Foundryman

GOVERNMENT OF INDIA
MINISTRY OF SKILL DEVELOPMENT & ENTREPRENEURSHIP
DIRECTORATE GENERAL OF TRAINING

COMPETENCY BASED CURRICULUM

FOUNDRYMAN
(Revised in 2017)

CRAFTSMEN TRAINING SCHEME (CTS)

NSQF LEVEL- 4

SECTOR –PRODUCTION & MANUFACTURING

Foundryman

FOUNDRYMAN (Engineering Trade)

(Revised in 2017)

CRAFTSMEN TRAINING SCHEME (CTS)

NSQF LEVEL - 4

Developed By

Ministry of Skill Development and Entrepreneurship

Directorate General of Training
CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE
EN-81, Sector-V, Salt Lake City,
Kolkata – 700 091
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ACKNOWLEDGEMENT

The DGT sincerely acknowledges contributions of the Industries, State Directorates,

Trade Experts, Domain Experts and all others who contributed in revising the curriculum.
Special acknowledgement is extended by DGT to the following expert members who had
contributed immensely in this curriculum.

List of Expert members contributed/ participated for finalizing the course curricula of TDM
(Dies &Moulds) trade held on 16.05.17 at Govt. ITI- Aundh, Pune
Name & Designation
S No. Organization Remarks
Shri/Mr/Ms
Industry Experts
1. Dr. K C Vora, Sr. Dy. The Automotive Research Chairman
Director & Head, Arai Association of India, S.No.102,
Academy Vetal Hill, Off Paud Road, Kothrud,
Pune
2. Jayanta Patra, Sr. Manager Micromatic Machine Tools (P) Ltd., Member
240/241,11th Main , 3rd Phase,
Peenya Industrial Area, Bangalore
3. Kashinath M. Patnasetty, Ace Designers Ltd. Plot No. 7&8, Member
Head - Application Support IIPhase Peenya Industrial Area,
Group Bangalore
4. Sunil Khodke, Training Bobst India Pvt. Ltd.,Pirangut, Member
Manager Mulashi, Pune
5. Lokesh Kumar, Manager, Volkswagen India Pvt. Ltd., Pune Member
Training Academy
6. Shriram Tatyaba Khaire, Sulzer India Pvt. Ltd.,Kondhapuri, Member
Executive Engineering Shirur, Pune
7. Milind P Desai, Sr. Shift Atlas Copco (I) Ltd Dapodi, Pune Member
Engineer
8. Shrikant Mujumdar, DGM John Deere India Pvt Ltd. Pune - Member
Nagar Road, Sanaswadi, Pune
9. G.D. Rajkumar, Director GTTI, Coimbatore Member
10. Milind Sanghai, Team Alfa Laval India Ltd. Dapodi, Pune Member
Manager
11. Rajesh Menon, Unit Manager Alfa Laval India Ltd., Dapodi, Pune Member
12. N K A Madhuubalan, DGM - Sandvik Asia Pvt. Ltd., Dapodi, Member
QC, QA & SMPS Pune
13. Irkar Balaji, Sr. Engineer Mfg. Premium Transmission Ltd., Member
Chinchwad, Pune
14. Rajendra Shelke, Sr. Engineer Premium Transmission Member
Mfg. Ltd.,Chinchwad, Pune - 19
15. Bhagirath Kulkarni, Manager Tata Ficosa Auto Sys Ltd., Member
Maintenance Hinjawadi, Pune
16. Rohan More, Hr & Admin Tata Ficosa Auto Sys Ltd., Member
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Hinjawadi, Pune
17. G. Venkateshwaran, TEC Cummins India Ltd. Member
Manger- Corporate
Responsibility
18. Mahesh Dhokale, Engineer Tata Toyo Radiator Ltd. Member
19. Pankaj Gupta, DGM- HR & IR Tata Toyo Radiator Ltd. Member
20. S K Joshi Head - Business Radheya Machining Ltd., Pune- Member
Development Nagar Road, Sanaswadi, Pune
21. A L Kulkarni, DGM Mfg. PMT Machines Ltd Pimpri, Pune Member
22. S V Karkhanis, DGM Planning PMT Machines Ltd Pimpri, Pune Member
23. Kiran Shirsath, Asso. Manager Burckhardt Compression Pvt. Ltd., Member
M.E. Ranjangaon, Pune
24. Ajay Dhuri, Manager Tata Motors Ltd Pimpri, Pune Member
25. Arnold Cyril Martin, DGM Godrej & Boyce Mfg Co Ltd, Member
Mumbai
26. Ravindra L. More Mahindra CIE Automotive Ind. Ltd. Member
Ursc- Pune
27. Kushagra P. Patel NRB Bearings Ltd., Chiklthana Member
Aurangabad
28. M. M. Kulkarni, Sr. Manager - NRB Bearings Ltd., Chiklthana Member
Tool room Aurangabad
DGT & Training Institute
29. Nirmalya Nath, CSTARI, Kolkata Member cum
Asst. Director of Trg. Co-coordinator
30. Goutam Sutradhar, Prof. Jadavpore University Member
31. Rajib Chaudhuri, Principal Foundry Cluster Development Member
Association
32. Damodar Mondal, Trg. Officer ATI, Howrah Member
33. Jugal Kishore Biswas, ITI Midnapore Member
Instructor
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CONTENT
S
S No. Topics Page No.
1. Course Information 1
2. Training System 2-5
3. Job Role 6
4. General Information 7-8
5. NSQF Level Compliance 9
6. Learning/ Assessment Outcome 10-11
7. Learning Outcome with Assessment Criteria 12-18
8. Syllabus 19-26
9. Syllabus - Core Skill
9.1 Core Skill – Workshop Calculation & Science and 27-30
Engineering Drawing
9.2 Core Skill – Employability Skill 31-34
10. Annexure I
List of Trade Tools & Equipment 35-38
List of Tools & Equipment for Employability Skill 39
11. Annexure II - Format for Internal Assessment 40
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1. COURSE INFORMATION

During the one year duration of Foundryman trade, a candidate is trained on subjects
Professional Skill, Professional Knowledge, Engineering Drawing, Workshop Science &
Calculation and Employability Skills. In addition to this, a candidate is entrusted to make/do
project work and Extra Curricular Activities to build up confidence. The practical skills are
imparted in simple to complex manner & simultaneously theory subject is taught in the same
fashion to apply cognitive knowledge while executing task.

It broadly covers all aspects of skills required to make casting in foundry industry.

1stSemester– In this semester, it broadly covers safety aspect in general to safety aspect specific
to the trade, identify tools & equipment, raw materials used in casting. Further sand sieving and
mixing, sand testing is taught. Other operations like ramming, channel cutting, sand preparation,
backing and gate cutting are covered. In addition, core making, preparation of green sand mould,
leveling of floor, bedding in mould, preparing mould with different types of core, preparing
differing mould as per equipment are also covered. The related wood working different pattern
making are also part of the practical task. Different metal working like chipping, filing, grinding,
drilling etc. are also covered. Finally, the melting practice on induction furnace is undertaken in
this semester.

2ndSemester– In this semester, preparation of different moulds viz., loam sand mould, pit mould,
CO2mould and making casting is covered in the beginning. In addition, preparation of mould
with different core setting viz., balancing core, hanging core along with casting different metals
are covered. Finding the yield percentage is also part of the practical task. Simultaneously
preparation of complete core by joining half core is covered. Further, preparation of mould with
different gates viz., pencil, finger, wedge ring, branch, relief sprue, skim bob, horn gate, stepped
gate etc. including making casting of different metal is covered. Practical skills like relining
different furnace viz., fit, oil fired, muffles are covered along with ladle. The preparations of core
by linseed oil and ivpoils, preparing mould without pattern are also part of practical skills.
Finally, making cast by die & investment casting are covered.

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2. TRAINING SYSTEM

2.1 GENERAL

The Directorate General of Training (DGT) under Ministry of Skill Development &
Entrepreneurship offers a range of vocational training courses catering to the need of different
sectors of economy/ Labour market. The vocational training programmes are delivered under the
aegis of National Council of Vocational Training (NCVT). Craftsman Training Scheme (CTS)
and Apprenticeship Training Scheme (ATS) are two pioneer programmes of NCVT for
propagating vocational training.

Foundryman trade under CTS is one of the most popular courses delivered nationwide
through a network of ITIs. The course is of one-year (02 semester) duration. It mainly consists of
Domain area and Core area. In the Domain area, Trade Theory & Practical impart professional
skills and knowledge, while Core area (Employability Skills) imparts requisite core skill,
knowledge and life skills. After passing out of the training programme, the trainee is awarded
National Trade Certificate (NTC) by NCVT which is recognized worldwide.

