CITS Machinist and Operator Advance Machine Tool Trade Syllabus (English)

Overview

The CITS Machinist & Operator Advance Machine Tool trade is a one-year program designed to train instructors to teach advanced machining and CNC machine operation skills in ITIs. Divided into two semesters, the course covers Trade Technology (theory and practical), Training Methodology, Engineering Drawing, Workshop Calculation & Science, and Soft Skills. It aligns with NSQF Level 5 standards, emphasizing precision machining, CNC programming, and effective teaching methods. The syllabus adheres to the latest DGT guidelines for outcome-based learning.

Semester 1 Syllabus

Trade Technology - Theory

• Introduction to CITS and Machinist Trade: Role of instructors, scope of the machining industry, and trends (e.g., Industry 4.0, additive manufacturing).

• Safety and Standards:

  • Advanced workshop safety: Risk assessment, PPE usage, and machine guarding.

  • Compliance with IS, ISO, and ASME standards for machining.

  • Safe handling of cutting tools, coolants, and heavy components.

• Engineering Materials:

  • Properties of metals, alloys, and composites used in machining.

  • Heat treatment processes: Hardening, tempering, and annealing.

• Machine Tools:

  • Advanced operations: Lathe, milling, drilling, and grinding machines.

  • Tool geometry and selection for precision machining.

• Precision Measurement:

  • Use of micrometers, vernier calipers, and CMM (Coordinate Measuring Machine).

  • Geometric dimensioning and tolerancing (GD&T).

• CNC Technology Basics:

  • Introduction to CNC machines: Lathe and milling operations.

  • G-code and M-code fundamentals.

• Maintenance Basics:

  • Preventive maintenance of conventional and CNC machines.

  • Lubrication systems and spindle alignment.

• Quality Control: Inspection of machined components for accuracy and compliance.

Trade Technology - Practical

• Implement advanced safety protocols in the workshop (e.g., machine guarding).

• Perform precision machining on lathe, milling, and grinding machines.

• Use precision measuring tools (e.g., CMM, dial gauges) for component inspection.

• Set up and operate CNC lathe/milling machines for basic operations.

• Write and simulate simple G-code programs for CNC machining.

• Conduct heat treatment processes on metal components.

• Perform preventive maintenance on machine tools (e.g., spindle alignment).

• Apply GD&T principles in machining tasks.

• Document machining processes and quality control results.

Training Methodology

• Instructor Role: Lesson planning, teaching strategies, and student evaluation techniques.

• Communication Skills: Clear verbal and non-verbal communication for effective training.

• Classroom Management: Engaging diverse learners and ensuring discipline.

• Instructional Aids: Using projectors, digital tools, and e-learning platforms.

• Practical Training: Demonstrating machining tasks, guiding practice, and providing feedback.

Semester 2 Syllabus

Trade Technology - Theory

• Advanced CNC Technology:

  • Multi-axis CNC machining: 3-axis, 4-axis, and 5-axis operations.

  • CAM software: Fusion 360, Mastercam for toolpath generation.

• Tool and Die Making:

  • Design and fabrication of jigs, fixtures, and dies.

  • Precision tooling for mass production.

• Automation in Machining:

  • Robotics in CNC operations and material handling.

  • IoT for machine monitoring and predictive maintenance.

• Additive Manufacturing:

  • Basics of 3D printing for prototyping and tooling.

  • Integration with CNC for hybrid manufacturing.

• Industrial Maintenance:

  • Predictive maintenance: Vibration analysis and thermography.

  • Overhauling CNC and conventional machines.

• Sustainable Machining:

  • Energy-efficient machining processes.

  • Recycling of metal chips and coolants.

• Entrepreneurship:

  • Starting a machining or tooling business: Business plans, budgeting, and marketing.

  • Client acquisition and contract manufacturing.

• Industry 4.0 in Machining:

  • AI for process optimization and defect prediction.

  • Digital twins for machine performance analysis.

• Legal and Ethical Issues: Intellectual property, safety regulations, and ethical machining practices.

Trade Technology - Practical

• Program and operate multi-axis CNC machines for complex components.

• Design and fabricate jigs, fixtures, or dies using CAM software.

• Integrate robotics for automated material handling in a CNC setup.

• Perform 3D printing for prototyping a machined component.

• Conduct predictive maintenance using vibration analysis tools.

• Overhaul a CNC or conventional machine in a workshop.

• Implement IoT-based monitoring for machine performance (if available).

• Develop a business plan for a machining or tooling service.

• Document compliance with safety and ethical standards.

Training Methodology

• Advanced Teaching Techniques: Micro-teaching, flipped classrooms, and blended learning.

• Assessment and Evaluation: Designing tests, practical assessments, and grading systems.

• Digital Tools: Using Learning Management Systems (LMS), virtual labs, and e-learning modules.

• Mentoring: Supporting trainees in skill development and career planning.

• Project-Based Learning: Guiding trainees to complete machining projects (e.g., CNC component production).

Additional Components

Workshop Calculation & Science

• Calculations: Feed rate, spindle speed, and tolerance calculations.

• Science: Mechanics, material science, and properties of cutting fluids.

Engineering Drawing

• Drawing Basics: Detailed part and assembly drawings for machining.

• Schematics: Jigs, fixtures, and CNC toolpath layouts.

Soft Skills & Employability Skills

• Communication: Client consultations, report writing, and technical presentations.

• Leadership: Managing machining teams and production workflows.

• Time Management: Meeting production and project deadlines.

Assessment

• Internal Assessment: Continuous evaluation through assignments, practicals, and tests.

• Final Examination: Theory and practical exams conducted by NCVT at year-end.

• Project Work: Complete a machining project (e.g., producing a precision component) and a teaching demonstration.