Mechanic Machine Tools Maintenance

ITI Mechanic Machine Tools Maintenance Trade Syllabus 

The ITI Mechanic Machine Tools Maintenance trade is a two-year vocational training program under the Craftsman Training Scheme (CTS), governed by the National Council for Vocational Training (NCVT). This course equips trainees with skills in maintaining, troubleshooting, repairing, and overhauling machine tools such as lathes, milling machines, drilling machines, grinders, and CNC machines used in manufacturing and industrial settings. The syllabus integrates theoretical knowledge, practical mechanical skills, and employability skills to prepare students for roles such as maintenance technicians, machine tool mechanics, or service engineers in industries like automotive, aerospace, or tool manufacturing, or as self-employed service providers.

Course Overview

• Duration: 2 years (4 semesters, each 6 months)
• NSQF Level: Level 5
• Eligibility: Minimum 10th grade pass with Science and Mathematics (or equivalent)
• Objective: To train individuals in ensuring the operational efficiency, precision, and longevity of machine tools through maintenance and repair.

Detailed Syllabus Breakdown

1. Trade Theory (Theoretical Knowledge)

Covers principles of machine tools, maintenance techniques, and industrial systems.

• Semester 1
  
  • Introduction to Machine Tools Maintenance
    
    • Overview: types of machine tools (lathes, mills, grinders), their industrial applications.
    • Industry scope: maintenance roles, safety regulations, downtime reduction.
    • Safety: PPE (gloves, goggles, helmets), handling heavy tools, lockout-tagout procedures.
  • Fundamentals of Mechanics
    
    • Concepts: force, torque, friction, stress, strain in machine components.
    • Systems: levers, gears, pulleys, bearings, couplings in machine tools.
    • Materials: properties of steel, alloys, lubricants for machine parts.
  • Machine Tool Components
    
    • Parts: spindles, chucks, tool posts, beds, slides, tailstocks.
    • Functions: power transmission, motion control, precision machining.
    • Wear: causes of wear (abrasion, fatigue), preventive measures.
  • Tools and Measuring Instruments
    
    • Hand tools: wrenches, screwdrivers, hammers, pliers for maintenance.
    • Precision tools: vernier calipers, micrometers, dial gauges, spirit levels.
    • Diagnostic tools: vibration analyzers, thermal imagers, alignment kits.
  • Lubrication Systems
    
    • Types: manual, centralized, oil mist lubrication in machine tools.
    • Lubricants: oils, greases, synthetic fluids, viscosity grades.
    • Maintenance: checking oil levels, cleaning sumps, replacing filters.
  • Workshop Practices
    
    • Operations: filing, drilling, tapping, reaming for repair tasks.
    • Assembly: fitting bearings, aligning shafts, adjusting clearances.
    • Documentation: maintenance logs, spare parts lists, schedules.
• Semester 2
  
  • Machine Tool Operations
    
    • Machines: lathes, milling, drilling, grinding, shapers, their working principles.
    • Controls: manual, hydraulic, pneumatic systems in machine tools.
    • Faults: misalignment, chatter, tool wear, spindle runout.
  • Hydraulic and Pneumatic Systems
    
    • Components: pumps, valves, actuators, compressors, hoses.
    • Operation: pressure regulation, fluid flow, air supply in machines.
    • Maintenance: checking leaks, replacing seals, topping fluids.
  • Electrical Systems in Machine Tools
    
    • Basics: motors, relays, switches, wiring in machine tools.
    • Controls: starters, limit switches, overload protection.
    • Faults: short circuits, motor overheating, control panel issues.
  • Preventive Maintenance
    
    • Schedules: daily, weekly, monthly checks for machine tools.
    • Techniques: cleaning, lubricating, tightening, inspecting wear.
    • Records: logging downtime, repair history, predictive maintenance data.
  • Troubleshooting Basics
    
    • Methods: root cause analysis, symptom observation, fault isolation.
    • Tools: multimeters, tachometers, alignment lasers for diagnostics.
    • Solutions: adjusting belts, replacing worn parts, recalibrating.
  • Industrial Safety Standards
    
    • Regulations: OSHA, ISO for machine maintenance, shop floor safety.
    • Practices: guarding, emergency stops, hazard identification.
    • Audits: conducting safety checks, ensuring compliance.
• Semester 3
  
  • CNC Machine Maintenance
    
    • Basics: CNC lathes, milling machines, control units (Fanuc, Siemens).
    • Components: servo motors, ball screws, linear guides, encoders.
    • Faults: backlash, axis errors, software glitches, spindle issues.
  • Machine Overhauling
    
    • Processes: dismantling, inspecting, reconditioning, reassembling machines.
    • Checks: bed alignment, spindle concentricity, gear wear.
    • Tools: torque wrenches, honing machines, scraping tools.
  • Vibration and Noise Analysis
    
