maintain working workshop. regulations. should explain the principles First aid kit.
environment. Use the first aid kit. of: Aprons.

Care for an injured Performing first aid to Stretcher.
person. an injured person. Gloves.
Keep the working, Handling alarm in the Safety glasses.
environment safe. workshop. Fire proof uniforms.
Adhere to Using first aid tools and Safety helmet.
workshop safety equipment at the Sound protectors.
rules and workplace. Fire extinguishers.
regulations. Safety signs.
12
CRITERIA TRAINING
ASSESSMENT
Handle the first aid Using fire fighting Safety boots.
equipment and equipment. Fire or accident alarm.
tools properly. Performing handling Vacuum cleaners.
Use fire protectors workshop accident. Dust pans.
and alarms. Dust bin.
Clean workshop. Theories: The trainee Mop.
Place non skid should explain: Nose musk.
mats. Types of fire fighting Brooms.
tools and equipment. Smoke detector.
Types of fire Ladder.
extinguishers. Burglar alarm.
Laws which govern Dusters.
health and safety at the
work places.
Personal health care.
Importance of
maintaining cleanness in
the workshop.
Reasons for avoiding
hoseplay and jokes in
the working place.
13
CRITERIA TRAINING
ASSESSMENT
Types of safety signs
and how to place them
in the working place.
Circumstantial
knowledge
Detailed knowledge
about:
Safety precautions to be
observed, when
handling tools and
equipment.
Environment issues.
First aid.
Fire fighting techniques.
Workshop safety rules.
14
LEVEL: I
UNIT NO: 2 UNIT TITLE: MAINTAINING WORKSHOP EQUIPMENT DURATION: 12 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Maintain fire The trainee should The setup of Knowledge evidence: This unit can be achieved at
achieved this unit protecting gears. be able to: equipment in the Detailed knowledge of: a work place or training
should be able to 2. Maintain workshop Arrange the work workshop should Method used: The trainee institution.
perform cleanness. place. confirm to safety should explain how to The following tools,
maintenance and 3. Maintain Service working rules and maintain the workshop equipment and safety gears
care for workshop handling/care of machine. procedures as per equipment. should be available:
equipment as per equipments. Service working specifications. Workshop manuals.
manufacturer’s tools and Principles: The trainee Spanners.
specifications. equipment. should explain the principles Overalls.
Handle servicing of maintaining different Aprons.
equipment and set workshop equipment. Helmet.
service schedule. Fire extinguishers.
Clean the work Theories: The trainee Safety gloves.
place. should explain: Safety boots.
Clean tools. Types of auto-body Work bench.
Clean equipment. equipment.
Keep records.
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CRITERIA TRAINING
ASSESSMENT
Different specifications
of equipment and
applications of different
equipment and
machines.
Circumstantial
knowledge:
Detailed knowledge
about:
Safety precautions when
servicing or adjusting.
Environmental issues.
First aid.
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LEVEL: I
UNIT NO: 3 UNIT TITLE: MAINTAINING WORKSHOP TOOLS DURATION: 28 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Tools and The trainee should Tools maintained Knowledge evidence: This unit can be achieved at
achieved this unit equipments records be able to: and function Detailed knowledge of: a work place or in the
should be able to keeping. Select proper tool according to Method used: The trainee training institution
perform care and 2. Safety precautions for proper job. manufacturer’s should explain how to workshop.
use of tools as per in tools. Adhere to safety specifications. maintain tools for auto body The following tools and
specifications. 3. Proper handling of precautions when repair. safety gears should be
tools.
handling tools. available:
Clean tools. Principles: The trainee Tool boxes.
Store tools at should explain the principles Tool Carbinates.
proper places. of: Tool trays and racks.
Keep tools after Using auto-body jacks. Safety glasses.
use in safe custody. Using auto-body dolly Grinders.
tools. Service kits.
Using different spanners Hammers.
for different fixtures. Spanners.
Holding particular tools. Body jacks.
Safety boots.
Screw drivers.
17
CRITERIA TRAINING
ASSESSMENT
Theories: The trainee Palatines.
should explain: Wash trays.
Types of tools required
in the auto-body repair
workshop.
Different properties of
tools.
Safety precautions in
handling different tools.
How to adjust some
tools for proper job.
Class of fire.
Circumstantial
knowledge:
Detailed knowledge
about:
Safety precautions of
tools.
First aid.
18
LEVEL: I
MODULE NUMBER: 2 MODULE TITLE: PERFORMING BENCH WORK
UNIT NO: 1 UNIT TITLE: CARRYING OUT HAND HACKSAW CUTTING DURATION: 12 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Perform straight The trainee should A cut work piece Knowledge evidence: This unit can be achieved at
achieved this unit sawing. be able to: conforms to Detailed knowledge of: a work place or training
should be able to 2. Perform angular Interpret working technical Method used: The trainee institution.
cut straight and sawing. drawing. specifications. should explain hand The following tools,
angular sawing as Select blade Teeth hacksaw cutting technique. equipment and safety
per technical Per Inch (TPI). gears should be available:
specifications. Set the right Principles: The trainee Working drawing.
direction of blades should explain the principles Scriber.
and teeth. of: Bench bush.
Take correct Cutting by using Hacksaw blade.
measurements. hacksaw. Measuring tape.
Follow the Taking measurements. Bench vice.
recommended Setting the blade. Try square.
cutting procedures. Centre punch.
Clean tools and Theories: The trainee Work bench.
equipment. should explain: Ball pein hammer.
Clean work place. Types of metals and Overalls.
their properties. Industrial boots.
19
CRITERIA TRAINING
ASSESSMENT
Store tools and Drawings interpretation.
equipment safely. Cutting stroke.
The meaning of (Teeth
Per Inch) TPI.
Types of measuring
instruments.
Circumstantial
knowledge:
Detailed knowledge
about:
observed while doing
bench work.
First aid.
20
LEVEL: I
MODULE NUMBER: 2 MODULE TITLE: PERFORM BENCH WORK
UNIT NO: 2 UNIT TITLE: CARRYING OUT POWER SAW CUTTING DURATION: 16 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has Saw a round/flat metal. The trainee should A cut work piece Knowledge evidence: This unit can be achieved at
achieved this unit be able to: conforms to the Detailed knowledge of: a work place or training
should be able to Interpret working technical Method used: The trainee institution.
cut materials by drawing. specifications. should explain how to cut The following tools,
power saw Select proper materials by power saw. equipment and safety gears
machine as per materials. should be available.
technical Clamp the work Principles: The trainee Working drawing.
specifications. piece. should explain the principles Power saw machine.
Select proper tools. involved in: Safety gloves.
Set the right Adjusting power saw. Bench and vice.
direction of blade Setting different angles Safety boot.
teeth. of cut. Rule.
Mark the work Operating a power saw Calliper.
piece. machine. Scriber.
Measure the work Overall.
piece. Try square.
Operate power Wire brush.
saw. Adjustable stand.
21
CRITERIA TRAINING
ASSESSMENT
Cut with power Theories: The trainee Centre punch.
saw. should explain: Hammer.
Clean the work Types of cutting teeth Soft brush.
place, tools and and speed. Electrical power supply.
equipment. Types of cooling media.
Store the tools and Properties of materials.
equipment safely. Simple calculations
related to operations.
How to read scales.
Method of cooling while
cutting.
Parts of power saw and
their functions.
Circumstantial
knowledge:
Detailed knowledge
about:
observed when using
power saw machine.
22
CRITERIA TRAINING
ASSESSMENT
First aid.
Fire fighting.
23
LEVEL: I
UNIT NO: 3 UNIT TITLE: CARRYING OUT METAL FILLING DURATION: 38 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Perform draw filing. The trainee should Filed work piece Knowledge evidence: This unit can be achieved at
achieved this unit 2. Perform be able to: conform to Detailed knowledge of: a work place or training
should be able to longitudinal filing. Interpret the technical Method used: The trainee institution.
file metals as per 3. Perform cross filing. drawing. specifications. should explain different The following tools, safety
technical Mark the work ways of performing filling on gears and equipment
specifications. piece. metals. should be available:
Select a file for Working drawing.
proper job. Principles: The trainee Working bench.
Use try square. should explain the principles Bench vice.
Measure the work of: Safety gloves.
piece. Taking measurements. Safety glass.
Clump the work File cutting. Apron or overall.
piece. De-pinning. Hand files.
Apply filing Filing. Steel rule.
techniques. Try square.
Clean work place Wire brush.
and tools. Scriber.
Centre punch.
24
CRITERIA TRAINING
ASSESSMENT
Store tools and Theories: The trainee Hammer.
equipment safely. should explain: Industrial boots.
The different types of Divider.
materials which can be Protractor.
filed. Soft brush.
The different types of
file cuts.
File materials.
The different types of
file grades.
Methods of taking
measurement.
Circumstantial
knowledge:
Detailed knowledge
about:
Safety precautions
observed when filing.
First aid.
Fire fighting.
25
LEVEL: I
UNIT NO: 4 UNIT TITLE: CARRYING OUT HAND DRILLING DURATION: 6 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Drill a hole on a The trainee should The drilled holes Knowledge evidence: This unit can be achieved at
plate.
achieved this unit be able to: conform to Detailed knowledge of: a work place or training
perform hand drawing. specifications. should explain how to The following tools, safety
drilling on various Select materials. perform hand drilling and gears and equipment
metal plates and Select suitable bits. methods of taking should be available:
woods as per Mark the work measurement. Working drawing.
required technical piece. Hand drill.
specifications. Apply the centre Principles: The trainee Drill bits.
punch. should explain the principles Working bench.
Perform drilling. of: Bench vice.
Check accuracy of Operating drilling Scale.
drilled holes. machine. Scriber.
Clean the work Holding a work piece. Wire brush.
place. Selecting drill bit size. Safety gloves.
Store tools and Safety glass.
machines in safe Overall.
custody. Drill tray.
26
CRITERIA TRAINING
ASSESSMENT
Theories: The trainee Centre punch.
should explain: First aid kit.
Types of hand drills. Industrial boots.
Properties of materials. Ball pein hammer.
Application of different Protractor.
hand drills.
Circumstantial
knowledge:
Detailed knowledge
about:
hand drilling.
Safety Precaution for
handling drill bits.
First aid.
27
LEVEL: I
UNIT NO: 5 UNIT TITLE: CARRYING OUT BENCH DRILLING DURATION: 18 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Drill hole on a The trainee should Drilled and counter Knowledge evidence: This unit can be achieved at
achieved this unit plate. be able to: sunk holes conform Detailed knowledge of: a work place or training
should be able to 2. Counter sink a Interpret the to technical Method used: The trainee institution.
perform various drilled hole. drawing. specifications. should explain how bench The following tools, safety
bench drilling task 3. Counterbore a Measure the work drilling and counter gears and equipment
drilled hole.
as per technical piece correctly. sinking/boring is performed. should be available:
specifications. Mark the work Working drawing
piece. Principles: The trainee Work bench.
Clamp the work should explain the principles Bench vice.
piece. of: Bench drilling machine.
Select appropriate Operating a bench Try square.
speed. drilling machine. Rule.
Drill the workplace. Counter sinking. Centre punch.
Use cooling media. Counter boring. Hack saw and blades.
Counter sinking the Selecting drill bit size. Hand gloves.
drilled hole. Measure and mark. Knier caliper.
Clean the tools and Selecting types of twist Overall.
work place. drills. Safety glass.
28
CRITERIA TRAINING
ASSESSMENT
Store tools and Theories: The trainee Files.
machines in safe should explain: Scribers.
custody. Types of bench drill Wire brush.
machines and bits. Hammer.
Properties of materials. Electrical power supply.
Cooling methods while Chuck key.
drilling.
How to read scales.
Make simple calculations
related to operations.
Circumstantial
knowledge
Detailed knowledge
about:
bench drilling.
First aid.
Fire extinguishing
techniques.
29
LEVEL: I
UNIT NO: 6 UNIT TITLE: CARRYING OUT MANUAL THREAD CUTTING DURATION: 12 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Tap a drilled hole. The trainee should A threaded work Knowledge evidence: This unit can be achieved at
achieved this unit 2. Die a round bar. be able to: piece conforms to Detailed knowledge of: a work place or training
should be able to Interpret the technical Method used: The trainee institution.
perform manual drawing. specifications. should explain how thread The following tools, safety
thread cutting Select materials. cutting is performed. gears and equipment
according to Mark the work should be available:
technical piece. Principles: The trainee Tap and die sets.
specifications. Perform drilling. should explain the principles Work bench.
Select tap and dies. of: Bench vice.
Perform threat Tap and die sequencing. Bench drilling machine.
cutting. Taking measurements. Drill chuck.
Clamp the work Calculating TDS (Tap Try square.
piece. drill size). Rule.
Take Centre punch.
measurements. Theories: The trainee Hack saw and blades.
Check accuracy. should explain: Hand gloves.
Clean the work Types of threads. Knier caliper.
area. Overall.
30
CRITERIA TRAINING
ASSESSMENT
Store tools and Main parts of taps and Safety glass.
work piece in a dies. Files.
safe place. Properties of materials. Scribers.
Function of threads. Wire brush.
Categories of taps and Hammer.
dies. Vernier caliper.
Circumstantial
knowledge:
Detailed knowledge
about:
Safety precautions while
threading.
First aid.
31
LEVEL: I
UNIT NO: 7 UNIT TITLE: CARRYING OUT BENDING FLAT BARS AND PLATES DURATION: 16 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Perform channel The trainee should A bended work Knowledge evidence: This unit can be achieved at
achieved this unit box and right be able to: piece conforms to Detailed knowledge of: a work place or training
should be able to angles bracket. Interpret the technical Method used: The institution.
perform various drawing. specifications. trainees should explain how The following tools, safety
bends on bars and Select materials. to bend different metals of gears and equipment
plates as per Mark the work different shapes i.e. flat bars should be available:
technical piece. and plates. Working drawing.
specifications. Clamp the work Bending machine {work
piece firmly. Principles: The trainee bench}.
Perform bending. should explain the principles Levers.
Clean the work of: Work bench.
place and piece. Performing bending. Bench vice.
Store in safe Cutting different bars Bench drilling machine.
custody. and plates. Try square.
Holding work piece. Rule.
Taking measurements. Centre punch.
Hack saw and blades.
Hand gloves.
32
CRITERIA TRAINING
ASSESSMENT
Theories: The trainee Vernier caliper.
should explain: Overall.
Types of bend. Safety glass.
Properties of materials. Files.
How to read scales. Scribers.
Wire brush.
Circumstantial
Industrial boots.
knowledge:
Helmet.
Detailed knowledge
Ballpen hammer.
about:
Mallet.
Anvil.
threading.
First aid.
33
LEVEL: I
UNIT NO: 8 UNIT TITLE: CARRYING OUT METAL GRINDING DURATION: 12 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Grind welded The trainee should A grinded work Knowledge evidence: This unit can be achieved at
achieved this unit seams and weld be able to: piece conforms to Detailed knowledge of: a work place or training
should be able to joints. Interpret drawings. technical Method used: The trainee institution.
perform various 2. Sharpen cutting Take measurement. specifications. should explain how to grind The following tools, safety
grinding activities tools. Adjust wheel on various tools and work gears and equipment
according to guards. pieces. should be available:
technical Adjust work rest. Bench grinder.
specifications. Clamp/hold work Principles: The trainee Pedestal grinder.
piece. should explain the principles Work bench.
Switch on grinder. of: Bench vice.
Perform grinding. Adjusting work rest. Try square.
Switch off the Grinding different tools. Rule.
grinder. Wheel dressing. Centre punch.
Clean the work Taking measurements. Chisel.
piece and place. Grinding by using a Hand gloves.
Store tools and pedestal/angle grinding Venier caliper.
equipment safely. machine. Overall.
Safety glass.
34
CRITERIA TRAINING
ASSESSMENT
Theories: The trainee Files.
should explain: Apron
Types of grinding disc Scribers.
grades. Wire brush.
The importance of Electrical power supply.
selecting abrasives.
The importance of
grooving and sharpening
of materials.
Adjustment of work rest
and wheel guard.
The properties of
materials.
How to read scales.
35
CRITERIA TRAINING
ASSESSMENT
Circumstantial
knowledge:
Detailed knowledge
about:
observed while grinding.
First aid.
36
LEVEL: I
MODULE NUMBER: 3 MODULE TITLE: PERFORMING SHEET METAL WORK
UNIT NO: 1 UNIT TITLE: CARRYING OUT HAND SHEARING/SNIPPING DURATION: 18 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Perform straight The trainee should A sheared work Knowledge evidence: This unit can be achieved at
achieved this unit shearing. be able to: piece conforms to Detailed knowledge of: a work place or training
should be able to 2. Perform hand Interpret working technical Method used: The trainee institution.
cut metal sheets snipping. drawing. specifications. should explain how hand The following tools, safety
by hand shearing 3. Perform circular Make calculations. shearing is performed. gears and equipment
as per technical shearing. Select materials. should be available:
specifications. Select sniper for Principles: The trainee Working drawing.
the job. should explain the principles Metal sheets.
Take correct involved in: Tin snips.
measures. Hand snip cutting. Shearing machine.
Mark work piece. Machine shearing. Bending machine {work
Perform sheet Holding a work piece. bench}.
shearing. Taking measurement. Work bench.
Hold work piece. Bench vice.
Clean the working Theories: The trainee Bench drilling machine.
area. should explain: Try square.
Types of sharing Rulee.
machines. Centre punch.
37
CRITERIA TRAINING
ASSESSMENT
Store tools and Properties of materials. Hack saw and blades.
work piece in safe Importance of technical Hand gloves.
custody. drawing. Knier caliper.
Different types of Overall.
snipers and their Safety glass.
applications. Files.
Soft hammer.
Circumstantial Scribers.
knowledge Wire brush.
Detailed knowledge
about:
threading.
First aid.
38
LEVEL: I
UNIT NO: 2 UNIT TITLE: CARRYING OUT MACHINE SHEARING DURATION: 6 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Perform straight The trainee should A sheared metal Knowledge evidence: This unit can be achieved at
achieved this unit shearing. be able to: conforms to Detailed knowledge of: a work place or training
cut metal sheets drawings. specifications. should explain: The following tools, safety
using shearing Select suitable Different ways of gears and equipment
machine as per materials and sizes. performing shearing. should be available:
technical Take Shearing process. Working drawing.
specification. measurements. Shearing machine.
Mark out. Principles: The trainee Scriber.
Check sharpness should explain the principles Straight edge.
and tightness of of: Measuring tape.
blade. Shearing. Try square.
Cut the metal. Taking measurements. Work bench.
Check accuracy of Centre punch.
cuts. Theories: The trainee Ball pein hammer.
Clean tools and should explain: Leather gloves.
equipment. Properties of metals. Leather apron.
Clean work place. Safety boots.
39
CRITERIA TRAINING
ASSESSMENT
Store tools and Parts and function of Steel ruler.
equipment safely. shearing machines. Soft hammer.
Drawing interpretation.
Measuring techniques.
Calculation methods for
allowances.
Circumstantial
knowledge:
Detailed knowledge
about:
observed while
performing the task.
First aid.
40
LEVEL: I
UNIT NO: 3 UNIT TITLE: CARRYING OUT SHEET METAL FORMING DURATION: 58 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Bend sheet metal The trainee should A formed work Knowledge evidence: This unit can be achieved at
achieved this unit at right angle. be able to: piece conforms to Detailed knowledge of: a work place or training
should be able to 2. Form single and Identify types of technical Method used: The trainee institution.
form sheet metals double seam. metals. specifications. should explain different The following tools, safety
as per technical 3. Form grooved Take correct ways of forming metals. gears and equipment
specifications. seam. measurements. should be available:
4. Form cylindrical, Calculate Principles: The trainee Working drawing.
cone, prism and allowances using should explain the principles Steel ruler
shapes. proper formulae. involved in: Measuring tape.
Develop different Forming. Divider.
types of patterns. Taking measurements. Protractor.
Set work piece into Try square.
a machine. Theories: The trainee Hammers.
Form sheet metal should explain: Scriber.
to the required Types of metals and Grooving tool.
shape. their properties. Bending machine.
Check accuracy of Forming procedures. Seaming machines.
dimensions. Cutting machine.
41
CRITERIA TRAINING
ASSESSMENT
Clean machine and Types of forming Forming tools.
tools. machines/tools. Overalls.
Clean work place. Calculation steps for Safety boots.
Store tools and forming. Leather gloves.
equipment safely. Development steps. Anvil.
Major parts of forming Mallet.
machines and their
applications.
Circumstantial
knowledge:
Detailed knowledge
about:
Safety precaution to be
observed while forming
the task.
First aid.
42
LEVEL: I
UNIT NO: 4 UNIT TITLE: CARRYING OUT RIVETING DURATION: 18 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Join thick plates by The trainee should Riveted metal Knowledge evidence: This unit can be achieved at
achieved this unit hot riveting. be able to: conforms to Detailed knowledge of: a work place or training
should be able to 2. Join sheet metal by Interpret working technical Method used: The trainee institution.
perform riveting cold riveting. drawing. specifications. should explain the riveting The following tools, safety
on metals as per 3. Join sheet metal by Take techniques used. gears and equipment
technical pop riveting. measurements of should be available:
specifications. metals for riveting. Principles: The trainee Working drawing.
Calculate holes should explain the principles Drill bits.
clearances. of: Bench vice.
Select suitable drills Operating riveting Hammers.
and rivets. tools/equipment. Doll.
Align metal plates Taking measurements. Rivet set.
for riveting. Rivet head.
Drill holes. Theories: The trainee Pop riveting gun.
Select rivet should explain: Drilling machine.
thickness. Drawings interpretation. Measuring tape.
Join two pieces of Types of measuring Divider.
metal by riveting. instruments. Scriber.
43
CRITERIA TRAINING
ASSESSMENT
Check common Types of twist drills. Try square.
defect in riveted Types of rivets. Tongs.
joint. Calculations of hole Centre punch.
Clean work place. clearances. Overalls.
Clean tools and Tools and equipment for Safety boots.
equipment. riveting. Leather gloves.
Store tools and Reasons for aligning Leather apron.
equipment safely. metals during riveting. Straight edge bar.
Common defects in Canvas spats.
riveted joint. Ear plugs.
Circumstantial
knowledge:
Detailed knowledge
about:
observed while
operating the riveting
equipment.
First aid.
44
LEVEL: I
MODULE NUMBER: 4 MODULE TITLE: PERFORMING SOFT AND HARD SOLDERING ON VEHICLE COMPONENTS/PANELS
UNIT NO: 1 UNIT TITLE: CARRYING OUT SOFT SOLDERING DURATION: 28 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Join metal sheets The trainee should Soldered work Knowledge evidence: This unit can be achieved at
achieved this unit by soldering. be able to: piece conforms to Detailed knowledge of: a work place or training
should be able to 2. Join pipes by Interpret working technical Method used: The trainee institution.
join metals by soft soldering. drawings. specifications. should explain different The following tools, safety
soldering process Choose suitable soldering technique. gears and equipment
as per technical materials to be should be available:
specifications. sorted. Principles: The trainee Working drawing.
Choose solder should explain the principles Soldering drawing.
alloy. of: Work bench.
Clean the work Soldering by using Snipers.
piece properly. soldering gun/iron. Wire brush.
Apply flux and Taking measurements. Grip pliers.
soldering gun. Tinning. Scriber.
Follow soldering Curing. Measuring tape.
procedure. Overalls.
Maintain soldering Leather gloves.
heat. Leather apron.
Safety boots.
45
CRITERIA TRAINING
ASSESSMENT
Remove flux Theories: The trainee Canvas spats.
residues. should explain: Soldering iron/gun.
Check quality of Types of soldering filler Blow lamp.
seams. wire.
Attend house Chemical composition of
keeping. solder and flux.
Clean tools and Soldering process.
equipment. Tinning temperatures.
Store the tools in Melting temperatures of
safe place. solder.
Active and non active
fluxes.
Flux residue removal.
Different types of
soldering gun/iron.
46
CRITERIA TRAINING
ASSESSMENT
Circumstantial
knowledge:
Detailed knowledge
about:
observed while
undertaking soldering.
First aid.
47
LEVEL: I
MODULE NUMBER: 4 MODULE TITLE: SOFT AND HARD SOLDERING ON VEHICLE COMPONENTS AND PANELS
UNIT NO: 2 UNIT TITLE: CARRYING OUT SHEET METAL WELDING DURATION: 68 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Soldering metals The trainee should Sheet metal work Knowledge evidence: This unit can be achieved at
achieved this unit into lap joint on flat be able to: piece welded as per Detailed knowledge of: a work place or training
should be able to position. Inspect gas welding technical Method used: The trainee institution.
weld sheet metal 2. Repair leakage of equipment. specifications. should explain gas welding The following tools, safety
by gas as per water to the Assemble gas techniques used. gears and equipment
technical radiator. cylinder. should be available:
specifications. Select nozzle sizes. Principles: The trainee Oxy-acetylene plant.
Select welding should explain the principles Pressure regulator.
rods. of: Welding torch.
Set working Minimizing heat input. Hose pipes.
pressure. Obtaining good fusion. Gas trolley.
Cut and file a sheet Blow pipe construction. Cylinder key.
metal. Flame setting. Blow pipe spanner.
Light the torch. Spark lighter.
Adjust welding Theories: The trainee Tinted goggles.
flames. should explain: Ball pein hammer.
Align and tack weld Leftward welding. Chisel.
work pieces. Right ward welding. Wire brush.
48
CRITERIA TRAINING
ASSESSMENT
Weld sheet metal. Weld defects. Centre punch.
Maintain movement Metal properties. Leather apron.
of blow pipe and Different sizes of Leather gloves.
rod. nozzles. Safety boots.
Maintain angle of Filler metal used. Canvas spats.
torch and filler rod. Back fires and flash
Check fusion on back.
metals. Metallurgical effects on
Maintain weldment.
orderliness of weld Colour codes.
ripples. The science of welding
Check root flame.
penetration. Distortion control.
Inspect quality of Welding symbols.
weld ripples.
Clean tools and
equipment after
work.
Store tools and
equipment safely.
49
CRITERIA TRAINING
ASSESSMENT
Circumstantial
knowledge:
Detailed knowledge
about:
observed while welding
sheet metal.
First aid.
50
LEVEL: I
MODULE NUMBER: 4 MODULE TITLE: PERFORMING SOFT AND HARD SOLDERING ON VEHICLES COMPONENTS AND PANELS
UNIT NO: 3 UNIT TITLE: CARRYING OUT METAL BRAZING AND BRONZE WELDING DURATION: 78 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Joining metals into The trainee should Ferrous metal Knowledge evidence: This unit can be achieved at
achieved this unit butt joint. be able to: bronze welded as Detailed knowledge of: a work place or training
should be able to 2. Joining metal into Inspect gas welding per technical Method used: The trainee institution.
braze ferrous lap joint. equipment. specifications. should explain ways of The following tools, safety
metals as per 3. Joining metals into Assemble gas performing brazing. gears and equipment
flat position.
technical cylinder. should be available:
Principles: The trainee
specifications. Select nozzle sizes. Oxy-acetylene plant.
should explain the principles
Select welding rods Pressure regulator.
of:
(bronze rods). Welding torch.
Obtaining good fusion
Set working Hose pipe.
on metals.
pressure. Truck (trolley).
Obtaining root
Cut and file a plate. Cylinder key.
penetration.
Light the torch. Blow pipe spanner.
Blow pipe.
Adjust welding Spark lighter.
Setting gas pressure.
flames. Ball pein hammer.
Align and tack weld Chisel
Theories: The trainee
work pieces. Wire brush.
should explain:
Braze weld joint. Centre punch.
Metal properties.
51
CRITERIA TRAINING
ASSESSMENT
Maintain movement Bronze weld defects. Tongs.
of torch and bronze Metallurgical effect on Tinted goggles.
welding rod. weldment. Leather apron.
Maintain angle of Different sizes of Leather gloves.
torch and bronze welding nozzle and Industrial boots.
rod. application. Canvas spat.
Ensure non fusion Different sizes and types Dust mask.
on metals. of bronze rods.
Maintain Different types of flames
orderliness of and their application.
bronze weld Back fire flashback
ripples. effect and prevention.
Check root
Circumstantial
penetration.
knowledge:
Inspect quality of
Detailed knowledge
bronze weld.
about:
Clean work place.
Clean tools and
observed while welding.
equipment.
First Aid.
Store tools and
equipment safely.
52
LEVEL: I
MODULE NUMBER: 5 MODULE TITLE: PERFORM VEHICLE GENERAL CHECKUP
UNIT NO: 1 UNIT TITLE: CARRYING OUT VEHICLE GENERAL CHECKUP DURATION: 68 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Check for damage The trainee should General vehicle Knowledge evidence: This unit can be achieved at
achieved this unit and setup. be able to: outlook conform to Detailed knowledge of: a work place or training
should be able to 2. Check for missing Check the general manufacturer’s Method used: The trainee institution.
carry out vehicle parts, bolts and vehicle set up. specification. should explain how to The following tools, safety
general check-up nuts for tightness. List down body and inspect a vehicle. gears and equipment
as per 3. Check tyre pressure chassis should be available:
manufacturer’s and ware. deformations. Principles: The trainee Vehicle layout
specifications. 4. Check vehicle level. Identify missing should explain the principles catalogue.
parts. of: Inspection pit.
Carryout Vehicle inspection. Overall.
information from Components set Helmet.
user. up/layout. Industrial boots.
Clean tools and Hammer.
equipment. Theories: The trainee Screw driver.
Store tools and should explain: Gloves.
equipment in safe Vehicle body layout. Cotton rag.
custody. Vehicle components Clear safety goggles.
arrangement.
53
CRITERIA TRAINING
ASSESSMENT
General vehicle Types of pressure
standards. gauge.
Identification of body Levers.
and chassis Vehicles.
deformation. Inspection light.
General Service Tyre pressure gauge.
schedule. Measuring tape.
Circumstantial
knowledge
Detailed knowledge
about safe handling of
vehicle inspection as per
technical specifications.
54
LEVEL: I
MODULE NUMBER: 6 MODULE TITLE: PERFORMING GAS WELDING AND CUTTING VEHCILE BODY PANELS
UNIT NO: 1 UNIT TITLE: CARRYING OUT GAS WELDING ON BODY PANELS DURATION: 40 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Welding metals in The trainee should A gas welded work Knowledge evidence: This unit can be achieved at
achieved this unit butt joint on be able to: piece conforms to Detailed knowledge of: a work place or training
should be able to horizontal position. Inspect gas welding technical Method used: The trainee institution.
carry out gas 2. Welding metals into equipment. specifications. should explain gas welding The following tools, safety
welding on body lap joint on Assemble gas procedures. gears and equipment
panels as per horizontal position. cylinder. should be available:
technical 3. Welding metals in Select nozzle sizes. Principles: The trainee Oxy-acetylene plant.
specifications. corner joint on Select welding should explain the principles Pressure regulator.
vertical position. rods. of: Welding torch.
4. Welding metals in Cut plate to Welding metals by gas Hose pipes.
lap joint on specifications. flame. Gas trolley.
overhead position. Light the torch. Setting welding flame. Cylinder key.
flames. Theories: The trainee Ball pein hammer.
Align and weld should explain: Chisel.
work piece. Parts of gas welding Wire brush.
Weld the joint. equipment and their Centre punch.
functions. Leather gloves.
55
CRITERIA TRAINING
ASSESSMENT
Keep on Recommended working Clear goggles.
maintaining flames and pressure. Angle grinder.
movement of torch Side effects of back fire Bench vice.
and rod. and flash back. Safety boots.
Keep on Different welding Canvas spats.
maintaining angle procedures and Dust mask.
of torch and filler techniques. Overalls.
rod.
Circumstantial
Keep on
knowledge:
maintaining
Detailed knowledge
orderliness of weld
about:
ripples.
Check root
penetration.
the task.
Inspect quality of
First aid.
weldment.
Clean the work
place.
Clean equipment
and tools.
56
CRITERIA TRAINING
ASSESSMENT
Store tools and
equipment safely.
57
LEVEL: I
MODULE NUMBER: 6 MODULE TITLE: PERFORMING GAS WELDING AND CUTTING VEHCILE BODY PANELS
UNIT NO: 2 UNIT TITLE: CARRYING OUT BODY PANEL CUTTING BY FLAME DURATION: 20 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Cutting the rusted The trainee should A cut metal work Knowledge evidence: This unit can be achieved at
