CAPACITY DEVELOPMENT CURRICULUM FOR ENGINEERING SECTOR SHOP FLOOR WORKERS (MANUFACTURING OPERATIO)

FROM THE AMERICAN PEOPLE

CAPACITY DEVELOPMENT CURRICULUM FOR ENGINEERING SECTOR SHOP FLOOR WORKERS (MANUFACTURING OPERATIONS)

SUGGESTED DURATION: 18 HOURS SPREAD OVER 12 DAYS WITH 4-6 WEEKS OF PRACTICAL WORK

OCTOBER, 2010 This publication was produced for review by the United States Agency for International Development.

It was prepared by CARE International in Pakistan

ACKNOWLEDGMENT The Pakistan JOBS project is a USAID funded project designed to improve the competitiveness of the Pakistani economy by strengthening systems for workforce development, encourage Pakistani companies to invest in human capital, and improve access to training, jobs, and business opportunities, especially for youth and women. The four components are (1) Industry Sector-Led Technical Training; (2) Employability, Job Placement, and Entrepreneurship for Secondary School and University Graduates; (3) Integrated Work and Learning Program for Less-Educated Youth; and (4) Youth Employability Exchange Systems.

USAID PAKISTAN JOBS project is working for the skill enhancement of the workforce in Pakistan in several growing economic sectors including agriculture, energy, construction, information technology, call centers, pharmaceuticals, garment manufacturing, carpet making, and fisheries.

Preparation of standardized and tested curriculum is one of the major contributions of this project.

The engineering sector in Pakistan is recovering from an economic downturn and a few segments of the sector have shown tremendous growth, driving demand for quality workers at all levels.

Presently the industry is faced with an acute shortage of trained engineers, supervisors and workers at the level of assembly operations as well as parts manufacturing. Under the “Shop Floor Workers Training”, Xavor was responsible for carrying out skill gap assessment, developing curriculum and conducting trainings of 400 shop floor workers in the automobile industry for each of the following three training streams: i. CNC (Computerized Numerical Control) machine operations. ii. Manufacturing Operations (grinding, forging, welding and metal sheet). iii. Casting and Die Casting operations The USAID PAKISTAN JOBS project wishes to thank all the persons and organizations that contributed in many ways to the preparation of this curriculum. Special thanks are extended to Xavor's Social Development Consulting team especially Mr. Mohsin Aziz, VP Professional Services, Mr. Adnan Qureshi and Ms. Sana Majeed. We would like to thank Mr. Fahad Iqbal, Director, Ravi Automobiles (Pvt.) Ltd, and Mr. Abdur Razzaq Gauhar, CEO Infinity Engineering (Pvt.) Ltd who coordinated the preparation of this curriculum. Muhammad Mukhtar Pasha, BTN Specialist and Dr. Nazir Mahmood, Curriculum Consultant for USAID PAKISTAN JOBS Project were also instrumental in the finalization of the syllabus.

Mark Nolan Chief of Party USAID PAKISTAN JOBS Project Implemented by Care International in Pakistan

USAID PAKISTAN JOBS CAPACITY DEVELOPMENT CURRICULUM FOR ENGINEERING SECTOR SHOP FLOOR WORKERS (Manufacturing Operations) SUGGESTED DURATION: 18 HOURS SPREAD OVER 12 DAYS WITH 4-6 WEEKS OF PRACTICAL WORK

Disclaimer: The author's views expressed in this publication do not necessarily reflect the views of the United States Agency for International Development or the United States Government

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Introduction Rationale

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Objective

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Purpose of this document Methodology

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Need Assesment Selection of Priority Areas

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Program Planning Template

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Synopsis

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Day - Wise Session Planning

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Day 1: Introduction to training program

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Day 2: Sheet Metal Forming Process

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Day 3: Sheet Metal Forming Defects.

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Day 4: Introduction to Welding & Equipments

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Day 5: Description of Arc Welding Processes

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Day 6: Introduction to Grinding

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Day 7: Grinding Processes, Properties of Grinding Materials

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Day 8: Surface, cylindrical & centreless grinding

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Day 9: Maintenance, Health and Safety Instructions

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Day 10: Assessment and Learning by sharing

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Day 11: Introduction to Quality Systems

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Day 12: Personal Attributes

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USAID PAKISTAN JOBS CAPACITY DEVELOPMENT CURRICULUM FOR ENGINEERING SECTOR SHOP FLOOR WORKERS (Manufacturing Operations) SUGGESTED DURATION: 18 HOURS SPREAD OVER 12 DAYS WITH 4-6 WEEKS OF PRACTICAL WORK

Disclaimer: The author's views expressed in this publication do not necessarily reflect the views of the United States Agency for International Development or the United States Government

Session 1: Introduction To Sheet Metal Works Session 2: Sheet Metal Forming Proesses

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Session 3: Defects In Sheet Metal Works Session 4: Welding Processes

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Session 5: Shielded Metal Arc Welding (Smaw)

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Session 6: Grinding

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Session 7: General Grinding Processes

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Session 8: Horizontal-Spindle, Reciprocating Table Surface Grinding

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Session 9: Maintenance Work

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Session 10: Assessment Day Session 11: Quality and Quality Systems

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Session 12: Personal Attributes Training Methodology

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Assessments

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