    • Causes: imbalance, misalignment, bearing failure in machines.
    • Tools: vibration meters, sound level meters, spectrum analyzers.
    • Solutions: balancing rotors, realigning shafts, replacing bearings.
  • Gearbox and Transmission Systems
    
    • Types: spur, helical, worm gears, belt drives in machine tools.
    • Maintenance: inspecting teeth, adjusting backlash, lubricating.
    • Faults: gear wear, belt slippage, clutch failures.
  • Quality Control in Maintenance
    
    • Standards: tolerances, surface finish, machine accuracy post-repair.
    • Tests: alignment checks, runout measurements, performance trials.
    • Documentation: repair reports, calibration certificates.
  • Customer and Vendor Interaction
    
    • Skills: coordinating with machine operators, suppliers for spares.
    • Communication: explaining downtime, repair costs, timelines.
    • Contracts: understanding service agreements, warranties.
• Semester 4
  
  • Advanced CNC Maintenance
    
    • Systems: multi-axis CNC, robotic integration, IoT-enabled machines.
    • Diagnostics: reading error codes, using PLC software, network issues.
    • Repairs: replacing servo drives, updating firmware, recalibrating.
  • Automation and Robotics Maintenance
    
    • Components: sensors, actuators, controllers in automated systems.
    • Maintenance: calibrating robots, checking wiring, programming basics.
    • Faults: sensor drift, motor failures, communication errors.
  • Condition Monitoring
    
    • Techniques: thermal imaging, oil analysis, vibration trending.
    • Tools: infrared cameras, oil debris sensors, data loggers.
    • Analysis: predicting failures, scheduling repairs proactively.
  • Entrepreneurship and Management
    
    • Business: starting a maintenance service, sourcing spare parts.
    • Planning: budgeting, inventory management, service contracts.
    • Marketing: promoting maintenance services, client retention.
  • Industry Trends
    
    • Innovations: Industry 4.0, predictive maintenance, smart factories.
    • Standards: ISO 9001, lean maintenance, energy-efficient machines.
    • Future: AI diagnostics, additive manufacturing in repairs.
  • Professional Ethics
    
    • Practices: transparency, quality assurance in repairs.
    • Responsibilities: minimizing downtime, ensuring machine safety.
    • Compliance: adhering to environmental, labor regulations.

2. Trade Practical (Hands-On Skills)

Focuses on practical tasks in workshops and machine tool setups.

• Semester 1
  
  • Safety Practices
    
    • Using PPE: wearing helmets, gloves, safety shoes in workshops.
    • Procedures: applying lockout-tagout, handling heavy components.
    • Drills: fire safety, emergency evacuation, first aid for injuries.
  • Tool Handling
    
    • Using tools: tightening bolts, adjusting slides with wrenches, pliers.
    • Measuring: checking alignments with dial gauges, micrometers in labs.
    • Maintaining: cleaning, calibrating tools, organizing toolkits.
  • Machine Dismantling
    
    • Dismantling: removing spindles, chucks from mock lathes, mills.
    • Inspecting: checking wear, cracks, alignment of parts.
    • Cleaning: degreasing components, preparing for reassembly.
  • Lubrication System Maintenance
    
    • Servicing: topping oils, replacing filters in mock machines.
    • Inspecting: checking pumps, sumps, lubrication lines.
    • Testing: verifying oil flow, pressure in labs.
  • Workshop Operations
    
    • Performing: filing, drilling, tapping for repair fixtures in labs.
    • Assembling: fitting bearings, aligning gears in mock setups.
    • Documenting: preparing maintenance checklists, part inventories.
  • Project Work
    
    • Servicing a lathe: lubricating, adjusting slides, testing.
    • Report: documenting faults fixed, tools used, outcomes.
• Semester 2
  
  • Machine Tool Repair
    
    • Servicing: dismantling milling machines, grinders in mock setups.
    • Repairing: replacing belts, adjusting tool posts, fixing runout.
    • Testing: verifying accuracy, spindle speed post-repair.
  • Hydraulic/Pneumatic Maintenance
    
    • Servicing: inspecting pumps, valves in mock hydraulic systems.
    • Repairing: replacing seals, topping fluids in labs.
    • Testing: checking pressure, flow in pneumatic circuits.
  • Electrical System Repair
    
    • Servicing: checking motors, relays in mock machine panels.
    • Repairing: replacing switches, fixing wiring faults.
    • Testing: verifying motor function, control operation.
  • Preventive Maintenance Practice
    
    • Performing: cleaning, lubricating mock drilling machines.
    • Inspecting: checking belts, gears for wear in labs.
    • Logging: preparing maintenance schedules, downtime reports.
  • Troubleshooting Practice
    