achieved this unit or collided panel of be able to: piece conforms to Detailed knowledge of: a work place or training
should be able to car body and Inspect gas welding technical Method used: The trainee institution.
cut metals by replacing a new equipment. specifications. should explain gas cutting The following tools, safety
flame as per formed section. Assemble gas procedures. gears and equipment
technical cylinders. should be available:
specifications. Select nozzle sizes. Principles: The trainee Oxy-acetylene plant.
Select cutting should explain the principles Pressure regulator.
torch. of: Cutting torch.
Set working Cutting metal by gas Hose pipes.
pressure. flame. Gas trolley.
Cut and file plate to Obtaining smooth Kerf. Cylinder key.
specifications. Setting cutting flame. Spark lighter.
Light the torch. Ball pein hammer.
Adjust cutting Chisel.
flames. Wire brush.
Align and tack cut Centre punch.
the work pieces. Leather gloves.
58
CRITERIA TRAINING
ASSESSMENT
Keep on Theories: The trainee Clear goggles.
maintaining should explain: Angle grinder.
movement of torch. Parts of gas cutting Bench vice.
Keep on equipment and their Safety boots.
maintaining angle functions. Canvas spats.
of torch. Recommended working Dust mask.
Inspect quality of flames and pressure. Overalls.
cutting. Side effects of back fire
Clean the work and flash back.
place. Different cutting
Clean equipment procedures and
and tools after techniques.
working.
Circumstantial
Store tools and
knowledge:
equipment safely.
Detailed knowledge
about:
metal cutting.
First aid.
59
LEVEL: I
MODULE NUMBER: 7 MODULE TITLE: PERFORMING ARC WELDING AND CUTTING ON VEHICLE FRAME
UNIT NO: 1 UNIT TITLE: CARRYING OUT MILD STEEL ARC WELDING DURATION: 58 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Weld straight The trainee should Welded metal Knowledge evidence: This unit can be achieved at
achieved this unit beads. be able to: conforms to Detailed knowledge of: a work place or training
should be able to 2. Weld metal in Inspect the technical Method used: The trainee institution.
weld mild steel downhand butt machine, cable and specifications. should explain the welding The following tools, safety
work piece as per joint. electrode holder. technique used. gears and equipment
technical 3. Weld metal in Interpret working should be available:
specifications. downhand lap joint. drawing. Welding machine.
4. Weld metal in Prepare materials Welding cables.
involved in:
downhand corner for welding. Electrode holder.
Arc welding.
joint. Select type and size Welding shield.
Minimizing distortion.
5. Weld metal in of electrode for the Chipping hammer.
Obtaining good
downhand tee job. Wire brush.
penetration.
joint. Set recommended Work bench.
Selecting weld current.
6. Weld metal in current. Welding tongs.
horizontal butt Weld a work piece. Theories: The trainee Angle grinder.
joint. should explain: Flat file.
7. Weld metal in Types of metals and Bench vice.
horizontal tee joint. their properties. Scriber.
60
CRITERIA TRAINING
ASSESSMENT
8. Weld metal in Keep on Types and functions of Earth clamp.
horizontal lap joint. maintaining welding equipment. Ball pein hammer.
9. Weld metal in electrode angle and Groove preparations. Centre punch.
horizontal corner
arc length. Uses of wire brush and Overalls.
joint.
Control electrode chipping hammer. Leather gloves.
travel speed along Metallurgical effects on Canvas spats.
the joint. weldment. Safety boots.
Chip off metal slag Characteristics of AC Leather apron.
and wire brush. and DC welding Electrical power supply.
Inspect for weld machine.
defect. Types of welds.
Clean work place. Types of electrode
Clean tools and coatings and function.
equipment. Work angle and lead
Store tools and angle.
equipment in safe Welding symbols.
place. Types of distortion.
Joint design.
61
CRITERIA TRAINING
ASSESSMENT
Circumstantial
knowledge:
Detailed knowledge
about:
the work piece.
First Aid.
62
LEVEL: I
MODULE NUMBER: 7 MODULE TITLE: PERFORMING ARC WELDING AND CUTTING ON VEHICLE FRAMES
UNIT NO: 2 UNIT TITLE: CARRY OUT MILD STEEL ARC CUTTING DURATION: 14 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Perform arc cutting The trainee should A cut work piece Knowledge evidence: This unit can be achieved at
achieved this unit on dented frame. be able to: conforms to Detailed knowledge of: a work place or training
should be able to 2. Perform arc Inspect the technical Method used: The trainee institution.
cut thick mild steel gouging. machine, cable and specifications. should explain different The following tools, safety
materials as per electrode holder. ways of cutting thick metals. gears and equipment
technical Interpret working should be available:
specifications. drawing. Principles: The trainee Welding machine.
Set recommended should explain the principles Welding cables.
current and air flow involved in: Electrode holder.
pressure. Cutting by arc. Welding shield.
Cut work piece with Taking measurements. Compressor.
electrode. Chipping hammer.
Control electrode Theories: The trainee Wire brush.
travel speed along should explain: Work bench.
the cut. Parts and functions of Welding tongs.
Clean the oxides cutting equipment. Angle grinder.
along the kerf. Metallurgical effect Flat file.
during cutting. Bench vice.
63
CRITERIA TRAINING
ASSESSMENT
Clean the The science supporting Scriber.
equipment, tools the cutting process. Earth clamp.
and work place. The formula for current Ball pein hammer.
Store the selections. Centre punch.
equipment and Overalls.
tools in safe place. Circumstantial Leather gloves.
knowledge: Canvas spats.
Detailed knowledge Safety boots.
about: Leather apron.
Safety precautions to be Electrical power supply.
observed while cutting
work piece by arc.
First Aid.
64
LEVEL: I
MODULE NUMBER: 8 MODULE TITLE: PERFORMING STRAIGHTENING OF CAR BODY PANEL
UNIT NO: 1 UNIT TITLE: CARRYING OUT STRAIGHTENING OF BENT PANEL DURATION: 107 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Dismantling the The trainee should The straightened Knowledge evidence: This unit can be achieved at
achieved this unit damaged panel be able to: body panel Detailed knowledge of: a work place or training
should be able to from the body Use available tools conforms to Method used: The trainee institution.
carry out structure (shell). to perform the technical should explain how to The following tools, safety
straightening of 2. Straightening by task. specifications. properly straighten the bent gears and equipment
bent panel as per harmonising Arrange the work body panel. should be available:
technical method. place. Auto-body panel
specifications. 3. Re-fixing the panel Set and adjust the Principles: The trainee beating kit.
and parts to the equipment. should explain the principles Hand operated body
body shell. Perform involved in straightening jack.
4. Reducing the straightening by bent panel. Hydraulic body jack.
stretched car metal different methods. Beating file.
panel by hot and Beat the bent Theories: The trainee Overalls.
cold shrinking. surface. should explain: Leather gloves.
5. Filling the body filer Apply plastic filter. Properties of dented Soft hammer.
to the repaired Sand the surface. surface. Ball pein hammer.
body panel. Clean the working Different types of Set spanners.
area. accidented surfaces.
65
CRITERIA TRAINING
ASSESSMENT
6. Apply undercoat Store tools and Different application of Oxy-acetylene welding
solid paint.
equipment into equipments. plant.
proper custody. Different types of tools Hand dollies.
and equipment used in Industrial boots.
straightening bent
panels (surfaces).
Circumstantial
knowledge:
Detailed knowledge
about:
Safety precautions
observed while
straightening.
First aid.
Fire extinguisher.
66
LEVEL: II
MODULE NUMBER: 1 MODULE TITLE: PERFORMING GAS WELDING ON AUTOBODY PANELS
UNIT NO: 1 UNIT TITLE: CARRYING OUT WELDING ON FERROUS METALS BODY PANELS DURATION: 32 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Weld metal joints in The trainee should Welded metal Knowledge evidence: This unit can be achieved at
achieved this unit vertically. be able to: conforms to Detailed knowledge of: a work place or training
should be able to 2. Weld metal joints Inspect plasma technical Method used: The trainee institution.
carry out welding horizontally. welding equipment. specifications. should explain different The following tools, safety
of ferrous metals Select welding techniques. gears and equipment
by gas flame as recommended type should be available:
per technical and size of nozzle. Principles: The trainee Oxy-acetylene plant.
specifications. Prepare materials should explain the Pressure regulator.
for cutting. principles: Welding torch.
Set recommended Involved in operation of Hose pipe.
current. welding plant. Gas trolley.
Maintain torch Welding metal by gas Cylinder key.
angle and travel flame. Spark lighter.
speed. Setting and operating of Welding tongs.
Adjust flow rate of welding torches. Ball pein hammer.
water and gas. Setting recommended Work bench.
Align and tackweld flame and pressure. Chisel.
67
CRITERIA TRAINING
ASSESSMENT
Weld the joint. Theories: The trainee Centre punch.
Maintain movement should explain: Leather apron.
of torch and rod. Main parts of gas Clear goggles.
Maintain angle of welding equipment and Leather gloves.
torch and filler rod. their functions. Industrial boots.
Check fusion on The effects of backfire Canvas spats.
metals. and flashback. Overalls.
Maintain The equipment for Leather Apron.
orderliness of weld welding metals by gas
ripples. flame.
Check root Functions of low and
penetration. high pressure gas
Inspect quality of generating.
weldment. Circumstantial
Clean and store knowledge:
equipment and Detailed knowledge
tools. about:
observed when
performing gas cutting.
First Aid.
68
LEVEL: II
UNIT NO: 2 UNIT TITLE: CARRYING OUT WELDING ONF NON FERROUS METALS DURATION: 32 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Weld stainless steel The trainee should Welded metal Knowledge evidence: This unit can be achieved at
achieved this unit by gas welding. be able to: conforms to Detailed knowledge of: a work place or training
should be able to 2. Weld carbon steel Inspect gas welding technical Method used: The trainee institution.
weld Non-ferrous by gas welding. equipment. specifications. should explain welding The following tools, safety
metals by gas as Assemble gas techniques used. gears and equipment
per technical cylinders. should be available:
specifications. Select welding Oxy-acetylene plant.
rods. Pressure regulator.
of:
Set working Welding torch.
Operating process of
pressure. Hose pipe.
gas welding plant.
Cut and file the Gas trolley.
Welding metal by gas
plate. Cylinder key.
flame.
Light the torch. Spark lighter.
Operation of welding
Adjust welding Welding tongs.
torches.
flame. Ball pein hammer.
Setting of recommended
Align and tack weld Work bench.
flame and pressure.
work pieces. Chisel.
Weld the joint. Wire brush.
69
CRITERIA TRAINING
ASSESSMENT
Maintain uniform Theories: The trainee Centre punch.
movement of torch should explain: Tinted goggles.
and rod. Main parts of gas Leather apron.
Maintain angle of welding equipment and Clear goggles.
torch and filler rod. their function. Safety boots.
Check fusion of The effects of backfire Canvas spatters.
metals. and flashback. Overalls.
Maintain Function of low and high Leather Apron.
orderliness of weld pressure gas generating
ripples. systems.
Check root
Circumstantial
penetration.
knowledge:
Inspect root
Detailed knowledge
penetration.
about:
Inspect quality of
weldment.
observed while
Clean work place.
performing gas cutting.
Clean and store
First Aid.
equipment and
tools after work.
70
LEVEL: II
UNIT NO: 3 UNIT TITLE: CARRY OUT METAL BRAZING AND BRONZE WELDING. DURATION: 48 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Weld panels by The trainee should Ferrous metal Knowledge evidence: This unit can be achieved at
achieved this unit brazing. be able to: bronze welded as Detailed knowledge of: a work place or training
should be able to 2. Filling metal Inspect gas welding per technical Method used: The trainee institution.
braze ferrous surface equipment. specifications. should explain: The following tools, safety
metals as per 3. Weld copper and Assemble gas Brazing techniques gears and equipment
technical steel pipes. cylinder. used. should be available:
specifications. Select nozzle sizes. Procedures of Oxy-acetylene plant.
Select welding rods preventing distortion. Pressure regulator.
(bronze rods). Welding torch.
Set working Hose pipe.
pressure. Truck (trolley).
of:
Cut and file a plate. Cylinder key.
Obtaining good fusion
Light the torch. Blow pipe spanner.
on metals.
Obtaining root
flames. Ball pein hammer.
penetration.
Align and tack weld Chisel
Blow pipe.
Setting gas pressure.
Braze weld joint. Centre punch.
71
CRITERIA TRAINING
ASSESSMENT
Maintain movement Theories: The trainee Tongs.
of torch and bronze should explain: Tinted goggles.
welding rod. Metal properties. Leather apron.
Maintain angle of Bronze weld defects. Leather gloves.
torch and bronze Metallurgical effect on Industrial boots.
rod. weldment. Canvas spat.
Ensure non fusion Different sizes of Dust mask.
on metals. welding nozzle and
Maintain application.
orderliness of Different sizes and types
bronze weld of bronze rods.
ripples. Different types of flames
Check root and their application.
penetration. Back fire flashback
Inspect quality of effect and prevention.
bronze weld.
Clean work place.
Clean tools and
equipment.
Store tools and
equipment safely.
72
CRITERIA TRAINING
ASSESSMENT
Circumstantial
knowledge
about:
Detailed knowledge
about:
First Aid.
73
LEVEL: II
MODULE NUMBER: 2 MODULE TITLE: PERFORMING REPAIR OF ACCIDENTED BODY PANELS
UNIT NO: 1 UNIT TITLE: CARRYING OUT DISMANTLING OF BODY PARTS. DURATION: 40 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Identify the The trainee should Dismantling Knowledge evidence: This unit can be achieved at
achieved this unit damage. be able to: process conform to Detailed knowledge of: a work place or training
should be able to 2. Dismantle body Dismantle different the technical Method used: The trainee institution.
part.
disintegrate body panels. specifications. should explain how The following tools, safety
vehicle body parts Fix the parts back particular body panel can be gears and equipment
as per the after repair. dismantled from the body. should be available:
specifications. Clean the working Lay out dismantling
area. Principles: The trainee plan, or procedures.
Store the tools and should explain the principles Spanner kit.
equipments in of: Body jack.
safety. Assembling and Overall.
dismantling a particular Special levers.
body part. Hammer.
Vehicle body Safety leather gloves.
constructions. Safety boots.
Chassis welding plant.
Oxy-acetylene plant.
74
CRITERIA TRAINING
ASSESSMENT
should explain:
Properties of materials.
Uses of different tools.
Straightening
procedures.
Circumstantial
knowledge:
Detailed knowledge
about:
dismantling auto body
parts.
Environment issues.
First Aid.
75
LEVEL: II
MODULE NUMBER: 2 MODULE TITLE: PERFORMING REPAIR OF ACCIDENTED BODY PANELS
UNIT NO: 2 UNIT TITLE: CARRYING OUT STRAIGHTENING BY HOT SHRINKING DURATION: 70 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Straightening. The trainee should The straightened Knowledge evidence: This unit can be achieved at
achieved this unit 2. File biting. be able to: body panel Detailed knowledge of: a work place or training
should be able to 3. Hot shrinking. Light the welding conforms to Method used: The trainee institution.
carry out metal touch and set manufacturers should explain how to: The following tools, safety
straightening by required flame. specifications. Adjust the flame. gears and equipment
hot shrinking as Locate high spot, Heat the spot. should be available:
per manufacturer’s heat and strike the Apply dolly tools and Work plan.
specifications. panels using beating file. Oxy-acetylene plant.
beating tools. Apply coolant. Shrinking dolly blocks.
Identify the Shrinking hammer.
affected areas Principles: The trainee Water dish.
using should explain the principles Cloth or sponge.
recommended of: Lighter.
procedures. Hot shrinking. Welding tourch.
Repeat the process Cold shrinking. Beating file.
if need be. Overall/apron.
Clean the working Safety boots.
place and tools. Safety glasses.
76
CRITERIA TRAINING
ASSESSMENT
Store tools and Theories: The trainee Hand tools.
equipments in safe should explain:
custody. Types of beating tools.
Functions of each.
Properties of materials.
Heating effects.
Circumstantial
knowledge:
Detailed knowledge
about:
panel beating.
Beating properties.
Environmental
requirement.
First aid.
77
LEVEL: II
MODULE NUMBER: 3 MODULE TITLE: PERFORMING VEHICLE BODY PANEL STRAIGHTENING
UNIT NO: 1 UNIT TITLE: CARRYING OUT BODY PANEL STRAIGHTENING DURATION: 32 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Identify the The trainee should The straightened Knowledge evidence: This unit can be achieved at
achieved this unit damage. be able to: body panel Detailed knowledge of: a work place or training
should be able to 2. Select the method. Use working tools conforms to Method used: The trainee institution.
perform 3. Shrink the panel. properly. technical should explain the The following tools, safety
straightening bent Service equipment. specifications. sequential procedure of gears and equipment
body according to Clean the work body straightening. should be available:
technical place. Work plan.
specifications. Store tools and Principles: The trainee Panel lifter.
equipments to safe should explain the principles Portable hydraulic
custody. of: power jack.
Body straightening. Hand dollies assorted.
Hand jack operations. Oxy-acetylene welding
Panel beating. plant.
Panel files.
Dolly heads and stands.
Levers.
Hammer.
Leather apron.
78
CRITERIA TRAINING
ASSESSMENT
Theories: The trainee Industrial boots.
should explain: Wire brush.
Why the under painting Chisels.
is necessary. Body clamps.
Measuring procedures. Leather gloves.
Measuring tape.
Circumstantial
Spanners.
knowledge:
Detailed knowledge
about:
Safety precautions while
performing the
straightening
procedures.
First aid.
79
LEVEL: II
MODULE NUMBER: 4 MODULE TITLE: PERFORMING RESISTANCE WELDING
UNIT NO: 1 UNIT TITLE: CARRY OUT RESISTANCE WELDING ON SHEET METALS DURATION: 32 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Weld sheet metals The trainee should Welded metal Knowledge evidence: This unit can be performed
achieved this unit using resistance be able to: conforms to Detailed knowledge of: at a work place or training
should be able to welding. Interpret working technical Method used: The trainee institutions.
carry out 2. Weld sheet metal drawings. specifications. should explain resistance The following tools, safety
resistance welding by projection Take correct welding technique used. gear and equipment should
on sheet metals as welding. measurements. be available:
per technical 3. Weld metal rods by Inspect resistance Principles: The trainee Resistance welding
specifications. percussion welding welding equipment. should explain the principles machine.
machine. Adjust current in of: Working drawing.
4. Weld sheet metal commensurate with Resistance welding. Measuring tape.
by high frequency metal thickness. Cleaning and Tool box.
resistance welding. Place and align maintaining electrode Scriber.
work piece. rollers after each work Work bench.
Set squeeze time. piece is welded. Wire brush.
Set weld time. Grinding and cleaning Flat files.
Set hold time. copper electrodes. Clear goggles.
Set off period time. Leather gloves.
80
CRITERIA TRAINING
ASSESSMENT
Set proper pressure Aligning equidistantly Tongs.
for the job. the two work pieces on Safety boots.
Grind copper chucks. Electrical power supply.
electrodes. Chipping hammer.
Clean electrode Theories: The trainee
from time to time should explain:
during process. The main parts of
Clean work place, resistance welding
tools and equipment and their
equipment. functions.
Store tools and The working principle of
equipment safely. resistance welding
equipment.
The importance of
setting suitable current
and time according to
plate thickness.
The meaning and
difference between hold
time, squeeze time and
off period time.
81
CRITERIA TRAINING
ASSESSMENT
Requirement and
quantities of resistance
welding electrodes.
Resistance welding
variables
Selection of resistance
welding process.
Joint design.
Metallurgical effects on
weldment.
Circumstantial
knowledge:
Detailed knowledge
about:
First Aid.
82
LEVEL: II
MODULE NUMBER: 5 MODULE TITLE: PERFORM STRAIGHTENING OF BENT BODY FRAME
UNIT NO: 1 UNIT TITLE: CARRYING OUT DISMANTLING BODY ATTACHMENTS DURATION: 52 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Dismantle door The trainee should Dismantling body Knowledge evidence: This unit can be achieved at
achieved this unit from the frame and be able to: panels conforms to Detailed knowledge of: a work place or training
should be able to attachments. Locate which part technical Method used: The trainee institution.
dismantle attached 2. Dismantle the to dismantle. recommendations. should explain different The following tools, safety
body panels as per interior Use correct dismantling procedures of gears and equipment
technical components. spanners. vehicle body panels. should be available:
specifications. 3. Glass and winding Lift with care. Work plan.
machine removing. Follow the Principles: The trainee Tool box with spanners
4. Remove channels. procedure. should explain the principles .
5. Remove hinges and Identify the of: Adjustable/pipe
locks.
problem. Dismantling vehicle wrenches.
Keep dismantled body panel. G purpose pliers.
parts safely. Fixing. Hammers.
Clean the working Overalls.
place. Theories: The trainee Leather boots.
Store tools and should explain: Gloves.
equipment safely. Main parts of vehicle Screw drivers.
body. Body jack.
83
CRITERIA TRAINING
ASSESSMENT
Types of vehicle Tape measure.
frames/chassis. Chisels.
Main components of a Oxy-acetylene plant.
vehicle. Spark lighter.
Fixing procedures. Clear goggles.
Identification of problem
and metal properties.
Circumstantial
knowledge:
Detailed knowledge
about:
observed when body
dismantling.
First aid.
84
LEVEL: II
MODULE NUMBER: 5 MODULE TITLE: PERFORMING STRAIGHTENING OF BENT BODY FRAME
UNIT NO: 2 UNIT TITLE: CARRYING OUT STRAIGHTENING BENT VEHICLE BODY DURATION: 74 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Panel straightening The trainee should The straightened Knowledge evidence: This unit can be achieved at
achieved this unit by body jack. be able to: vehicle body Detailed knowledge of: a work place or training
should be able to 2. Heat and weld. Select tools and conforms to Method used: The trainee institution.
straighten bent 3. File beating. equipment. technical should explain procedure The following tools, safety
vehicle body using 4. Apply body plastic Carry out specifications. used in straightening vehicle gears and equipment
power body jack filler. adjustment and body by power jack. should be available:
according to alignment. Working plan.
technical Instruct other to Principles: The trainee Power body jacks.
specifications. assist in should explain the principles Hydraulic body.
accordance. of: Hand dollies assorted.
Apply Taking measurements. Oxy-acetylene welding
heating/welding/cut Setting power body jack. plant.
where need be. Panel file.
Perform Theories: The trainee Dolly heads and stand.
straightening. should explain: Sanding machine.
Repeat the process Main fixtures of power Beating files.
as far as it requires hydraulic. Ball pein hammer.
so. Properties of metals. Safety boots.
85
CRITERIA TRAINING
ASSESSMENT
Apply plastic fillers. Circumstantial Leather apron.
Grind the dented knowledge: Leather gloves.
areas. Detailed knowledge Spanners.
Clean the work about: Levers.
place and tools. Safety precautions to be Wire brush.
Store equipment is observed when body Chisels.
safe custody. dismantling. Clamps.
First aid.
86
LEVEL: II
MODULE NUMBER: 6 MODULE TITLE: PERFORMING REPAIR OF RUSTED BODY PART
UNIT NO: 1 UNIT TITLE: CARRYING OUT WELDING OF RUSTED PARTS DURATION: 78 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Patching. The trainee should A mended rusted Knowledge evidence: This unit can be achieved at
achieved this unit 2. Beating. be able to: body part conforms Detailed knowledge of: a work place or training
should be able to 3. Apply body filler. Cut and form metal to technical Method used: The trainee institution.
perform weld 4. Sanding. sheets for patches. specifications. should explain how to mend The following tools, safety
patching on rusted Cut rusted areas rusted body panel. gears and equipment
body part with gas flame should be available:
according to cutting. Principles: The trainee Work plan.
technical Regulate gas should explain the principles Gas welding plant.
specifications. flames regularly. of: Weld goggles.
Select filler rods of Settings weld gas Hand snips.
proper sizes. pressure. Panel hammers.
Mend the panel. Metal patching. Dolly blocks.
Finish welding/shut Surface straightening Spark lighter.
gas off. and smoothing. Body spoon.
Beat the surface. Cold chisel.
Sand the surface. Wire brush.
Apply plastic filler. Overall.
Safely boots.
87
CRITERIA TRAINING
ASSESSMENT
Clean the work Theories: The trainee Fire extinguishers.
place. should explain: Ball pein hammer.
Store tools in safe The importance of Clamps.
custody. selecting proper size Pliers.
Role gas pipes and filler rods. Leather gloves.
store gas cylinder Heat effect on metal. Canvas spats.
in proper way. Properties of materials. Leather aprons.
Importance of cutting
rusted areas.
Gas welds techniques.
Circumstantial
knowledge
Detailed knowledge
about:
observed while
performing gas welding
of rusted body part.
Environment issues.
First aid.
88
LEVEL: II
MODULE NUMBER: 7 MODULE TITLE: PERFORMING ALIGNMENT OF CAR BODY PANELS
UNIT NO: 1 UNIT TITLE: CARRYING OUT ALIGNMENT OF BODY PANELS DURATION: 44 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Fix the bonnet, The trainee should The aligned body Knowledge evidence: This unit can be achieved at
achieved this unit boot and door. be able to: panel conforms to Detailed knowledge of: a work place or training
should be able to 2. Adjust for Apply body jack technical Method used: The trainee institution.
align body panels alignment. and levers to align specifications. should explain different The following tools, safety
as per technical 3. Tighten the fixed body panel. procedures in body panel gears and equipment
specifications. attachments. Strengthen the alignment. should be available:
damaged body Hydraulic body jack.
part. Principles: The trainee Toolbox (spanners).
Select the pushing should explain the principles Levers/extensions.
or pulling points. of: Hammer.
Select the anchor Aligning misaligned body Screw drivers.
points for panels. Overall.
alignment. Select anchoring points. Leather gloves.
Inspect for Taking measurements. Punch.
correctness. Safety boots.
Clean the work Pusher heads.
place. Light hammer.
Tape measure.
89
CRITERIA TRAINING
ASSESSMENT
Store tools and Theories: The trainee
equipment in safe should explain:
custody. Application of force and
calculations.
Types of body panel and
their purpose.
Body materials.
Circumstantial
knowledge:
Detailed knowledge
about:
observed while
performing body panel
alignment.
First aid.
90
LEVEL: II
MODULE NUMBER: 7 MODULE TITLE: PERFORMING ALIGNMENT OF CAR BODY PANEL
UNIT NO: 2 UNIT TITLE: CARRYING OUT SANDING CAR BODY PANELS DURATION: 104 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Sanding by disc The trainee should Sand grinded body Knowledge evidence: This unit can be achieved
achieved this unit grinding. be able to: panel conforms to Detailed knowledge of: at a work place or training
should be able to 2. Polishing and Connect sending technical Method used: The trainee institution.
perform car body checking for disc to the grinder. specifications. should explain the technique The following tools, safety
sanding as per correctness. Identify starting used in sanding car body gears and equipment
technical 3. Re-apply body filler. areas. panels. should be available:
specifications. 4. Regrinding/sanding. Select working Body files.
5. Undercoat paint. tools. Principles: The trainee Disc grinding machine
Sand the surface. should explain the principles (sand disc).
Use body file at of: Disc grinding spanner.
corners. Sanding process. Hand sanding plate.
Dust out. Obtaining smooth Nose mask.
Switch of sanding surface. Overall.
machine. Selecting disc grades. Apron.
Clean the tools. Hand/machine sanding. Safety glasses.
Store them in safe Sand papers (assorted).
custody. Water bath.
91
CRITERIA TRAINING
ASSESSMENT
Theories: The trainee Electrical power.
should explain: Supply.
The importance of
removing old paint or
body filler.
The importance of body
filler.
The reason for
undercoat paint.
Emery paper size and its
application.
Circumstantial
knowledge:
Detailed knowledge
about:
observed while sanding.
First aid.
92
LEVEL: II
MODULE NUMBER: 8 MODULE TITLE: PERFORMING THICK METAL CUTTING BY GAS WELDING
UNIT NO: 1 UNIT TITLE: CARRYING OUT GAS CUTTING ON THICK METAL PLATES DURATION: 91 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Metal selection and The trainee should Gas cut work piece Knowledge evidence: This unit can be achieved at
achieved this unit properties. be able to: conform to Detailed knowledge of: a work place or training
should be able to 2. Blow pipe pressure Prepare and inspect technical Method used: The trainee institution.
cut thick metal setting. gas welding plant. specifications. should explain the cutting The following tools, safety
plates as per 3. Metal cutting. Interpret working technique used. gears and equipment
technical drawing. should be available:
specifications. Mark the work Principles: The trainee Working drawing.
piece. should explain the principles Gas welding plant.
Measure the limits. of: Cutting torch.
Regulate the flame. Gas weld cutting. Spark lighter/match
Perform the metal Properties of materials. box.
cutting. Obtaining good cut. Divider.
Shut off gas Setting flame pressure. Chalk (white).
regulators. Steel rule.
Chip of slag’s. Theories: The trainee Measuring tape.
Inspect the should explain: Overall.
correctness. Types of metal cut. Leather apron.
Types of flame setting. Industrial boots.
93
CRITERIA TRAINING
ASSESSMENT
Clean the working Preparation on gas Leather gloves.
area. cutting. Welding goggles.
Clean tools and Cutting angle. Hammer.
equipments. Fusion techniques. Chisel.
Store tools and gas Types of distortion. Try square.
plant in safety.
Circumstantial
knowledge:
Detailed knowledge
about:
observed with the
trainee while performing
the task.
First aid.
94
LEVEL: II
MODULE NUMBER: 9 MODULE TITLE: PERFORMING CAR BODY PLASTIC FILLING
UNIT NO: 1 UNIT TITLE: CARRYING OUT PLASTIC FILLING ON BODY PANEL DURATION: 52 HOURS
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Prepare surface. The trainee should The body filled Knowledge evidence: This unit can be achieved at
achieved this unit 2. Mix the body filler be able to: surface conforms to Detailed knowledge of: a work place or training
should be able to materials. Inspect the surface. technical Method used: The trainee institution.
perform plastic 3. Apply body filler. Mix the plastic filler specifications. should explain body filler The following tools, safety
filling on a body 4. Disc grind. with hardener. mixing techniques. gears and equipment
panel as per the 5. Sanding. Apply the plastic should be available:
specifications. filler on a dented Principles: The trainee Piece of glass sheet.
surface. should explain the principles Scrapers.
Weight for cure. of: Rubbers squish
Sand grind the Body filling. spreader.
surface. Body filler material Gloves.
Recheck for mixing ratio. Nose mask.
corrections. Curing time and Apron.
Re-torch the filler. reasons. Overall.
Resend grind the Selection of body fillers. Hand disc grinder
surface. Applications of body machine.
Polish/clean. filler in the surface. Safety goggles.
95
CRITERIA TRAINING
ASSESSMENT
Clean the work Theories: The trainee
area. should explain:
Store tools and Types of body fillers.
materials safely. Properties of materials.
Use of scrapers.
Purpose of body filling.
Circumstantial
knowledge:
Detailed knowledge
about:
observed while body
filling.
First aid.
96
LEVEL: II
MODULE NUMBER: 10 MODULE TITLE: PERFORMING PAINTING ON A PANEL
UNIT NO: 1 UNIT TITLE: CARRYING OUT PAINTING ON A PANEL DURATION: 68 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Inspect the body. The trainee should A painted panel Knowledge evidence: This unit can be achieved at
achieved this unit 2. Prepare the surface be able to: conforms to Detailed knowledge of: a work place or training
should be able to for painting. Remove dirt from technical Method used: The trainee institution.
perform painting 3. Hand brush/spray the panel. specifications. should explain the panel The following tools, safety
on a panel as per paint. Apply sand paper. painting procedures. gears and equipment
technical Clean the surface. should be available:
specifications. Mix painting Principles: The trainee Brushes.
materials. should explain the principles Spray gun.
Apply under of: Masks.
painting by brush Metal painting. Scrapers.
or spraying. Paint mixing. Air compressor.
Apply second coat. Painting. Air hose.
Apply final coat. Under painting. Overall.
Cure the painted Paint cure. Apron.
plate. Gloves.
Polish and check Pliers.
for correctness. Boots.
Gloves.
97
CRITERIA TRAINING
ASSESSMENT
Clean or wash the Theories: The trainee Water bath.
tools. should explain: Spray painting
Store tool in safe Structure and properties room/workshop.
custody. of different paints.
Application of each
emery paper sizes.
Why cleaning is
important before
painting.
Circumstantial
knowledge:
Detailed knowledge
about:
observed when
performing the task.
First aid.
98
LEVEL: III
MODULE NUMBER: 1 MODULE TITLE: PERFORMING SPRAY PAINTING ON CAR BODY
UNIT NO: 1 UNIT TITLE: CARRYING OUT SPRAY PAINTING ON CAR BODY DURATION: 76 HOURS.