Candidates broadly need to demonstrate that they are able to:

 Read & interpret technical parameters/documentation, plan work, identify necessary

materials and tools;
 Perform task with due consideration to safety rules, accident prevention regulations and
environmental protection stipulations;
 Apply professional knowledge, core skills & employability skills while performing the
job.
 Check the job/assembly as per drawing for functioning, identify and rectify errors in
job/assembly.
 Document the technical parameters related to the task undertaken.

2.2 CAREER PROGRESSION PATHWAYS:

 Can join Apprenticeship programme in different types of industries leading to National
Apprenticeship certificate (NAC).
 Can join Crafts Instructor Training Scheme (CITS) in the trade for becoming instructor in
ITIs.

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2.3 COURSE STRUCTURE:
Table below depicts the distribution of training hours across various course elements
during a period of one year (02 semesters):

Notional Training
S No. Course Element
Hours
1 Professional Skill (Trade Practical) 1075
2 Professional Knowledge (Trade Theory) 258
3 Workshop Calculation & Science 86
4 Engineering Drawing 129
5 Employability Skills 110
6 Library & Extracurricular Activities 62
7 Project Work 80
8 Revision & Examination 280
Total 2080

2.4 ASSESSMENT & CERTIFICATION

The trainee will be tested for his skill, knowledge and attitude during the period of course
and at the end of the training programme as notified by the Govt. of India from time to time. The
employability skills will be tested in first two semesters itself.

a) The Internal Assessment during the period of training will be done by Formative
Assessment Method by testing for assessment criteria listed against learning outcomes. The
training institute have to maintain individual trainee portfolio as detailed in assessment
guideline. The marks of internal assessment will be as per the template (Annexure – II).

b) The final assessment will be in the form of summative assessment method. The All India
Trade Test for awarding NTC will be conducted by NCVT at the end of each semester as per the
guideline of Govt. of India. The pattern and marking structure is being notified by Govt. of India
from time to time. The learning outcome and assessment criteria will be basis for setting
question papers for final assessment. The examiner during final examination will also
check individual trainee’s profile as detailed in assessment guideline before giving marks for
practical examination.

2.4.1 PASS REGULATION

The minimum pass percentage for Practical is 60% & minimum pass percentage for
Theory subjects is 40%. For the purposes of determining the overall result, 25% weightage is
applied to the result of each semester examination.

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2.4.2 ASSESSMENT GUIDELINE

Appropriate arrangements should be made to ensure that there will be no artificial

barriers to assessment. The nature of special needs should be taken into account while
undertaking assessment. Due consideration should be given while assessing for teamwork,
avoidance/reduction of scrap/wastage and disposal of scrap/wastage as per procedure, behavioral
attitude, sensitivity to environment and regularity in training. The sensitivity towards OSHE and
self-learning attitude are to be considered while assessing competency.
Assessment will be evidence based, comprising the following:
 Job carried out in labs/workshop
 Record book/ daily diary
 Answer sheet of assessment
 Viva-voce
 Progress chart
 Attendance and punctuality
 Assignment
 Project work

Evidences of internal assessments are to be preserved until forthcoming semester

examination for audit and verification by examination body. The following marking pattern to be
adopted while assessing:

Performance Level Evidence

(a) Weightage in the range of 60-75% to be allotted during assessment
For performance in this grade, the  Demonstration of good skill in the use of hand tools,
candidate should produce work which machine tools and workshop equipment.
demonstrates attainment of an acceptable  Below 70% tolerance dimension achieved while
standard of craftsmanship with undertaking different work with those demanded by
occasional guidance, and due regard for the component/job.
safety procedures and practices.  A fairly good level of neatness and consistency in the
finish.
 Occasional support in completing the project/job.
(b) Weightage in the range of 75-90% to be allotted during assessment
For this grade, a candidate should  Good skill levels in the use of hand tools, machine
produce work which demonstrates tools and workshop equipment.
attainment of a reasonable standard of  70-80% tolerance dimension achieved while
craftsmanship, with little guidance, and undertaking different work with those demanded by
regard for safety procedures and the component/job.
practices.  A good level of neatness and consistency in the

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finish.
 Little support in completing the project/job.
(c) Weightage in the range of above 90% to be allotted during assessment
For performance in this grade, the  High skill levels in the use of hand tools, machine
candidate, with minimal or no support in tools and workshop equipment.
organization and execution and with due  Above 80% tolerance dimension achieved while
regard for safety procedures and undertaking different work with those demanded by
practices, has produced work which the component/job.
demonstrates attainment of a high  A high level of neatness and consistency in the finish.
standard of craftsmanship.  Minimal or no support in completing the project.

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3. JOB ROLE

Brief description of Job roles:

In Foundryman trade, Mould maker makes mould by hand or machine which is a basic
step for making casting metal parts. Mould may be Green sand mould, chemically banded sand
(hot box or cold box) mould. Core maker makes core by core box or using machine, for placing
inside the mould to have designed holes, undercut or recesses. Metals are melted in different
types of furnaces. Different types of treatments are done during meting and pouring of metal
inside into the mould. After solidifying, the casting are cleaned and required to improve on
machinability, mechanical & metallurgical properties and also reliving internal stresses caused
due to process. Executes annealing normalizing and tempering as part of heat treatment.

Foundry charge calculation for cupola, induction and Arc furnaces are necessary to get
correct quality of metal considering melting losses.

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

Reference NCO-2015:

(i) 7211.0100
(ii) 8121.4200
(iii) 8121.4700
(iv) 8121.4600

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4. GENERAL INFORMATION

Name of the Trade FOUNDRYMAN

NCO - 2015 7211.0100, 8121.4200, 8121.4700, 8121.4600

NSQF Level Level – 4
Duration of Craftsmen One Year (Two semesters each of six months duration)
Training

Entry Qualification Passed 10th Class Examination

Unit Strength (No. Of

20 (Max. supernumeraries seats: 6)
Student)

Space Norms 128 Sq. m

Power Norms 11 KW
Instructors Qualification for
1. Foundryman Trade Degree in Mechanical/Metallurgy Engineering/Advanced
Diploma in Foundry Technology from recognized university with
one year post qualification experience in the relevant field.
OR
Diploma in Mechanical/Metallurgy Engineering from a recognized
board of technical education with two-year post qualification
experience in the relevant field.
OR
NTC/NAC passed in "Foundryman" trade with three-year post
qualification experience.

Desirable:
Preference will be given to a candidate with CIC(Craft Instructor
Certificate) in Foundryman trade.

Note:
Out of two Instructors required for the unit of 2(1+1), one must
have Degree/Diploma and other must have NTC/NAC
qualifications.
2. Workshop Calculation Degree in Engineering with one year experience.
& Science OR
Diploma in Engineering with two-year experience.

Desirable:
Craft Instructor Certificate in RoD&A course under NCVT.

3. Engineering Drawing Degree in Engineering with one year experience.

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OR
Diploma in Engineering with two-year experience.
OR
NTC/ NAC in the Draughtsman (Mechanical) with three-year
experience.

Desirable:
Craft Instructor Certificate in RoD&A course under NCVT.

4. Employability Skill MBA OR BBA with two-year experience OR Graduate in

Sociology/ Social Welfare/ Economics with two-year experience
OR Graduate/ Diploma with two-year experience and trained in
Employability Skills from DGT institutes.
AND
Must have studied English/ Communication Skills and Basic
Computer at 12th/ Diploma level and above.
OR
Existing Social Studies Instructors duly trained in Employability
Skills from DGT institutes.

List of Tools and

Equipment As per Annexure – I

Distribution of training on hourly basis: (Indicative only)

Work Extra-
Total Trade Trade Engg. Employability
shop Cal. curricular
Hours/Week Practical Theory Drawing Skills
&Sc. Activity

40 Hours 25 Hours 6 Hours 2 Hours 3 Hours 2 Hours 2 Hours

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5. NSQF LEVEL COMPLIANCE

NSQF level for Foundryman trade under CTS: Level 4

As per notification issued by Govt. of India dated- 27.12.2013 on National Skill

Qualification Framework total 10 (Ten) Levels are defined.

Each level of the NSQF is associated with a set of descriptors made up of five outcome
statements, which describe in general terms, the minimum knowledge, skills and attributes that a
learner needs to acquire in order to be certified for that level.

Each level of the NSQF is described by a statement of learning outcomes in five domains,
known as level descriptors. These five domains are:

a. Process
b. Professional Knowledge
c. Professional Skill
d. Core Skill
e. Responsibility

The broad learning outcome of Foundryman trade under CTS mostly matches with the
Level descriptor at Level- 4.
The NSQF level-4 descriptor is given below:

Process Professional
Level Professional Skill Core Skill Responsibility
Required Knowledge
Level 4 Work in Factual Recall and Language to Responsibility
familiar, knowledge demonstrate communicate for own work and
predictable, of field of practical skill, written or oral, learning.
routine, situation knowledge routine and with required
of clear choice. or study. repetitive in narrow clarity,skill to
range of basicArithmetic
application, using and algebraic
appropriate rule principles, basic
and understanding of
tool, using quality social political
concepts. and natural
environment.