    • Diagnosing: tracing faults (vibration, noise) in mock machines.
    • Repairing: adjusting alignments, replacing parts in labs.
    • Testing: ensuring fault-free operation post-repair.
  • Project Work
    
    • Restoring a milling machine: servicing, testing all systems.
    • Portfolio: presenting repair logs, photos, performance data.
• Semester 3
  
  • CNC Machine Maintenance
    
    • Servicing: inspecting servo motors, ball screws in mock CNC setups.
    • Repairing: replacing encoders, adjusting backlash in labs.
    • Testing: verifying axis movement, spindle accuracy.
  • Machine Overhauling
    
    • Overhauling: dismantling, reconditioning mock grinders, lathes.
    • Inspecting: checking bed wear, spindle alignment.
    • Testing: ensuring precision post-overhaul in labs.
  • Vibration Analysis
    
    • Measuring: using vibration meters on mock machines.
    • Analyzing: identifying imbalance, misalignment issues.
    • Repairing: balancing rotors, realigning shafts in labs.
  • Gearbox Maintenance
    
    • Servicing: inspecting gears, clutches in mock transmissions.
    • Repairing: replacing worn teeth, adjusting backlash.
    • Testing: verifying smooth operation, torque transfer.
  • Quality Control Practice
    
    • Testing: checking machine accuracy post-repair in labs.
    • Measuring: using lasers, gauges for alignment, runout.
    • Documenting: preparing calibration reports, test logs.
  • Project Work
    
    • Overhauling a CNC lathe: full repair, testing precision.
    • Portfolio: presenting repair process, test results, photos.
• Semester 4
  
  • Advanced CNC Repair
    
    • Servicing: troubleshooting PLC, servo drives in mock CNC systems.
    • Repairing: updating firmware, replacing control boards.
    • Testing: verifying multi-axis motion, program execution.
  • Robotics Maintenance
    
    • Servicing: inspecting sensors, actuators in mock robots.
    • Repairing: recalibrating arms, fixing wiring in labs.
    • Testing: ensuring robot accuracy, connectivity.
  • Condition Monitoring Practice
    
    • Monitoring: using thermal cameras, vibration sensors on mock machines.
    • Analyzing: trending data, predicting failures in labs.
    • Reporting: preparing maintenance forecasts, failure logs.
  • Entrepreneurship Practice
    
    • Simulating: running a mock maintenance service, sourcing spares.
    • Planning: budgeting repairs, managing mock inventory.
    • Marketing: creating mock service ads, client proposals.
  • Safety and Compliance
    
    • Inspecting: checking guards, emergency stops in mock setups.
    • Auditing: conducting mock safety audits, documenting gaps.
    • Testing: ensuring machines meet ISO, OSHA standards.
  • Project Work
    
    • Restoring a CNC milling machine: repair, automation setup, testing.
    • Portfolio: presenting repair logs, condition reports, photos.

3. Workshop Calculation and Science

Supports machine tool maintenance with relevant concepts.

• Semester 1: Arithmetic (torque, tolerances), physics (mechanics, friction).
• Semester 2: Algebra (gear ratios, power), chemistry (lubricants, corrosion).
• Semester 3: Geometry (alignments, spindle angles), thermodynamics (heat in machines).
• Semester 4: Statistics (failure rates), applied physics (vibration, fluid dynamics).

4. Engineering Drawing

Focuses on technical drafting for machine tools.

• Semester 1: Sketching machine components, orthographic views, gear diagrams.
• Semester 2: Drawing lathe assemblies, hydraulic circuits, wiring layouts.
• Semester 3: Designing CNC machine parts, gearbox layouts, alignment charts.
• Semester 4: Creating blueprints for automation systems, maintenance schematics.

5. Employability Skills

Enhances job readiness and soft skills.

• Semester 1: Communication (reporting faults), time management, basic IT (maintenance apps).
• Semester 2: Teamwork (with operators), problem-solving (diagnosing faults).
• Semester 3: Leadership (supervising repairs), negotiation (vendor deals), advanced IT (PLC software).
• Semester 4: Entrepreneurship (service business), client management, industry trends (Industry 4.0).

Assessment and Certification

• Examinations: Semester-wise (theory + practical).
• Certification: National Trade Certificate (NTC) from NCVT, recognized nationally.
• Evaluation: Based on repair accuracy, diagnostic proficiency, machine performance, and project work.

Career Opportunities

• Employment: Maintenance technician, machine tool mechanic, service engineer in manufacturing, automotive, or aerospace industries.
• Self-Employment: Starting a machine tool maintenance or repair service.
• Further Studies: Diploma in Mechanical Engineering, certifications in CNC maintenance, or industrial automation.

Note

• This syllabus aligns with NCVT guidelines and may vary slightly by institution or state.
• For the latest version, refer to the Directorate General of Training (DGT) or local ITI.