CRITERIA TRAINING
ASSESSMENT
A person who has 1. Inspecting the The trainee should Spray painted car Knowledge evidence: This unit can be achieved at
achieved this unit surface. be able to: conforms to Detailed knowledge of: a work place or training
should be able to 2. Performing Primer Carry out surface technical Method used: The trainee institution.
spray paint car painting. straightening with specifications. should explain the spray The following tools, safety
body as per 3. Applying first coat. soft putty. paint technique used. gears and equipment
technical 4. Applying final coat. Water sanding the should be available:
specifications. surface. Principles: The trainee Air compressor.
Dry smooth the should explain the principles Air pipes.
surface. of: Spray gun.
Cover the areas Spray painting. Nose mask.
which are not Paint removing. Apron.
painted. Overall.
Apply primer paint. Theories: The trainee Head shield with
Water-sand wash should explain: respirators.
the surface. Spray painting. Scrapers.
Dry wash the Preparation of surface. Hand gloves.
surface. Different paint mixing. Industrial boots.
99
CRITERIA TRAINING
ASSESSMENT
Spray the 1st Paint removing Painting
coating. techniques. room/workshop.
Spray the final Types of abrasives Water bath.
coats. materials. Polishing machine.
Switch off Soft putting the surface.
compressors. Spray pressure setting.
Clean the tools.
Circumstantial
Store tools in safe
knowledge:
custody.
Detailed knowledge
about:
observed while spray
painting.
First aid.
Environmental effects.
100
LEVEL: III
MODULE NUMBER: 1 MODULE TITLE: PERFORMING SPRAY PAINTING ON CAR BODY
UNIT NO: 2 UNIT TITLE: CARRYING OUT METALIC SPRAY PAINTING ON CAR BODY DURATION: 30 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Performing paint The trainee should Spray painted car Knowledge evidence: This unit can be achieved at
achieved this unit mixing. be able to: conforms to Detailed knowledge of: a work place or training
should be able to 2. Application on Carry out surface technical Method used: The trainee institution.
spray metallic auto-body. straightening with specifications. should explain the metallic The following tools, safety
paints on car body soft putty. paint spray techniques. gears and equipment
as per technical Water sanding the should be available:
specifications. surface. Principles: The trainee Air compressor.
Dry smooth the should explain the principles Air pipes.
surface. of: Spray gun.
Cover the part Spray painting. Clean cloth.
which are not Paint mixing. Nose mask.
painted. Metallic paints. Apron.
Apply primer paint. Overall.
Mixing metallic Theories: The trainee Head shield with
paints with should explain: respirators.
hardner. Spray painting Scrapers.
Water-sand wash technique. Hand gloves.
the surface. Preparation of surface. Industrial boots.
101
CRITERIA TRAINING
ASSESSMENT
Dry wash the Different paint colour Spray painting room.
surface. mixing. Open container/bucket.
st
Spray the 1 Paint removing
coating. techniques.
Spray the final Types of abrasives
coats. materials.
Switch off Soft putting the surface.
compressors. Spray pressure setting.
Clean the tools.
Store tools in safe Circumstantial
custody. knowledge
Detailed knowledge
about:
observed while spray
painting.
First aid.
Environmental effects.
102
LEVEL: III
MODULE NUMBER: 2 MODULE TITLE: PERFORMING ARC WELDING ON VARIOUS VEHICLE BODY PARTS
UNIT NO: 1 UNIT TITLE: CARRY OUT ARC WELDING ON NON FERROUS METALS DURATION: 52 HOURS.