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6. LEARNING/ ASSESSABLE OUTCOME

Learning outcomes are a reflection of total competencies of a trainee and assessment will
be carried out as per the assessment criteria.

6.1. GENERIC LEARNINGOUTCOME

The following are minimum broad Common occupational Skills/ Generic Learning Outcome
after completion of the Foundryman course of one year duration:

1. Recognize & comply with safe working practices, environment regulation and
housekeeping.

2. Understand and explain different mathematical calculation & science in the field of study
including basic electrical. [Different mathematical calculation & science-Work, Power &
Energy, Algebra, Geometry & Mensuration, Trigonometry, Heat & Temperature,
elasticity]

3. Interpret specifications, different engineering drawing and apply for different application
in the field of work. [Different engineering drawing-Geometrical construction,
Dimensioning, Layout, Method of representation, Symbol, Different Projections,
Assembly drawing, Sectional views, Estimation of material]

4. Select and measure dimension of components and record data.

5. Explain the concept in productivity,quality tools, and labour welfare legislation and apply
such in day-to-day work to improve productivity & quality.

6. Explain energy conservation, global warming and pollution and contribute in day-to-day
work by optimally using available resources.

7. Explain personnel finance, entrepreneurship and manage/organize related task in day-to-

day work for personal & societal growth.

8. Plan and execute the work related to the occupation.

6.2. SPECIFIC LEARNING OUTCOME

Semester – I

9. Categorize different types of tools, equipment & raw material used in foundry.
10. Prepare sand mix for moulding.
11. Perform different types of sand testing & find out result.
12. Produce green sand moulds by using appropriate hand tools.

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13. Produce different casting components by different metal with different moulding process
and finish the casting as per requirement.
14. Produce wooden joint, make pattern and repair defective pattern and boxes.
15. Prepare mould with loose piece pattern and loose piece core box.
16. Perform metal working such as marking, sawing, filling, grinding, drilling etc.
17. Make casting of aluminum/ magnesium by melting on Induction furnace & identify
defects.

Semester – II

18. Prepare mould by different moulding process, make cast iron castings identify defects.
19. Make a casting, fettle the casting & calculation yield percentage.
20. Prepare complete core by joining half cores.
21. Make mould by various types of gate to produce different type of metal casting. Find out
defects & visit industry to show different operation for casting making.
22. Make an extra thick casting & finish it.
23. Reline & prepare different types of furnaces for melting cast metals.
24. Make by using linseed oil & ivpoils.
25. Prepare mould without pattern & with sweep pattern.
26. Make casting by die casting process & yield percentage of casting.
27. Make casting by investment casting process & binder less process.

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7. LEARNING OUTCOME WITH ASSESSMENT CRITERIA

GENERIC LEARNING/ ASSESSABLE OUTCOME

LEARNING/ ASSESSABLE
ASSESSMENT CRITERIA
OUTCOMES
1. Recognize & comply with 1.1 Follow and maintain procedures to achieve a safe
safe working practices, working environment in line with occupational health
environment regulation and and safety regulations and requirements.
housekeeping. 1.2 Recognize and report all unsafe situations according to
site policy.
1.3 Identify and take necessary precautions on fire and safety
hazards and report according to site policy and
procedures.
1.4 Identify, handle and store/ dispose of
dangerous/unsalvageable goods and substances according
to site policy and procedures following safety regulations
and requirements.
1.5 Identify and observe site policies and procedures in regard
to illness or accident.
1.6 Identify safety alarms accurately.
1.7 Report supervisor/ Competent of authority in the event of
accident or sickness of any staff and record accident details
correctly according to site accident/injury procedures.
1.8 Identify and observe site evacuation procedures according
to site policy.
1.9 Identify Personal Productive Equipment (PPE) and use the
same as per related working environment.
1.10 Identify basic first aid and use them under different
circumstances.
1.11 Identify different fire extinguisher and use the same as per
requirement.
1.12 Identify environmental pollution andcontribute to
avoidance of same.
1.13 Take opportunities to use energy and materials in an
environmentally friendly manner.
1.14 Avoid waste and dispose waste as per procedure.
1.15 Recognize different components of 5S and apply the same
in the working environment.

2. Understand and explain 2.1 Explain concept of basic science related to the field such as
different mathematical Material science, Mass, weight, density, heat & temperature,
calculation & science in the heat treatment.
field of study including 2.2 Measure dimensions as per drawing
basic electrical. [Different
2.3 Use scale/ tapes to measure for fitting to specification.

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mathematical calculation & 2.4 Comply with given tolerance.
science-Work, Power & 2.5 Prepare list of appropriate materials by interpreting detail
Energy, Algebra, Geometry, drawings and determine quantities of such materials.
Mensuration, Trigonometry, 2.6 Ensure dimensional accuracy of assembly by using different
Heat & Temperature, instruments/gauges.
elasticity]
2.7 Explain basic electricity, insulation & earthing.

3. Interpret specifications, 3.1 Read & interpret the information on drawings and apply in
different engineering executing practical work.
drawing and apply for 3.2 Read & analyse the specification to ascertain the material
different application in the requirement, tools, and assembly/maintenance parameters.
field of work. [Different 3.3 Encounter drawings with missing/unspecified key
engineering drawing- information and make own calculations to fill in missing
Geometrical construction, dimension/parameters to carry out the work.
Dimensioning, Layout,
Method of representation,
Symbol, Different
Projections, Assembly
drawing, Sectional views,
Estimation of material]

4. Select and measure

4.1 Select appropriate measuring scale/tape/gauges.
dimension of components
and record data.
4.2 Measure dimension of the components/assembly & compare
with given drawing/measurement.

5. Explain the concept in 5.1 Explain the concept of productivity and quality tools and
productivity, quality tools, apply during execution of job.
and labour welfare 5.2 Understand the basic concept of labour welfare legislation
legislation and apply such in and adhere to responsibilities and remain sensitive towards
day-to-day work to improve such laws.
productivity & quality.
5.3 Knows benefits guaranteed under various acts.

6. Explain energy 6.1 Explain the concept of energy conservation, global

conservation, global warming, pollution and utilize the available resources
warming and pollution and optimally & remain sensitive to avoid environmental
contribute in day-to-day pollution.
work by optimally using
6.2 Dispose waste following standard procedure.
available resources.

7. Explain personnel finance, 7. 1. Explain personnel finance and entrepreneurship.

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entrepreneurship and 7. 2. Explain role of various schemes and institutes for self-
manage/organize related employment i.e. DIC, SIDA, SISI, NSIC, SIDO, Idea for
task in day-to-day work for financing/ non-financing support agencies to familiarize
personal & societal growth. with the Policies/Programmes, procedure & the available
scheme.
7. 3. Prepare project report to become an entrepreneur for
submission to financial institutions.

8. Plan and execute the work 8. 1. Use documents, drawings and recognize hazards in the work
related to the occupation. site.
8. 2. Plan workplace/ assembly location with due consideration to
operational stipulation.
8. 3. Communicate effectively with others and plan project tasks.
8. 4. Execute the task effectively.

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SPECIFIC LEARNING/ ASSESSABLE OUTCOME

LEARNING/ ASSESSABLE
ASSESSMENT CRITERIA
OUTCOMES
Semester-I
9. Categorize different types of 9.1 Select appropriate tools &equipments.
tools, equipment & raw 9.2 Identify raw materials used in foundry.
material used in foundry. 9.3 Ensure function of every raw material.
9.4 Ensure proper use of every tools and equipment.
9.5 Identify wrong & defective tools &equipments.

10. Prepare sand mix for 10.1 Plan & identify tools, equipment required for the job.
moulding. 10.2 Select raw materials required for preparing sand mix.
10.3 Prepare the proper mixing of the sand.
10.4 Check the correct proportion of the mixing sand.
10.5 Check the moisture content of the mixing sand.

11. Perform different types of 11.1 Identify testing specific equipment for particular test.
sand testing & find out 11.2 Check accuracy of the equipments.
result. 11.3 Perform sand test correctly.
11.4 Evaluate testing result.

12. Produce green sand moulds 12.1 Plan &identify tools &equipments required for producing
by using appropriate hand green sand mould.
tools. 12.2 Select the raw materials, pattern required for making
mould & channels.
12.3 Make necessary mould with the given pattern and cut
channel cutting & gate cutting observing standard
procedure.
12.4 Make coating of pattern observing standard procedure.
12.5 Repair the mould, if necessary.

13. Making different types of 13.1 Plan & identify proper tools and equipments for making
core. Produce different different casting components.
casting components by 13.2 Select all raw materials required for the mould, different
different metal with metal melting.
different moulding process 13.3 Select pattern for the mould.
and finish the casting as per 13.4 Make the floor and level it and level checked with sprit
requirement. level & straight edge.
13.5 Make the core with the help of core box and assemble the
mould with core.
13.6 Select all charging materials for casting.
13.7 Prepare the furnace for melting the metal as per type of
metal.
13.8 Pour melting metal into the mould cavity with special

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care. (maintain all safety measure)
13.9 Fettle the casting carefully.

