Fitter

FIRST YEAR: The practical part starts with basic fitting in the beginning and the candidate also imparted training on allied trades viz., Sheet Metal, Welding (Gas & Arc) which leads to multi-skilling. In the basic fitting the skills imparted are sawing, filing, marking, chipping, measurement, riveting, soldering, brazing, drilling and observation of all safety aspects is mandatory. The accuracy achieved is of ±0.25 mm. The safety aspects cover components like OSH & E, PPE, Fire extinguisher, First Aid and in addition 5S being taught. Different drilling operations (through, blind, angular), reaming, offhand grinding, tapping, dieing, different fits viz., sliding fit, etc., scraping, fastening (nuts & bolts, riveting, studs, screws, etc.,). The accuracy achieved is of± 0.04 mm and angular accuracy to 30minutes. Different turning operations on lathe (step, grooving, chamfering, drilling, boring, knurling & threading), simple repair, overhauling and lubrication work on machine are being taught in the practical.

SECOND YEAR: Power tool operation, different complex assembling and fitting, fastening, lapping, making gauges, pipe works and pipe joints, Dismantling, overhauling& assembling valves are covered. The accuracy achieved is of an accuracy of ± 0.02 mm & 10 minutes. Making & using drill jigs, making of critical components, repair & maintenance of power transmission system, making of template &complex gauges, identify different Pneumatic & hydraulic components and circuit construction, repair & maintenance of machinery like lathe, drill, grinding, bench drilling, Inspection of Machine tools, Accuracy testing of Machine tools and erection of simple machines are being performed as part of practical training. Professional Knowledge subject is simultaneously taught in the same fashion to apply cognitive knowledge while executing task. In addition components like Physical properties of engineering materials, Interchangeability, Method of expressing tolerance as per BIS Fits, different types of iron, properties and uses, special files, honing, Metallurgical and metal working processes such as Heat treatment, the various coatings used to protect metals, different bearing, working material with finished surface as aluminium, duralumin and stainless steel, topics related to non-ferrous metals, Method of lubrication are also covered under theory part. Total three projects need to be completed by the candidates in a group. In addition to above components the core skills components viz., Workshop calculation & science, Engineering drawing, employability skills are also covered. These core skills are essential skills which are necessary to perform the job in any given situation.

Candidates broadly need to demonstrate that they are able to

1. Read & interpret technical parameters/ document, plan and organize work processes, identify necessary materials and tools;
2. Perform task with due consideration to safety rules, accident prevention regulations and environmental protection stipulations;
3. Apply professional skill, knowledge, core skills & employability skills while performing jobs.
4. Check the job/ assembly as per drawing for functioning, identify and rectify errors in job/assembly.
5. Document the technical parameters related to the task undertaken.

1. Can join industry as Technician and will progress further as Senior Technician, Supervisor and can rise to the level of Manager.
2. Can become Entrepreneur in the related field.
3. Can appear in 10+2 examination through National Institute of Open Schooling (NIOS) for acquiring higher secondary certificate and can go further for General/ Technical education.
4. Can take admission in diploma course in notified branches of Engineering by lateral entry.
5. Can join Apprenticeship programme in different types of industries leading to National Apprenticeship certificate (NAC).
6. Can join Crafts Instructor Training Scheme (CITS) in the trade for becoming instructor in ITIs.
7. Can join Advanced Diploma (Vocational) courses under DGT as applicable.

Table below depicts the distribution of training hours across various course elements during a period of two years: –

Fitter General; Sizes metal parts to close tolerances and fits and assembles them using hand tools for production or repairs of machines, or other metal products. Studies drawings to understand specification of different parts, fittings or assembles to be made and their functions. They select materials, appropriate tool and equipments to carry out their work.  Holds the work in Vice, Cuts and shapes required parts to dimensions and specifications by processes of sawing, chipping, filing, grinding, drilling holes, screw cutting, scrapping etc., using hand tools for making specimens or finished components.

Measures object while working using foot rules, calipers, micrometer, gauges etc. and checks for correct filing with square. Gets half-finished object marked or marks it himself using face plate, marking block scriber, vernier, height gauges, vee-blocks, angle plate, sine plate, slip gauges, combination set, etc. depending on accuracies required, to indicate guide lines for finished sizes, holes to be drilled and pitch centres, threads to be cut and other working details as specified in drawing or sample. Clamps object securely in correct position in vice and files it to required dimensions according to punch marks and guide lines frequently measuring it with calipers, micrometer, vernier, gauges etc, makes holes with drill, cuts threads with taps and dies ensuring that they are square or at required angle to base. Measures finished article with dial indicator, micrometer, vernier, height gauges, screw gauges, plug gauges, sine bar, slip gauge, etc according to prescribed accuracies.