CRITERIA TRAINING
ASSESSMENT
A person who has 1. Welding aluminium The trainee should Welded thick plate Knowledge evidence: This unit can be achieved at
achieved this unit by arc welding. be able to: conforms to Detailed knowledge of: a work place or training
should be able to 2. Welding copper by Inspect the technical Method used: The trainee institution.
carry out arc arc welding. machine, cable and specifications. should explain The following tools, safety
welding on thick welding torch. Resistance welding gears and equipment
plates in all Interpret working technique used. should be available:
positions as per drawing. Welding procedure. Welding machine (TIG,
technical Prepare materials MIG).
specifications. for welding. Welding cables.
Set recommended Earth clamps.
of:
current. Welding shield.
Welding thick materials.
Select types and Chipping hammer.
Heat treatment.
sizes of Wire brush.
Purging.
consumable wires. Work bench.
Align and tackweld Tongs.
the work piece. Angle grinder.
Bench vice.
Scriber.
103
CRITERIA TRAINING
ASSESSMENT
Maintain torch Theories: The trainee Hammer.
Angle and arc should explain: Center punch.
length. Properties of non- Leather Apron.
Control torch travel ferrous materials. TIG, MIG welding
speed along the Metallurgy of materials. torch.
joint. Identification of Regulator.
Control distortion materials. Flow meter.
and warpage. Heat treatment Carbon dioxide cylinder.
Avoid weld defect. processes. Argon cylinder.
Clean workplace, Joint design. Leather gloves.
tools and Welding polarities and Overalls.
equipment. application. Industrial boots.
Store tools and Weld defects. Clear goggles.
equipment safely. Various shielding and Canvas spats.
application. Tape measure.
Filling of job cards and
feed back forms.
Maintenance works and
prioritization.
Estimation of materials
for a job.
104
CRITERIA TRAINING
ASSESSMENT
Controlling stock and
ordering of materials.
Non-destructive and
destructive test.
Heat and temperature
related to welding.
Technical drawing skills.
Work costing.
Estimation of time taken
for a job.
Circumstantial
knowledge:
Detailed knowledge
about:
thick plates.
First Aid.
105
LEVEL: III
MODULE NUMBER: 2 MODULE TITLE: PERFORMING ARC WELDING ON VARIOUS VEHICLE BODY PARTS
UNIT NO: 2 UNIT TITLE:CARRYING OUT WELDING ON PLATES USING MIG, TIG WELDING DURATION: 48 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Welding mild steel The trainee should Welded stainless or Knowledge evidence: This unit can be achieved at
achieved this unit by MIG welding. be able to: carbon steel work Detailed knowledge of: a work place or training
should be able to 2. Welding cooper by Inspect TIG and piece conforms to Method used: The trainee institution.
carry out arc TIG welding. MIG welding technical should explain different The following tools, safety
welding of 3. Welding aluminium equipment and specifications. welding techniques. gears and equipment
stainless and by TIG welding. accessories. should be available:
carbon steel by Select inert gases. MIG and TIG welding
TIG and MIG as Select welding machines.
of:
per technical polarity. Argon cylinder.
MIG welding.
specifications. Prepare tungsten Flow meter.
TIG welding.
electrodes. Welding cables.
Purging.
Regulate gas flow Welding gun/torch.
rate. Theories: The trainee Work bench.
Select correct torch should explain: Bench vice.
nozzle. Basic principles of TIG Angle grinder.
Adjust and MIG welding. Welding shield.
recommended Leather gloves.
current. Leather apron.
106
CRITERIA TRAINING
ASSESSMENT
Select correct filler How to identify metals Overalls.
metal. and composition of Canvas spats.
Prepare metal for steel. Chipping hammer.
welding. Different types of
File grooves on tungsten electrodes.
work piece. Different types of TIG
Align and tackweld. filler wires and nozzles.
Initiate the arc and The importance of high
weld the metal. frequency starting unit.
Maintain work and Different TIG welding
lead angle. techniques.
Maintain uniform The use of cleaning
travel speed along acid.
the joint. Type of materials for
Control distortion. TIG welding.
Avoid weld metal
defects.
Clean weldment
with acid.
Inspect weld metal
defects.
107
CRITERIA TRAINING
ASSESSMENT
Clean work place. Circumstantial
Clean tools and knowledge:
equipment and Detailed knowledge
store them safely. about:
observed while
performing TIG and MIG
welding.
First Aid.
108
LEVEL: III
MODULE NUMBER: 3 MODULE TITLE: PERFORMING GAS WELDING ON VEHICLE BODY BRACKETS
UNIT NO: 1 UNIT TITLE: CARRY OUT GAS WELDING ON FERROUS AND NON FERROUS METALS DURATION: 54 HOURS.