14. Produce wooden joint, make 14.1 Plan & identify proper tools for making wooden joint,
pattern and repair defective making pattern and for repair patterns & core boxes.
pattern and boxes. 14.2 Study the design for the wooden joints.
14.3 Perform all operations and make the joints.
14.4 Observe safety procedure during above operations.
14.5 Check dimensional accuracy as per standard procedure.
14.6 Avoid waste.

15. Prepare mould with loose 15.1 Plan & identify proper tools and equipments required.
piece pattern and loose piece 15.2 Select loose piece pattern.
core box. 15.3 Select loose piece core box.
15.4 Select raw material for sand mixer.
15.5 Mix the sand with write quantity.
15.6 Make the mould with loose piece pattern.
15.7 Make core with loose piece core box.
15.8 Make the mould and assemble it.
15.9 Observe all step of operation during working.
15.10 Check correctness of the job.

16. Perform metal working such 16.1 Identify tools &equipments for making sawing, chipping,
as marking, sawing, filling, filling, grinding & drilling.
grinding, drilling etc. 16.2 Select appropriate material & the above operation.
16.3 Perform above operation carefully.
16.4 Observe safety & precaution during operation.
16.5 Check the accuracy of the job.

17. Make casting of aluminium/ 17.1 Observe the safe working of furnace for melting metal.
magnesium by melting on 17.2 Select raw materials for charging of furnace.
induction furnace & identify 17.3 Select raw materials for making mould.
defects. 17.4 Select pattern for making mould.
17.5 Make mould & pour molten metal to the mould.
17.6 Observe all safety & precaution maintained during metal
handling & pouring.
17.7 Fettled the casting & observe defects.
Semester-II
18. Make cast iron castings by 18.1 Plan & identify proper tools and equipments for making
different moulding process the iron casting.
and identify defects. 18.2 Plan & identify proper tools and equipments for making
specific mould.
18.3 Select all raw materials and prepare mould.
18.4 Select pattern required for the job.
18.5 Select core box for making cover core.

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18.6 Make the mould and insert core carefully.
18.7 Pour the molten metal carefully.
18.8 Safety should be maintain during handling and pouring of
molten metal.
18.9 Fettle the job.
18.10 Check the job as per specification.

19. Make a casting, fettle the 19.1 Plan and identify the tools and equipments required for
casting & calculation yield making casting.
percentage. 19.2 Check the core box.
19.3 Select the pattern and check the pattern.
19.4 Identify raw materials.
19.5 Make mould and assemble mould.
19.6 Identify chills & densers.
19.7 Locate position for chills.
19.8 Pour molten metal by observing safety.
19.9 Check the accuracy and quality of the job.
19.10 Calculate percentage of field.

20. Prepare complete core by 20.1 Identify and check core box for making jobs.
joining half cores. 20.2 Maintain heating temperature of core baking oven.
20.3 Control the mixed sand composition.
20.4 Check accuracy of dimensions and hardness of the core.

21. Make mould by various types 21.1 Plan and identify all hand tools and equipments.
of gate to produce different 21.2 Identify all raw materials.
type of metal casting and find 21.3 Select the pattern and check it.
out defects. 21.4 Mix the sand with correct proportion.
21.5 Maintain Core during meeting.
21.6 Maintain correct actions during working.
21.7 Identify defects, if any.
21.8 Repair the mould, if necessary.

22. Make an extra thick casting 22.1 Plan and identify tools and equipments required.
& finish it. 22.2 Select raw material required for the job.
22.3 Identify pattern and core box.
22.4 Mix the moulding sand with correct proportion and
quantity.
22.5 Follow every step for performing mould.
22.6 Repair mould, if needed.
22.7 Follow safety rule during carrying molten metal.
22.8 Find out defect and check quality of the job.

23. Reline & prepare different 23.1 Identify tools required for relining and repairing of
types of furnaces for melting furnace.
cast metals. 23.2 Identify raw materials required for reline and repair.
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23.3 Maintain correct proportion of charge materials.
23.4 Maintain relining thickness.
23.5 Maintain preheating temperature and heating time.
23.6 Maintain quality of charge metal for muffle furnace.
23.7 Maintain all safety and precaution during melting practice.
23.8 Check quality of casting.

24. Make core by using linseed 24.1 Plan and identify tool requirements.
oil & IVP oils. 24.2 Identify raw materials requirements for the job.
24.3 Maintain correct ratio for mixing the sand.
24.4 Check hardness of cores after curing.
24.5 Check quality and finishing of the core.

25. Prepare mould without 25.1 Plan and identify the tools and equipments required for the
pattern & with sweep pattern. mould.
25.2 Select suitable sweep pattern for sweep moulding.
25.3 Identify raw materials for the mould.
25.4 Mix the sand properly.
25.5 Check dimensions of mould cavity after mould making
without pattern.
25.6 Check the dimension of the mould cavity after mould
making by sweep pattern.

26. Make casting by die casting 26.1 Identify the machine required for gravity die casting.
process & yield percentage 26.2 Ensure the quality of the machine is useable.
of casting. 26.3 Observe releasing agent in applied in the metallic dies.
26.4 Maintain pouring temperature of molten metal.
26.5 Check the quality of the castings.
26.6 Calculate yield percentage of casting.

27. Make casting by investment 27.1 Identify raw materials required for making mould.
casting process & binder less 27.2 Maintain melting temperature of wax for investment
process. casting.
27.3 Follow steps of making the mould.
27.4 Maintain heating temperature for removal of wax from the
mould.
27.5 Extra care for handing the investment mould.
27.6 Check the quality of the casting.

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8. SYLLABUS

SYLLABUS FOR FOUNDRYMAN TRADE

First Semester - 06 Months
Professional Skills
Week Ref. Learning Professional Knowledge
(Trade Practical)
No. Outcome (Trade Theory)
With Indicative Hours
1 Recognize & 1. Importance of trade training, List of All necessary guidance to be
comply with safe tools & Machinery used in the provided to the newcomers to
working practices, trade.(01 hr) become familiar with the working
environment 2. Safety attitude development of the of Industrial Training Institute
regulation and trainee by educating them to use system including store’s
housekeeping. Personal Protective Equipment procedures.
(PPE).(05 hrs) Soft skills, its importance and job
3. First Aid Method and basic area after completion of training.
training. (02 hrs) Importance of safety and general
4. Safe disposal of waste materials precautions observed in the in the
like cotton waste, metal chips/burrs industry/shop floor.
etc. (02 hrs) Introduction of First aid. Operation
5. Hazard identification and of electrical mains and electrical
avoidance. (02 hrs) safety. Introduction of PPEs.
6. Safety signs for Danger, Warning, Response to emergencies e.g.
caution & personal safety power failure, fire, and system
message.(01 hr) failure.
7. Preventive measures for electrical Importance of housekeeping &
accidents & steps to be taken in good shop floor practices.
such accidents.(02 hrs) Introduction to 5S concept & its
8. Use of Fire extinguishers.(07 hrs) application.
9. Practice and understand precautions Occupational Safety & Health:
to be followed while working in Health, Safety and Environment
fitting jobs. (02 hrs) guidelines, legislations &
10. Safe use of tools and equipments regulations as applicable.
used in the trade. (01 hr)
Basic understanding on Hot work,
confined space work and material
handling equipment.
2 Categorize 11. Video show of large foundry History of Foundry Industries,
different types of industries in India. development of foundry in India.
tools, equipment & 12. PPT show of various tools & Importance of foundry Industries.
raw material used equipment used in foundry. Types of foundries, Advantage of
in foundry. 13. Identify each and every tools metal casting importance of quality
&equipments as per desired and quality awareness.
specification. Different tools &equipments used
14. PPT show of various raw materials in foundry.