May make parts separately and assemble those with screws, rivets, pins, etc. as specified so as to make complete unit according to drawing. Dismantles or removes worn out, broken or defective parts using hand tools or power tools and replaces them by repaired or new ones. Performs repairing and maintenance work (including preventive maintenance) of simple machines, dismantles and replaces different components to construct circuit of Pneumatics and Hydraulics.

Tests completed article/ assembly to ensure correct performance. May do simple turning of parts on machines and perform welding, brazing, and like operations. May explain heat treatment processes viz., annealing, hardening, tempering etc. May specialize in particular type of machine or product and be designated accordingly. May suggest alterations.

In addition, Fitter have the ability to visualize the job, good coordination, mechanical attitude, manual dexterity and perform work related mathematical calculations.

Plan and organize assigned work and detect & resolve issues during execution. Demonstrate possible solutions and agree tasks within the team. Communicate with required clarity and understand technical English. Sensitive to environment, self-learning and productivity.

May be designated as FITTER General according to nature of work done.

FIRST YEAR:

1. Plan and organize the work to make job as per specification applying different types of basic fitting operation and Check for dimensional accuracy following safety precautions. [Basic fitting operation – Marking, Hacksawing, Chiselling, Filing, Drilling, Taping and Grinding etc. Accuracy: ± 0.25mm]
2. Manufacture simple sheet metal items as per drawing and join them by soldering, brazing and riveting.
3. Join metal components by riveting observing standard procedure.
4. Join metal component by arc welding observing standard procedure.
5. Cut and join metal component by gas (oxyacetylene)
6. Produce components by different operations and check accuracy using appropriate measuring instruments. [Different Operations – Drilling, Reaming, Taping, Dieing; Appropriate Measuring Instrument – Vernier, Screw Gauge, Micrometer]
7. Make different fit of components for assembling as per required tolerance observing principle of interchange ability and check for functionality. [Different Fit – Sliding, Angular, Step fit, ‘T’ fit, Square fit and Profile fit; Required tolerance: ±0.04 mm, angular tolerance: 30 min.]
8. Produce components involving different operations on lathe observing standard procedure and check for accuracy. [Different Operations – facing, plain turning, step turning, parting, chamfering, shoulder turn, grooving, knurling, boring, taper turning, threading (external ‘V’ only)]
9. Plan & perform simple repair, overhauling of different machines and check for functionality. [Different Machines – Drill Machine, Power Saw, Bench Grinder and Lathe]

SECOND YEAR:

10. Make & assemble components of different mating surfaces as per required tolerance by different surface finishing operations using different fastening components, tools and check functionality. [Different Mating Surfaces – Dovetail fitting, Radius fitting, Combined fitting; Different surface finishing operations – Scraping, Lapping and Honing; Different fastening components – Dowel pins, screws, bolts, keys and cotters; Different fastening tools-hand operated & power tools, Required tolerance – ±0.02mm, angular tolerance ± 10 min.]
11. Make different gauges by using standard tools & equipment and checks for specified accuracy. [Different Gauges – Snap gauge, Gap gauge; Specified Accuracy – ±0.02mm]
12. Apply a range of skills to execute pipe joints, dismantle and assemble valves & fittings with pipes and test for leakages. [Range of skills – Cutting, Threading, Flaring, Bending and Joining]
13. Make drill jig & produce components on drill machine by using jigs and check for correctness.
14. Plan, dismantle, repair and assemble different damaged mechanical components used for power transmission & check functionality. [Different Damage Mechanical Components – Pulley, Gear, Keys, Jibs and Shafts.]
15. Identify, dismantle, replace and assemble different pneumatics and hydraulics components. [Different components – Compressor, Pressure Gauge, Filter Regulator Lubricator, Valves and Actuators.]
16. Construct circuit of pneumatics and hydraulics observing standard operating procedure & safety aspect.
17. Plan & perform basic day to day preventive maintenance, repairing and check functionality. [Simple Machines – Drill Machine, Power Saw and Lathe]
18. Plan, erect simple machine and test machine tool accuracy. [Simple Machines – Drill Machine, Power Saw and Lathe]