CRITERIA TRAINING
ASSESSMENT
A person who has 1. Welding cast iron The trainee should Welded metal Knowledge evidence: This unit can be achieved at
achieved this unit by gas welding. be able to: conforms to Detailed knowledge of: a work place or training
should be able to 2. Welding aluminium Inspect gas welding technical Method used: The trainee institution.
carry out gas by gas welding. equipment. specifications. should explain the welding The following tools, safety
welding on ferrous 3. Welding copper and Assemble and technique used. gears and equipment
and non ferrous its alloys by gas disassemble gas should be available:
metals in all welding. cylinders. Oxy-acetylene plant.
position as per Select nozzle sizes. Pressure regulator.
of:
technical Select welding filler Welding torch.
Welding by gas flame.
specifications. wires. Hose pipe.
Low pressure blow pipe.
Set working Gas trolley.
High pressure blow pipe.
pressure. Cylinder key.
Cut and file sheet Blow pipe spanner.
metal. Spark lighter.
should explain:
Light the torch and Hammer.
Types of flames.
adjust the correct Chisel.
welding flame. Wire brush.
Center punch.
109
CRITERIA TRAINING
ASSESSMENT
Align and tack weld Main parts of oxy- Leather apron.
work piece. acetylene plant and their Leather gloves.
Weld sheet metal. functions. Industrial boots.
Keep on Function of flash back Canvas spats.
maintaining arrestors and hose Tape measure.
movement of blow check valves. Steel rule.
pipe and filler wire. Operating principles of
Check fusion on low and high pressure
metals. blow pipes.
Keep on Different gas welding
maintaining techniques.
orderliness of Storage of gas cylinders.
welding ripples. Metallurgy of metals
Check root (basic).
penetration. Technical drawing skills.
Inspect quality of Work costing.
weld ripples. Filling of job cards and
Clean work place, feedback forms.
tools and Non-destructive and
equipment. destructive weld test.
110
CRITERIA TRAINING
ASSESSMENT
Store tools and Joint design.
equipment safely. Heat and temperature
relating to welding.
Circumstantial
knowledge:
Detailed knowledge
about:
metals.
First Aid.
111
LEVEL: III
MODULE NUMBER: 3 MODULE TITLE: PERFORMING GAS WELDING ON VEHICLE BODY BRACKETS
UNIT NO: 2 UNIT TITLE: CARRYING OUT GAS CUTTING ON FERROUS METALS DURATION: 36 HOURS.