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used in foundry. Different raw materials used in
15. Identify each raw materials used in foundry Industries.
foundry.
3 Prepare sand mix 16. Sieve the used sand with the help of Specification tools &equipments.
for moulding. riddle & shovel. (06 hrs) Procedure of use of different tools
17. Sieve the used sand with power &equipments.
riddle. (06 hrs) Making of green sand mixture.
18. Make Green sand mixture with Special casting process definition
tempering by shovel. (06 hrs) materials used composition, the
19. Make green sand mixture with process; use advantages and
tempering or moisturing by sand disadvantage of CO2 process and
muller. (07 hrs) shell moulding process.
4 Perform different 20. Test moisture content of green sand Sand testing different methods of
types of sand with the help of moisture trailer or moisture content test permeability
testing & find out infrared driver. (05 hrs) test, clay content test, strength test,
result. 21. Find out clay content of sand.(05 sand grain fineness test,
hrs) refractories test of moulding sand.
22. Find out permeability test of green Common types of natural &
sand with permeability tester. synthetic moulding sand as per IS
(05 hrs) 3343-1965 properties of moulding
23. Find out strength test with universal sand.
testing machine. (05 hrs)
24. Find out grain fineness no. of
moulding sand with sieve shaker
tester. (05 hrs)
5 Produce green 25. Ramming practice by open bedded Ramming procedure of rammer
sand moulds by method to obtain desired hardness and other tools used in marking
using appropriate such as 60, 70, 80, 90 by green mould.
hand tools. hardness tester. (13 hrs)
26. Ramming practice in moulding Importance of hardness test.
boxes with hand rammers to obtain
desire green hardness such as 70,
80, 90 by green hardness tester. (12
hrs)
6 -Do- 27. Cut channel on rammed boxes with Different types of Gate cutting
cross section such as square, semi- system with different tools used &
circular.(13 hrs) repairs of gates.
28. Cut channel on rammed boxed with
cross section such as trapezoid &
triangular and finish with cleaner &
double ender etc. (12 hrs)
7 -Do- 29. Prepare unit sand and prepare Difference between natural and
mould for block such as square, synthetic moulding sand principle
Rectangular and round.(25 hrs) ingredients in moulding sand &
their effect on physical properties
special additives in moulding sand
& their effect unit sand.

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8 -Do- 30. Prepare facing and backing sand Facing sand, baking sand
and simple moulds with top run Composition of various moulding
gates. (25 hrs) sand. Types of mould- advantage
and disadvantage of sand mould
and metal mould.
9 -Do- 31. Prepare mould with self-leaving Self-Core making procedure.
core pattern by using parting line Moulding boxes [As per IS 1280-
gates. (25 hrs) 1958]
Crucible [As per IS 1748-1961]
10 Produce different 32. Prepare green sand mould by using Definition of green sand
casting split pattern for aluminium casting. Advantage and disadvantage of
components by Use natural moulding sand melt green sand mould, skin dry sand
different metal aluminium in different furnace and mould, loam sand mould and
with different pour the same into moulds, fettle cement bonded sand mould.
moulding process aluminium casting. (25 hrs) Contraction, operation and
and finish the maintenance of pit furnace.
casting as per
requirement.
11 -Do- 33. Level the floor with sprit level and Moulding process – bench
straight edge and prepare open sand moulding different methods
mould. advantages, disadvantages and
their application.
12 -Do- 34. Prepare bedded in mould without Moulding process floor moulding.
core with parting line gate. (12 hrs) Different methods; advantage and
35. Prepare bedded in mould with core disadvantages and their application
and bottom run gate. (13 hrs) machine moulding different types
of moulding machines and slinger.
13-14 -Do- 36. Prepare mould with vertical core. Core: Uses and types, composition
(10 hrs) of various cores sand mixtures.
37. Prepare simple cores and assemble Types of core boxes core venting
in the mould. (10 hrs) and vein forcing or core-core
38. Prepare mould with horizontal core baking – core making machines.
and assemble in the mould.(12 hrs)
39. Prepare chair core and assemble in
the mould. (18 hrs)
15 -Do- 40. Prepare moulds for copper and Construction: Operation &
copper base alloys melts copper maintenance of oil fire furnace
alloy in pit furnace & pour & fettle pattern- pattern materials.
the casting. (13 hrs) Difference between wooden
41. Prepare moulds for copper and pattern and metal pattern.
copper base alloys melts copper
alloy in oil fired furnace & pour &
fettle the casting. (12 hrs)
16 -Do- 42. Prepare mould with draw back Pattern – types of patterns-
method & false check method. (10 allowance on pattern colouring of
hrs) pattern as per IS 1513-1959 care &
43. Prepare dry sand mould with maintenance of patter.

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skeleton pattern. (08 hrs)
44. Prepare black wash & coat on Different types of coating on
mould. (07 hrs) mould cores.
17 -Do- 45. Prepare stack mould. (13 hrs) Gating system. Various types of
46. Prepare snap flask mould. (12 hrs) top run gate part line gate &
bottom gate.
18 Produce wooden 47. Marking on wood for half lap joint. Brief description: Specification
joint, make pattern (03 hrs) and use of various wood working
and repair 48. Sawing on wood for half lap joint – hand tools. Types of joints & their
defective pattern (12 hrs) application in wood working.
and boxes. 49. Planning on wood for half lap joint.
(10 hrs)
19 -Do- 50. Making different types of joints on Methods of repairing the pattern &
wood. (09 hrs) core boxes. Induction hardening of
51. Prepare simple pattern. (08 hrs) S.G. Iron casting.
52. Repair wooden patterns & core
boxes. (08 hrs)
20 Prepare mould 53. Prepare mould with loose piece Prerequisites of gating system.
with loose piece pattern & core with loose piece Riser: Feeders & directional
pattern and loose core box. (25 hrs) solidification chill: chaplets,
piece core box. denseners & exothermic materials.
21 Perform metal 54. Metal working – Marking and Description, specification and use
working such as sawing on straight line – chipping of common, marking measuring,
marking, sawing, and filling to desired size on sawing, chipping and filing
filling, grinding, different metals. (10 hrs) instruments used in metal work.
drilling etc. 55. Grinding the metals to desire size Types of grinders – Brief
by pedestal grinder and flexible information about other metal
shaft grinder. (10 hrs) cutting equipments.
56. Drilling on various metals. (05 hrs) Various types of drill bits and
drilling machine.
22 Make casting of 57. Prepare induction furnace for Induction furnace types-
aluminum/ charging, prepare charges for construction, operation and
magnesium by charging, operate and melt maintenance.
melting on aluminium/ magnesium and pour
Induction furnace aluminium/ magnesium into the
& identify defects. mould and identify defects.(25 hrs)
23-25 Revision
26 Examination

Note: More emphasis to be given on video/real-life pictures during theoretical classes. Some
real-life pictures/videos of welded items like boiler drum, ship building, heavy welded structures
etc., may be shown to the trainees to give a feel of Industry and their future assignment.

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SYLLABUS FOR FOUNDRYMAN TRADE

Second Semester– 06 Months

Professional Skills
Ref. Learning Professional Knowledge
S No. (Trade Practical)
Outcome (Trade Theory)
With Indicative Hours
27 Prepare mould by 58. Prepare dry sand mould with odd Description of dry sand mould.
different moulding sided pattern and make casting.(10 Brief description types,
process, make cast hrs) advantages & disadvantages of
iron castings identify 59. Fettle the casting (07 hrs) die casting, centrifugal casting
defects. 60. Find out defect. (08 hrs) and ceramic moulding process.
28 -Do- 61. Prepare a loam sand mould for pan Slush casting process, continuous
shape casting. (10 hrs) casting process, permanent mould
62. Prepare a loam sand mould for bell casting process; Nishiyama
shape casting. (15 hrs) process (by using ferrosilicon
powder) common casting defects
appearance- causes and remedies-
salvaging of casting.
29 -Do- 63. Prepare a pit mould on foundry Slush casting process, continuous
floor. (10 hrs) casting process, permanent mould
64. Prepare a mould with pattern casting process; Nishiyama
having cover core print, assemble process (by using ferrosilicon
cover core in mould and cast by powder) common casting defects
cast iron. (12 hrs) appearance- causes and remedies-
65. Find out all defects. (03 hrs) salvaging of casting.
30 -Do- 66. Prepare simple CO2 mould.(07 Fettling of casting knock out and
hrs) removal and removal of casting
67. Prepare simple CO2 core. (08 hrs) from mould removal of gates &
68. Assemble in CO2 mould core.(05 risers; Fins & unwanted
hrs) projection – surface gleaning
69. Make a casting by C.I. (02 hrs) trimming and finishing.
70. Fettle the casting. (02 hrs) Inspection of casting – destructive
71. List out casting defects. (01 hrs) method – non-destructor
materials used in foundry and
their grades as per I.S.
31 -Do- 72. Prepare mould for setting Binders - Common binders used
“Balancing core” and set balanced in foundry and their application
core in mould with the help of and their grades as per I.S.
chaplets. (20 hrs) Common “Facing Materials” used
73. Make an aluminium casting using in foundry and their application
pit furnace. (03 hrs) and their grades as per I.S.
74. Fettle the casting. (02 hrs) Casting design functional design,
simplification of foundry practice.
Metallurgical design, economic
consideration.
32 Make a casting, fettle 75. Prepare a mould for setting Common “Fluxes” used in
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the casting & “Hanging core and set hanging foundry and their application.
calculation yield core in mould with the help of Specification
percentage. chaplets”. (15 hrs)
76. Make a casting. (05 hrs)
77. Fettle the casting.(03 hrs)
78. Find out yield percentage. (02 hrs)
33 -Do- 79. Prepare a mould using chills, Function of chills, densers.
densers. (20 hrs) Different between ferrous &non-
80. Make a casting. (04 hrs) ferrous metals. Physical &
81. Show a video chart of ferrous & mechanical properties of metals.
non-ferrous metals. (01 hr)
34 Prepare complete 82. Prepare core halves. (15 hrs) Classification of iron ores & its
core by joining half 83. Bake the core halves. (05 hrs) treatments.
cores. 84. Join the core valves by different
methods. (05 hrs)
35 Make mould by 85. Prepare mould with pencil gate. Different gating system
various types of gate (10 hrs) Common cost iron-alloys.
to produce different 86. Prepare mould with finger gate. Manufacturing process of chilled
type of metal casting. (10 hrs) cast iron; S.G. iron and malleable
Find out defects and 87. Make casting with aluminium.(05 cast iron.
visit industry to show hrs)
different operation
for casting making.
36 -Do- 88. Prepare mould with wedge gate. Effect of alloying elements for
(10 hrs) ferrous metals.
89. Prepare mould with ring gate.(10 Iron-carbon-equilibrium diagram
hrs) of plain carbon steel.
90. Make casting with copper base Inoculation: Purpose of
alloy. (05 hrs) inoculation.
37 -Do- 91. Prepare mould with branch gate Steel manufacturing process
mould with match plate pattern. classification common steel
(15 hrs) alloys and use.
92. Make casting with cast iron.(06
hrs)
93. Fettle the casting. (04 hrs)
38 -Do- 94. Prepare mould with relief sprue Advantages of sprue gate & skim
gate. (10 hrs) bob gates.
95. Prepare mould with skim bob gate. Wrought iron-manufacturing
(10 hrs) process- uses.
96. Make a casting with cast iron. (04 Copper manufacturing process –
hrs) properties use.
97. Find out defects. (01 hr)
39 -Do- 98. Prepare mould with horn gate Manufacturing process properties
[Gear wheel type pattern].(09 and use of aluminium, tin, zinc,
hrs) lead etc. Properties of grey iron.
99. Prepare mould with stepped gate. Microstructure, fracture,
(09 hrs) mechanical test-tensile test,