CRITERIA TRAINING
ASSESSMENT
A person who has 1. Cutting steel plate The trainee should A cut work piece Knowledge evidence: This unit can be achieved at
achieved this unit by automatic be able to: conforms to Detailed knowledge of: a work place or training
should be able to machine flame Inspect gas welding technical Method used: The trainee institution.
cut metals by gas cutting. equipment. specifications. should explain gas weld The following tools, safety
flame cutting as 2. Cutting steel plate Assemble gas cutting procedures. gears and equipment
per technical by stack cutting. cylinder set. should be available:
specifications. Select nozzle sizes. Principles: The trainee Work drawing and plan.
Select welding should explain the principles Oxy-acetylene plant.
rods. of: Regulators.
Set cut pressure. Gas welding. Welding torch.
Light the torch. Cutting metal by flame. Cutting torch.
Adjust the flame. Obtaining smooth cut. Hose pipes.
Cut and file plate to Setting cutting flames. Gas trolley.
specifications. Cylinder key.
Align and tack off Theories: The trainee Spark lighter.
work piece. should explain: Ball pein hammer.
Parts of gas cutting Wire brush.
equipments. Chisels.
112
CRITERIA TRAINING
ASSESSMENT
Keep on controlling Their functions. Centre punch.
movement of Recommended work Leather gloves.
cutting torch. flames and pressure. Apron.
Keep on Side effect of back fire Overalls.
maintaining cutting and flash back. Angle grinder.
angle of torch. Different cutting Bench vice.
Check fusion. procedures. Safety boots.
Maintain Canvas spats.
Circumstantial
orderliness of weld Dust mask.
knowledge:
nipples. Safety goggles.
Detailed knowledge
Check root
about:
penetration.
Check and inspect
observed while
weld and cut for
performing gas welding
correctness.
and cutting.
Clean work place.
First aid.
Keep tools and
equipment in safe
custody.
113
LEVEL: III
MODULE NUMBER: 4 MODULE TITLE: PERFORMING FABRICATION OF VEHICLE BODY COMPONENTS
UNIT NO: 1 UNIT TITLE: CARRYING OUT SHEET METAL WORK DURATION: 114 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Making wing The trainee should Sheet metal Knowledge evidence: This unit can be achieved at
achieved this unit panels. be able to: fabricated as per Detailed knowledge of: a work place or training
should be able to 2. Making bonnets. Interpret working technical Method used: The institution.
carry out sheet 3. Producing piece drawings. specifications. trainee should explain The following tools, safety
metal work as per channel. Take correct how to develop gears and equipment
technical 4. Restoring dented measurement. cylindrical and offset should be available:
specifications. panel. Calculate cones from the drawing. Working drawing.
allowances using Measuring tape.
formulae. Principles: The trainee Try square.
Develop different should explain the Tool box.
types of patterns. principles of: Hammer.
Operate different Developing different Scriber.
types of sheet types of patterns. Grooving tools.
metal works Transforming drawing Bending machine.
equipment. measurement to a sheet Seaming machine.
metal. Cutting machine.
Obtaining forming Forming tools.
allowances. Clear goggles.
114
CRITERIA TRAINING
ASSESSMENT
Assemble the Theories: The trainee Leather apron.
developed patterns should explain: Leather gloves.
to form the The properties of Industrial boots.
required item as material. Canvas spats.
per drawing. Transformation of Overalls.
Clean work place. measurements from Anvil.
Clean and store drawing to a sheet Bench vice.
tools and metal.
equipment. Construction of
geometrical figures.
Development techniques
of cylinder, cylinder with
oblique top and cones.
115
CRITERIA TRAINING
ASSESSMENT
Circumstantial
knowledge:
Detailed knowledge
about:
observed while
performing sheet metal
works.
First Aid.
116
LEVEL: III
MODULE NUMBER: 5 MODULE TITLE: PERFORMING INSTALLATION OF VEHICLE BODY ATTACHMENTS
UNIT NO: 1 UNIT TITLE: CARRYING OUT INSTALLATION OF A WIND SCREEN AND VENT GLASS
DURATION: 46 HOURS.

CRITERIA TRAINING
ASSESSMENT
A person who has 1. Checking pole for The trainee should The wind screen Knowledge evidence: This unit can be achieved at
achieved this unit straightness. be able to: and vent glass Detailed knowledge of: a work place or training
should be able to 2. Checking wind Fit rubber to the installed conform to Method used: The trainee institution.
install wind screen frame for wind screen. technical should explain the screen The following tools, safety
screens and vent correct Alignment Fix the rope. specifications. and vent glass fixing gears and equipment
glasses as per and fitting a wind Fit the wind screen. techniques. should be available:
technical screen into the Use others to Piece of stung chord.
specifications. frame. assist. Principles: The trainee Set of pliers.
3. Fitting glass Check for should explain the principles Screw drivers.
winding machine correctness. of: Soft hammers.
and window glass. Fix vent glasses. Fixing screen with Hand gloves.
Check for leakage. rubbers. Overalls.
Clean tools and Shock absorption. Rubber cutter.
store them safely. Apply rope when fixing. Step ladder/stand.
117
CRITERIA TRAINING
ASSESSMENT
should explain:
Glass properties.
Rubber functions.
Fixing tools.
Circumstantial
knowledge:
Detailed knowledge
about:
observed while fixing
the screen and vent
glass.
Environment issues.
First aid.
118
LEVEL: III
MODULE NUMBER: 5 MODULE TITLE: PERFORMING INSTALLATION OF VEHICLE BODY ATTACHMENTS
UNIT NO: 2 UNIT TITLE: CARRYING OUT INSTALLATION OF ELECTRICAL AND BODY SURFACE FITTINGS
DURATION: 64 HOURS.

CRITERIA TRAINING
ASSESSMENT
A person who has 1. Refitting vehicle The trainee should A decorated car Knowledge evidence: This unit can be achieved at
achieved this unit lightning holders be able to: body conforms to Detailed knowledge of: a work place or training
should be able to and exterior Inspect auto-body. technical Method used: The trainee institution.
install electrical fixtures. Identify required specifications. should explain decorating The following tools, safety
and body surface 2. Fitting body grills decorators. and surface fixturing gears and equipment
fittings as per and channels. Fix channels. procedures. should be available:
technical 3. Fitting body Fix side lamp Set of screw drivers.
specifications. decorators/mouldin holders. Principles: The trainee Adhesives materials.
gs. Use adhesive should explain the principles Rivet gun.
4. Fixing interior where required. of: Soft hammer.
fixtures/triming.
Use rivets where Decorating on car body. Set of spanners.
required. Handling/care Hand gloves.
Polish the car body. procedures. Overall.
Clean tools. Surface protection.
Store tools in safe
custody.
119
CRITERIA TRAINING
ASSESSMENT
should explain:
Main decorating areas.
Decorating materials.
Reasons for front and
show grilling.
Ventilation procedures.
Circumstantial
knowledge
Detailed knowledge
about:
observed when
performing body
decoration.
First aid.
120
LEVEL: III
MODULE NUMBER: 6 MODULE TITLE: PERFORMING VEHICLE FRAME WELDING
UNIT NO: 1 UNIT TITLE: CARRYING OUT HEAVY METAL WELDING DURATION: 66 HOURS.