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100. Industrial visit to observe the hardness test etc.
special casting process machine
moulding process, operation of
different furnaces sand
reconditioning process,
inspection of casting, fettling
process etc. (07 hrs)
40 Make an extra thick 101. Prepare mould for extra thick Manufacturing process of copper
casting & finish it. casting with large feeder heads. base alloys, aluminium base
(18 hrs) alloys and magnesium base
102. Make casting with cast iron.(04 alloys.
hrs) Brief information about cupola
103. Fettle the casting. (03 hrs) furnace.
41 Reline & prepare 104. Reline the pit furnace. (22 hrs) Brief information about blast
different types of 105. Show a video show for operation furnace, electric furnaces such as
furnaces for melting of blast furnace. (03 hrs) arc furnace and induction furnace.
cast metals.
42 -Do- 106. Relining the oil fired furnace. Brief information about open
(20 hrs) hearth furnace, air furnace,
107. Charging of oil fired furnace & paddling furnace and convertors.
melt aluminium. (05 hrs)
43 -Do- 108. Reline of ladle. (08 hrs) Heat treatment of casting.
109. Pre heat of ladle. (03 hrs)
110. Reline of muffle furnace.(10 hrs)
111. Metal melt by muffle furnace.
(04 hrs)
44 Make core by using 112. Prepare simple oil sand core by Calculation of ferrostatic
linseed oil &IVP oils. using linseed oil. (15 hrs) pressure. Calculation of weight
113. Prepare oil sand core by IVP required on a mould.
oils. (10 hrs)
45 Prepare mould 114. Prepare simple, regular shape Calculation of molten metal
without pattern & mould without pattern (by required for different size mould
with sweep pattern cutting practice). (08 hrs) (Aluminium, brass, copper, C.I.
115. Prepare mould by sweep pattern. etc.)
(08 hrs)
116. Make mould by ram up core. (09
hrs)
46 Make casting by die 117. Prepare simple casting by gravity Cost estimate of simple castings
casting process & die casting. (22hrs) of different metals. Low pressure,
yield percentage of 118. Calculation yield high pressure, gravity die casting
casting. percentage.(03hrs) process.
47 Make casting by 119. Prepare simple casting by Foundry mechanization- layout of
investment casting investment casting a small foundry- list of material
process & binder less process.(13hrs) handling equipments and their
process. 120. Prepare simple casting with use.
binder less dry sand process.
(12hrs)

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48-49 Implant training/ project works:
a) Sand control tests
b) Wooden joints
c) Gear casting by horn gate
d) Make a simple pattern
e) Oil sand core
f) Investment casting
g) Die casting
h) Ladle casting
i) S.G. iron casting
50-51 Revision
52 Examination

Note:

1. Some of the sample project works (indicative only) are given against each semester.
2. Instructor may design their own project and also inputs from local industry may be taken
for designing such new projects.
3. The project should broadly cover maximum skills in the particular trade and must involve
some problem solving skill. Emphasis should be on Teamwork: Knowing the power of
synergy/ collaboration, work to be assigned in a group (Group of at least 4 trainees). The
group should demonstrate Planning, Execution, Contribution and Application of
Learning. They need to submit Project report.
4. If the instructor feels that for execution of specific project more time is required than he
may plan accordingly to produce components/ sub-assemblies in appropriate time i.e.,
may be in the previous semester or during execution of normal trade practical.

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9. SYLLABUS - CORE SKILLS

9.1 WORKSHOP CALCULATION SCIENCE & ENGINEERING DRAWING:

First Semester
Duration: Six Months

S No. Workshop Calculation and Science Engineering

Drawing
1. Unit: Systems of unit- FPS, CGS, Engineering Drawing: Introduction and its
MKS/SI unit, unit of length, Mass and importance
time, Conversion of units
- Relationship to other technical drawing
types
- Conventions
- Viewing of engineering drawing sheets
- Method of Folding of printed Drawing
Sheet as per BIS SP:46-2003
2. Fractions: Fractions, Decimal fraction, Drawing Instruments: their Standard and uses
L.C.M., H.C.F., Multiplication and
- Drawing board, T-Square, Drafter
Division of Fractions and Decimals,
(Drafting M/c), Set Squares, Protractor,
conversion of Fraction to Decimal and Drawing Instrument Box (Compass,
vice versa. Simple problems using Dividers, Scale, Diagonal Scales etc.),
Scientific Calculator. Pencils of different Grades, Drawing pins/
Clips.
3. Ratio &Proportion: Simple calculation Lines:
on related problems.
- Definition, types and applications in
Drawing as per BIS SP:46-2003
- Classification of lines (Hidden, centre,
construction, Extension, Dimension,
Section)
- Drawing lines of given length (Straight,
curved)
- Drawing of parallel lines, perpendicular line
- Methods of Division of line segment

4. Percentage: Free hand drawing of

Introduction, Simple calculation.
- Lines, polygons, ellipse, etc.
Changing percentage to fraction and - geometrical figures and blocks with
decimal & vice-versa. dimension

Transferring measurement from the given

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object to the free hand sketches.

5. Material Science: Properties -Physical & Lettering and Numbering as per BIS SP46-
Mechanical, Types –Ferrous & Non- 2003:
Ferrous, difference between Ferrous and
Non-Ferrous metals, introduction of Iron, - Single Stroke, Double Stroke, inclined,
Cast Iron, Wrought Iron, Steel, difference Upper case and Lower case.
between Iron and Steel, Alloy steel,
carbon steel, stainless steel, Non-Ferrous
metals, Non-Ferrous Alloys.

6. Mass, Weight and Density: Mass, Unit Drawing of Geometrical Figures: Definition,
of Mass, Weight, difference between mass nomenclature and practice of :
and weight.
- Angle: Measurement and its types,
Density, unit of density. Relation between method of bisecting.
mass, weight & density. - Triangle-different types
- Rectangle, Square, Rhombus,
Simple problems related to mass, weight, Parallelogram.
and density. - Circle and its elements.

7. Work, Power and Energy: Work, unit of Sizes and Layout of Drawing Sheets
work, power, unit of power, Horse power
- Basic principle of Sheet Size
of engines, mechanical efficiency,
- Designation of sizes
energy, use of energy, potential and - Selection of sizes
kinetic energy, examples of potential - Title Block, its position and content
energyand kinetic energy. - Borders and Frames (Orientation marks
and graduations)
- Grid Reference
- Item Reference on Drawing Sheet (Item
List)
8. ----- Method of presentation of Engineering Drawing
- Pictorial View
- Orthographic View
- Isometric view
9. ------ Symbolic Representation used in the related
trade (as per BIS SP:46-2003) of:
- Fastener (Rivets, Bolts and Nuts)
- Bars and profile sections
- Weld brazed and soldered joints
- Electrical and electronics element
- Piping joints and fittings

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Second Semester
Duration: Six Months

S No. Workshop Calculation and Science Engineering

Drawing
1. Basic Algebra: Dimensioning practice:
Addition, Subtraction, Multiplication, - Position of dimensioning (unidirectional,
Division, Algebraic formula, Linear aligned, as per BIS SP:46-2003)
equations - Types of arrowhead
(with two variables). - Leader Line with text
- Symbols preceding the value of
dimension and dimensional tolerance.
2. Mensuration: Drawing of Solid figures (Cube, Cuboids,
Area and perimeter of square, rectangle, Cone, Prism, Pyramid, Frustum of Cone and
parallelogram, triangle, circle, semi-circle, Pyramid) with dimensions.
Volume of solids – cube, cuboid, cylinder
and Sphere.