CRITERIA TRAINING
ASSESSMENT
A person who has 1. Forming heavy The trainee should Welded metal Knowledge evidence: This unit can be achieved at
achieved this unit brackets. be able to: conforms to Detailed knowledge of: a work place or training
should be able to 2. Welding thick Inspect the technical Method used: The trainee institution.
weld heavy metals chassis frame. machine, cable and specifications. should explain the welding The following tools, safety
as per technical 3. Welding spring electrode holder. technique used. gears and equipment
specifications. hangers. Interpret working should be available:
4. Welding spring. drawing. Principles: The trainee Working plan.
Prepare materials should explain the principles Welding machine.
for welding. of: MIG and TIG machines.
Select type and size Arc welding. Welding cables.
of electrode for the Minimizing distortion. Electrode holder.
job. Obtaining good Welding shield.
Set recommended penetration. Chipping hammer.
current. Selecting weld current. Wire brush.
Weld a work piece. Work bench.
Welding tongs.
Angle grinder.
Flat file.
121
CRITERIA TRAINING
ASSESSMENT
Keep on Theories: The trainee Bench vice.
maintaining should explain: Scriber.
electrode angle and Types of metals and Earth clamp.
arc length. their properties. Ball pein hammer.
Keep on controlling Types and functions of Centre punch.
electrode travel welding equipment. Overalls.
speed along the Groove preparations. Leather gloves.
joint. Uses of wire brush and Canvas spats.
Chip off metal slag chipping hammer. Safety boots.
and wire brush. Metallurgical effects on Leather apron.
Inspect for weld weldment.
defect. Characteristics of AC
Clean work place. and DC welding
Clean tools and machine.
equipment. Types of welds.
Store tools and Types of electrode
equipment in safe coatings and function.
place. Work angle and lead
angle.
Welding symbols.
122
CRITERIA TRAINING
ASSESSMENT
Types of distortion.
Joint design.
Circumstantial
knowledge:
Detailed knowledge
about:
work piece.
First Aid.
123
LEVEL: III
MODULE NUMBER: 7 MODULE TITLE: MANAGING AUTOBODY SHOP
UNIT NO: 1 UNIT TITLE: ESTABLISHING TOOLS, EQUIPMENT AND MATERIALS PROFILE DURATION: 57 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Keeping tools and The trainee should Tools, equipment Knowledge evidence: This unit can be achieved at
achieved this unit material ledger. be able to: and materials Detailed knowledge of: a work place or training
should be able to 2. Preparing material Interpret auto-body profile hand-book Method used: The trainee institution.
make tools, profile. repair diagram. produced as should explain how to The following tools, safety
equipment and 3. Managing List type and reference for Auto- establish type of tools and gears and equipment
materials profile as equipment and quantities of tools body mechanics as equipment for a given task. should be available:
per catalogue tools. and equipment for per catalogue Skills log-book.
manual 4. Establishing shop a specific job. manual Principles: The trainee Tools and equipment
specifications. layout. Fill a requisition. specifications. should explain the principles catalogue.
Catalogue the data of making a tools and Stationeries.
as a reference tools equipment profile for a Scientific calculator.
and equipment given job. Staple machine.
profile source book. Overcoat.
Helmet.
Safety goggles.
Binding machine.
124
CRITERIA TRAINING
ASSESSMENT
should explain:
The importance of
making a standard
reference data book of
tools required for
various Auto-body tasks.
Store keeping
techniques.
Stock taking procedures.
Circumstantial
knowledge:
Detailed knowledge
about correctness of
information to be included in
reference data book.
125
LEVEL: III
UNIT NO: 2 UNIT TITLE: ESTIMATING MATERIAL AND LABOUR COSTS DURATION: 50 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Establishing The trainee should Cost estimate of Knowledge evidence: This unit can be achieved at
achieved this unit materials required. be able to: the materials and Detailed knowledge of: a work place or training
should be able to 2. Establishing price Interpret the labour cost Method used: The trainee institution.
estimate materials quotation and drawing. prepared as per should explain how to: The following tools,
and labour cost as quality. Identify tools, requirement. Read the drawing and materials, safety gears and
per repair lay out 3. Establishing equipment, safety identify materials equipment should be
plan. purchase gears and required needed. available:
procedure. materials. Calculate the cost of Repair lay out plan.
Prepare technical identified materials and Stationeries.
specifications. labour cost. Scientific calculator.
Prepare bills of Staple machine.
quantities (BOQ). Principles: The trainee Unit prices of the
Prepare cost should explain the principles materials.
estimates for of man hour rate to make Overcoat.
materials. cost estimates. Safety boots.
Prepare labour cost Helmet.
including other Safety goggles.
overheads. Binding machine.
126
CRITERIA TRAINING
ASSESSMENT
Keep documents in Theories: The trainee
proper custody. should explain:
The importance of
functional work plan.
The importance of
costing and pricing.
Circumstantial
knowledge:
Detailed knowledge
about precautions on
calculating profit margin.
127
LEVEL: III
UNIT NO: 3 UNIT TITLE: PREPARING A SMALL SCALE TENDER DOCUMENT DURATION: 49 HOURS.

CRITERIA TRAINING
ASSESSMENT
A person who has 1. Establishing The trainee should A tender document Knowledge evidence: This unit can be achieved at
achieved this unit marketing be able to: prepared and all Detailed knowledge of: a work place or training
should be able to procedures. Prepare auto-body contents conforms Method used: The trainee institution.
prepare a small 2. Preparing layout drawing. to PPRA should explain how to: The following tools, safety
scale tender brochures. Prepare technical requirements. Prepare short listed gears, and equipment
document as per 3. Preparing tender specifications of the tender document. should be available:
Public Procument documents. materials. Prepare open tender Stationeries.
Regulatory Prepare bills of document. Binding machine.
Authority (PPRA) quantities for the Staple machine.
requirement tender (BOQ). Principles: The trainee Brochures of materials.
Prepare related should explain the principles Overcoat.
documents of preparing the tender Safety boots.
(Instruction to documents. Safety gloves.
tenderers, special Computer and printer.
conditions of Public procurement Act.
contract).
128
CRITERIA TRAINING
ASSESSMENT
Prepare brochure of Theories: The trainee
the identified should explain:
material. Difference between
Bind the document. short listed tender and
Cross check the open tender.
contents of the Application of the short
tender document. listed and open tenders.
Send documents.
Circumstantial
knowledge:
Detailed knowledge
about confidentiality of the
tender document.
129
LEVEL: III
UNIT NO: 4 UNIT TITLE: TRAIN SUBORDINATES ON THE JOB DURATION: 70 HOURS.
CRITERIA TRAINING
ASSESSMENT
A person who has 1. Establishing on the The trainee should A training Knowledge evidence: This unit can be achieved at
achieved this unit job training be able to: programme Detailed knowledge of: a work place or training
should be able to schedule. Prepare capability properly Method used: The trainee institution.
train subordinates 2. Conducting training chart of the prepared and should explain how to The following tools,
on the job to meet needs assessment. subordinates. presented. prepare training material, safety gears and
their training 3. Arranging training Identify knowledge A person programme. equipment should be
needs. for subordinates. and skills to be trained is able available:
4. Establishing imported. to execute Principles: The trainee Work plan.
manpower level. Identify previous tasks to should explain the principles Automotive spanners.
5. Advising the knowledge and required of carrying out training Auto-body tool kit.
administration. skills possessed by standards programme by using the Auto-body jack (hand).
the person to be according to four steps plan (prepare, Auto-body power jack.
trained. regulations. present, try-out assign Auto-body stand.
Prepare a training work). Measuring tape.
programme for the Work bench.
subordinate. Safety goggles.
Safety boots.
Safety gloves.
130
CRITERIA TRAINING
ASSESSMENT
Carry out the Theories: The trainee Overcoat.
training programme should explain: Stationary.
by using four steps Necessity of identifying Workshop manuals.
plan (prepare, previous knowledge and Seminar room.
present, try-out, skill of the person to be
assign work). trained.
Continually assess The importance of step
progress of the by step guidance from
trainee. simple to complex tasks.
Make necessary
Circumstantial
adjustments to the
knowledge:
training programme
Detailed knowledge
schedule.
about:
The skills of the person
to be trained.
Basic educational
psychology.
Thorough analysis of
training needs.
131
LEVEL: III
UNIT NO: 5 UNIT TITLE: SUPERVISING SUBORDINATES DURATION: 30 HOURS.

CRITERIA TRAINING
ASSESSMENT
A person who has 1. Planning work The trainee should Assigned jobs Knowledge evidence: This unit can be achieved at
achieved this unit schedule. be able to: done to Detailed knowledge of: a work place or training
should be able to 2. Supervising on job. Maintain discipline specifications Method used: The trainee institution.
supervise 3. Inspecting and and keep control and according should explain how to: The following tools, safety
subordinates as check the over the to schedule. Manage by objectives. gears and equipment
per Management correctness. employees. Records of Fill up a job card. should be available:
outlined job Distribute work work progress Job cards.
description. among the workers properly kept. Principles: The trainee Work schedule sheets.
in such a way to Reports should explain the principles Drawing facilities.
secure maximum submitted as of: Work plan.
output. per regulations. Scientific management. Overcoat.
Keep coordination Managerial Helmet.
among the staff at management. Safety boots.
various levels. Stationary.
132
CRITERIA TRAINING
ASSESSMENT
Improve efficiency; Theories: The trainee
management keeps should explain:
sufficient watch Types of management
and strict objectives.
inspection. Managerial abilities.
Suggest new ideas
Circumstantial
and improvements.
knowledge:
Arrange for the
Detailed knowledge
efficient storing and
about:
recording.
Local cultural norms and
Make the
social behavior.
arrangement of
Leadership/management
payments and their
styles.
record.
Basic knowledge about
Impart the
industrial psychology,
instructions timely
supervision skills.
and provide
consistant
guidance.
133
CRITERIA TRAINING
ASSESSMENT
Provide facilities
and wages to the
workers.
134

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VOCATIONAL EDUCATION AND TRAINING AUTHORITY

CURRICULUM FOR AUTOBODY RREPAIR

VETA’s Vision Statement:

VETA’s mission statement

For and on behalf of:

ABR - Auto-Body Repair

TRADE ADVISORY COMMITTEE MEMBERS

1. Mr. Simon Kabolla - Chairperson.

1. Mr. W.M. Gideme - Dar es Salaam Institute of

1. Mrs. Rehema M. Binamungu - Curriculum Development Specialist

Occupational Standards: Specific requirements of competences people are expected

Performance criteria: indicate the expected end results or outcome in form of

Standard: it is a set of statement, which if proved true under working conditions,

Assessment: The process of collecting evidence and making judgments on whether

Underpinning Knowledge: This is essential knowledge needed in order to

Circumstantial knowledge: Detailed knowledge, which allows the decision-making in

To ensure that vocational education and training contributes to learners’ employability,

(h) To promote and to provide tailor – made course programs and

(j) To promote a flexible training approach and appropriate teaching methodologies.

3.0. CURRICULUM STRUCTURE

3.1. MEANING OF THE OCCUPATION

General competencies of the occupation

Employment opportunities for the occupation

(b) Private sector

3.2. AIM AND OBJECTIVE OF THE COURSE

MODULES MODULE TITLES

3.4. ENTRY REQUIREMENTS

3.5. STRUCTURE AND ORGANISATION OF THE COURSE CONTENT

3.7. RELATED SUBJECTS

3.8. CROSS-CUTTING SKILLS

4.0. LEARNING AND TRAINING METHODOLOGY

Learning and training methodology in CBET is based upon philosophy of learning

5.0 MANAGEMENT OF ASSESSMENT

5.1. MODES OF ASSESSMENT

5.2. ROLES OF A VOCATIONAL TEACHER IN ASSESSMENT

5.4. ASSESSMENT RECORDS

6.0 CERTIFICATION AND AWARD

6.1. ASSESSMENT CRITERIA

6.2. MARKING AND GRADING

6.3. PASS LEVELS

Continuous assessment marks shall be combined with final assessment marks

The pass mark of related subjects and cross-cutting skills shall be

Notwithstanding a candidate who qualifies for final assessment shall not be

7.0 VOCATIONAL TEACHERS’ QUALIFICATIONS

8.0. MONITORING AND EVALUATION

Implementation of the curriculum will be continuously monitored and summatively

9.1. Books Required:

[2] Maurice W. Cuming, (1976), The Theory and practical of Personal

[4] Chapman W.A.J. (2003), Workshop Technology Part 1, 5th Edition,

9.2. Recommended books

environment. Use the first aid kit. of: Aprons.

PERFORMANCE ELEMENTS COMPETENCE ASSESSMENT

PERFORMANCE ELEMENTS COMPETENCE ASSESSMENT

PERFORMANCE ELEMENTS COMPETENCE ASSESSMENT

PERFORMANCE ELEMENTS COMPETENCE ASSESSMENT

PERFORMANCE ELEMENTS COMPETENCE ASSESSMENT

PERFORMANCE ELEMENTS COMPETENCE ASSESSMENT

PERFORMANCE ELEMENTS COMPETENCE ASSESSMENT

PERFORMANCE ELEMENTS COMPETENCE ASSESSMENT

PERFORMANCE ELEMENTS COMPETENCE ASSESSMENT

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