Surface area of solids – cube, cuboid,

cylinder and Sphere.

3. Trigonometry: Trigonometrical ratios, Free hand Drawing of Solid figures (Prism,

measurement of angles. Pyramid, Frustum of Cone and Pyramid) with
dimensions.
Trigonometric tables

4. Elasticity: Free Hand sketch of hand tools and measuring

Elastic & Plastic material. Stress & strain tools used in respective trades.
and their units. Young’s modules.
Ultimate stress and breaking stress.
5. Heat & Temperature: Projections:
Heat and temperature, their units, - Concept of axes plane and quadrant.
difference between heat and temperature, - Orthographic projections
boiling point, melting point, - Method of first angle and third angle
projections (definition and difference)
Scale of temperature, relation between - Symbol of 1st angle and 3rd angle projection
different scale of temperature. as per IS specification.

Thermometer, pyrometer.

Transmission of heat, conduction,

convection, radiation.
6. Basic Electricity: Introduction, use of Drawing of Orthographic projection in 3rd
electricity, how electricity is produced, angle.
Types of current_ AC, DC, their
comparison, voltage, resistance, their
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Foundryman
units. Conductor, insulator, Types of
connections – series, parallel, electric
power, Horse power, energy, unit of
electrical energy.

- Electrical insulating materials.

- Basic concept of earthing.

7. - Area of irregular surfaces. Free hand Drawing of simple fastener (Rivet,

- Application related to shop problems. Bolts, Nuts & Screw)
8. - Material weight and cost problems Free hand sketching of simple objects related
related to trade. to trade.
9. - Temperature measuring instruments. - Riveted joints-Butt & Lap (Drawing one for
Specific heats of solids & liquids. each type).
10. - Thermal Conductivity, Heat loss and - Reading of drawing. Simple exercises related
heat gain. to missing lines, dimensions. How to make
queries.
11. - Heat treatment and advantages. - Simple exercises relating missing symbols.
- Missing views
12. ---------- - Concept of preparation of assembly drawing
and detailing. Preparation of simple assemblies
& their details of trade related job/exercises
with the dimensions from the given sample or
models.
13. ---------- Reading of fabricated engineering drawing

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9.2 EMPLOYABILITY SKILLS:(110 Hours)

CORE SKILL – EMPLOYABILITY SKILL

First Semester
Duration : 20 hrs
1. English Literacy
Marks : 09
Pronunciation Accentuation (mode of pronunciation) on simple words,
Diction (use of word and speech)

Functional Grammar Transformation of sentences, voice change, change of tense,

spellings.

Reading Reading and understanding simple sentences about self, work and
environment

Writing Construction of simple sentences

Writing simple English

Speaking/ Spoken Speaking with preparation on self, on family, on friends/ classmates,

English on known people, picture reading, gain confidence through role-
playing and discussions on current happenings, job description,
asking about someone's job, habitual actions. Cardinal (fundamental)
numbers ordinal numbers. Taking messages, passing on messages and
filling in message forms, greeting and introductions, office
hospitality, resumes or curriculum vitae’s essential parts, letters of
application reference to previous communication.

Duration : 20 hrs
2. IT Literacy
Marks : 09
Basics of Computer Introduction, computer and its applications, Hardware and
peripherals, Switching on-Starting and shutting down computer.

Computer Operating Basics of Operating System, WINDOWS, User interface of Windows

System OS, Create, Copy, Move and delete Files and Folders, Use of External
memory like pen drive, CD, DVD etc., Use of common applications.

Word Processing and Basic operating of Word Processing, Creating, opening and closing
Worksheet documents, Use of shortcuts, Creating and Editing Text, Formatting
the text, Insertion & creation of tables. Printing document.
Basics of Excel worksheet, understanding basic commands, creating
simple worksheets, understanding sample worksheets, use of simple
formulas and functions, Printing of simple excel sheets.
Computer Networking Basic of computer Networks (using real life examples), Definitions of
and Internet Local Area Network (LAN), Wide Area Network (WAN), Internet,
Concept of Internet (Network of Networks),
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Meaning of World Wide Web (WWW), Web browser, Website, Web
page and Search Engines. Accessing the Internet using web browser,
Downloading and printing web pages, Opening an email account and
use of email. Social media sites and its implication.
Information Security and antivirus tools, Do's and Don'ts in
Information Security, Awareness of IT - ACT, types of cyber crimes.

Duration : 15 hrs
3. Communication Skills
Marks : 07
Introduction to Communication and its importance
Communication Skills Principles of Effective communication
Types of communication - verbal, non-verbal, written, email, talking
on phone.
Non-verbal communication- characteristics, components-Para-
language
Body language
Barriers to communication and dealing with barriers.
Handling nervousness/discomfort.

Listening Skills Listening-hearing and listening, effective listening, barriers to

effective listening, guidelines for effective listening.
Triple- A Listening - Attitude, Attention & Adjustment.
Active listening skills.

Motivational Training Characteristics essential to achieving success.

The power of positive attitude.
Self-awareness
Importance of commitment.
Ethics and values
Ways to motivate oneself.
Personal goal setting and employability planning.

Facing Interviews Manners, etiquettes, dress code for an interview.

Do's & Don'ts for an interview.

Behavioral Skills Problem solving, confidence building, attitude.

Second Semester
Duration : 15 hrs
4. Entrepreneurship Skills
Marks : 06
Concept of Entrepreneur - Entrepreneurship - Enterprises: Conceptual issue
Entrepreneurship Entrepreneurship vs. management, Entrepreneurial motivation.
Performance & Record, Role & Function of entrepreneurs in relation
to the enterprise & relation to the economy, Source of business ideas,
Entrepreneurial opportunities, and the process of setting up a
business.
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Project Preparation & Qualities of a good Entrepreneur, SWOT and Risk Analysis.
Marketing Analysis Concept & application of PLC, Sales & distribution management.
Difference between small scale & large scale business, Market
survey, Method of marketing, Publicity and advertisement,
Marketing mix.
Institution’s Support Preparation of project. Role of various schemes and institutes for self-
employment i.e. DIC, SIDA, SISI, NSIC, SIDO, Idea for financing/
non-financing support agencies to familiarize with the Policies/
Programmes, procedure & the available scheme.

Investment Procurement Project formation, feasibility, Legal formalities i.e., Shop Act,
Estimation & costing, Investment procedure - Loan procurement -
Banking processes.

Duration : 10 hrs
5. Productivity
Marks : 05
Benefits Personal/ Workman - Incentive, Production linked Bonus,
Improvement in living standard.

Affecting Factors Skills, Working Aids, Automation, Environment, Motivation - How

it improves or slows down productivity.

Comparison with Comparative productivity in developed countries (viz. Germany,

Developed Countries Japan and Australia) in selected industries e.g. Manufacturing, Steel,
Mining, Construction etc. Living standards of those countries, wages.

Personal Finance Banking processes, Handling ATM, KYC registration, Safe cash
Management handling, Personal risk and insurance.

Duration : 15 hrs
6. Occupational Safety, Health and Environment Education
Marks : 06
Safety & Health Introduction to occupational safety and health importance of safety
and health at workplace.

Occupational Hazards Basic Hazards, Chemical Hazards, Vibroacoustic Hazards,

Mechanical Hazards, Electrical Hazards, Thermal Hazards.
Occupational health, Occupational hygiene, Occupational Diseases/
Disorders & its prevention.

Accident & Safety Basic principles for protective equipment.

Accident prevention techniques - control of accidents and safety
measures.

First-Aid Care of injured & sick at the workplaces, First-Aid &Transportation

of sick person.
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Basic Provisions Idea of basic provision legislation of India.

Safety, health, welfare under legislative of India.

Ecosystem Introduction to Environment. Relationship between society and

environment, Ecosystem and factors causing imbalance.

Pollution Pollution and pollutants including liquid, gaseous, solid and

hazardous waste.

Energy Conservation Conservation of energy, re-use and recycle.

Global Warming Global warming, climate change and Ozone layer depletion.
Ground Water Hydrological cycle, Ground and surface water, Conservation and
Harvesting of water.

Environment Right attitude towards environment, Maintenance of in-house

environment.
Duration : 05 hrs
7. Labour Welfare Legislation
Marks : 03
Welfare Acts Benefits guaranteed under various acts- Factories Act, Apprenticeship
Act, Employees State Insurance Act (ESI), Payment Wages Act,
Employees Provident Fund Act, The Workmen's Compensation Act.

Duration : 10 hrs
8. Quality Tools
Marks : 05
Quality Consciousness Meaning of quality, Quality characteristic.
Quality Circles Definition, Advantage of small group activity, Objectives of quality
circle, Roles and function of quality circles in organization, Operation
of quality circle. Approaches to starting quality circles, Steps for
continuation quality circles.
Quality Management Idea of ISO 9000 and BIS systems and its importance in maintaining
System qualities.
House Keeping Purpose of House-keeping, Practice of good housekeeping.
Quality Tools Basic quality tools with a few examples.

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ANNEXURE-I

LIST OF TOOLS & EQUIPMENT (For batch of 16 candidates)

FOUNDRYMAN
S No. Name of the Tool &Equipments Specification Quantity
A. TRAINEES TOOL KIT
1. Tool tray steel 145 x 145 x 5 cm 17 nos.

2. Taper trowel 18 cm round 17 nos.

3. Heart and square trowels 3 x 1.2 x 1.2 cm 17 nos.

4. Trowel heart and scoop 17 nos.

5. Trowel square and scoop 17 nos.

6. Trowel double scoop 17 nos.

7. Trowel double square 17 nos.

8. Tools Spoon 32 x 16 mm - 25 x 6 m 17 nos.

9. Cleaner 6 x 300 m 17 nos.

10. Cleaner 9 x 300 m 17 nos.

11. Vent wire 3 mm 17 nos.

12. Peg rammer 17 nos.

13. Flat rammer 75mm x 25mm height 17 nos.

14. Rapping spike forged and hardened 17 nos.

15. Hand bellows 25 cm 17 nos.

16. Safety goggles (with clear glass) 17 nos.

17. Goggles (antiglau heat proof) 17 nos.

18. Cleaner flange 17 nos.

19. Egg smoother 17 nos.

20. Smoother round corner 17 nos.

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21. Smoother square corner 17 nos.

22. Steel rule 300mm 17 nos.

23. Apron leather or asbestos 17 nos.

24. Legging pad 17 nos.

25. Hand gloves (Leather or asbestos) 17 nos.

B. INSTRUMENTS AND GENERAL SHOP OUTFIT

26. Hammers Ball Peen 0.45 kg 05 nos.
27. Ball peen hammers 650 to 700 gms 05 nos.
28. Sledge hammer 8 kg 02 nos.
29. Claw hammers 0.75 kg 02 nos.
30. Chisel cold flat 2x22 cm 11 nos.
31. Chisel 200x15 mm 11 nos.
32. File Flat 30 cm Bastard 11 nos.
33. File Flat 30 cm Second cut 11 nos.
34. File half round 30 cm bastard 8 nos.
35. File half round 30 cm second cut 11 nos.
36. Folding rule 60 cm 5 nos.
37. Steel rule 600 mm 5 nos.
38. Caliper odd leg 3 nos.
39. Caliper inside 15 cm 5 nos.
40. Scriber 5 nos.
41. Centre punch 15 cm 5 nos.
42. Hacksaw 30 cm adjustable 11 nos.
43. C Clamps 20 cm 11 nos.
44. C Clamps 30 cm light duty steel 11 nos.
45. Screw drivers 25cm with 15mm blade 11 nos.
46. Screw drivers 15 cm 11 nos.
47. Screw drivers 18 cm 11 nos.
48. Pliers 20cm 5 nos.
49. Plane grooving 6mm cutter 3 nos.
50. Cutting Pliers 3 nos.
51. Try Square (for wood work) 11 nos.
52. Brick layers hammer 20cm 11 nos.
53. Hand lamp wandering lead 3 nos.
54. Degassing bale 10cm perforated hood 3 nos.
55. Bench vice 12cm jaw 5 nos.
56. Work bench for bench vice (245x125x75cm) 5 nos.
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 Foundryman
57. Blow lamp (Kerosene) 5 nos.
58. Hand saw 3 nos.
59. Steel measuring tape 3 meter 2 nos.
60. Trammel 3 nos.
61. Shovel hand 11 nos.
62. Engineers try square 15 cm 5 nos.
63. Lockers steel with 8 drawers each 4 nos.
64. Black board with easel 2 nos.
65. Fire buckets (2 for water and 3 for 5 nos.
sand)
66. Stand for fire buckets 2 nos.
67. Fire extinguisher foam chemical type 3 nos.
68. Fire extinguisher soda ash, etc. type 1 each
CO2 gas type
69. Face shield clear 11 nos.
70. Helmet (engineers) 11 nos.
71. Gauntlets leather fettling 11pairs
72. Gauntlets leather fettling 11pairs
73. Footwear asbestos over shoes 11pairs
74. First Aid Box based on burn 1 nos.
treatment
75. Lividers firm joint 20cm 5 nos.
76. Moulding boxes 30 x 40 x 15 cm RSDL 21 pairs
77. Moulding boxes 75 x 75 x 25 cm RSDL 21 pairs
78. Snap flask 40 x 35 x 12 cm RSDL 1 pair
79. Snap flask 30 x 30 x 10 cm RSDL 1 pair
80. Spirit level 5 nos.
81. Wheel Barrows 2 nos.
82. Weighing machine (cap: 0.001 to 150gm) 1 no.
C. GENERAL MACHINERY SHOP OUTFIT
83. Air Compressor with maximum 17.5 kg/cm2 1 no.
working pressure
84. Pneumatic Rammer with Rubber 1 no.
Rammer head
85. Pneumatic Chisel (with suitable 1 no.
chisel)
86. Moulding Sand Muller 35 kg capacity with motor impeller 1 no.
30 RPM
87. Mould Green Hardness Tester dial 1 no.
type Risdaledielsst.
88. Core hardness tester 1 no.
89. CO2 cylinder with CO2 probe with nozzle 12 mm wheel valve 1 no.
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Foundryman
and Rubber Hoses
90. LPG Cylinder with heating torch 1 no.
91. Cylinder trolly suitable to CO2 1 no.
cylinder and Indane Gas Cylinder
92. Heating and pumping unit to suit to 1 no.
oil fired tilting type crucible furnace
with Heating pressure gauge etc.
Wesman model SPM Simplex model
motorized Rotary gear oil pump pre-
heater.
93. Sand Testing Equipment- 1 each
permeability meter, Universal
Strength tester, Sieve shaker,
standard sand rammer, Shatter
Index Tester, Clay content Tester,
Speedy Moisture teller.
94. Moulding Machine hand squeeze 1 no.
with stripping device pin lift type.
95. Weighing machine 300 kg by 100 gms 1 no.
96. Pedestal grinder DE operated 35 cm power 1 no.
97. Core oven 180 x 90 x 90 cm electric hot air 1 no.
circulated with maximum
temperature 350oC adjustable
98. Muffle Furnace (Electric) Capacity 20kgs. 1 no.
99. Sand Sampler 1 no.
100. Auto Sand riddle 3 tons/hors. ridding capacity 1 no.
101. Sand Erator 1 no.
102. Oil Fired tilting type crucible furnace 100 crucible 1 no.
103. Induction furnace (Cap:50Kg) suitable for non-ferrous 1 no.
metals
104. Pit Furnace Cap- 100kg 1 no.
105. Gravity die casting machine As per requirement 1 no.
106. USG testing machine Digital 1 no.
107. Magnetic particle testing 1 no.
equipment
108. LCD projector As per requirement 1 no.
109. Desktop computer with printer As per requirement 1 no.
110. White Board with stand As per requirement 1 no.

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TOOLS &EQUIPMENTS FOR EMPLOYABILITY SKILLS

S No. Name of the Equipment Quantity
1. Computer (PC) with latest configurations and Internet 10 nos.
connection with standard operating system and standard
word processor and worksheet software

2. UPS - 500VA 10 nos.

3. Scanner cum Printer 1 no.
4. Computer Tables 10 nos.
5. Computer Chairs 20 nos.
6. LCD Projector 1 no.
7. White Board 1200mm x 900mm 1 no.

Note: Above Tools &Equipments not required, if Computer LAB is available in the institute.

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ANNEXURE-II

FORMAT FOR INTERNAL ASSESSMENT

Name & Address of the Assessor: Year of Enrollment:

Name & Address of ITI (Govt./Pvt.): Date of Assessment:

Name & Address of the Industry: Assessment location: Industry/ ITI

Trade Name: Semester: Duration of the Trade/course:

Learning Outcome:

Maximum Marks (Total 100 Marks) 15 5 10 5 10 10 5 10 15 15

Assessment Marks
Quality in Workmanship
Attendance/ Punctuality

Skills to Handle Tools

Speed in Doing Work

Safety Consciousness

Total Internal
Workplace Hygiene

Economical Use of

Result (Y/N)
Manuals/ Written
Ability to Follow

Application of

& Equipment
Instructions

Knowledge
S No.

Materials

VIVA
Father's/Mother’s
Candidate Name
Name

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