CITS Mechanic Machine Tool Maintenance Trade Syllabus 

Overview

The CITS Mechanic Machine Tool Maintenance (MMTM) trade is a one-year program designed to train instructors to teach the maintenance, repair, and servicing of machine tools 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 advanced diagnostics, CNC maintenance, and effective teaching methods. The syllabus adheres to the latest Directorate General of Training (DGT) guidelines for outcome-based learning.

Semester 1 Syllabus

Trade Technology - Theory

• Introduction to CITS and MMTM Trade: Role of instructors, scope of the machine tool maintenance industry, and trends (e.g., predictive maintenance, Industry 4.0).

• Safety and Standards:

  • Advanced workshop safety: Risk assessment, PPE usage, and lockout-tagout procedures.

  • Compliance with IS, ISO, and safety standards for machine tools.

  • Safe handling of hydraulic fluids, lubricants, and electrical systems.

• Machine Tool Fundamentals:

  • Types: Lathe, milling, drilling, grinding, and shaping machines.

  • Components: Spindles, gearboxes, bearings, and slides.

• Mechanical Systems:

  • Power transmission: Belts, gears, and clutches.

  • Lubrication systems: Centralized and manual lubrication.

• Electrical Systems:

  • Basic electrical circuits: Motors, relays, and contactors.

  • Wiring diagrams and electrical troubleshooting.

• Hydraulic and Pneumatic Systems:

  • Principles: Pumps, valves, and actuators.

  • Maintenance of hydraulic and pneumatic circuits.

• Maintenance Basics:

  • Preventive maintenance: Schedules for machine tools.

  • Troubleshooting common faults: Vibration, misalignment, and overheating.

• Quality Control: Inspection of maintained machines for performance and compliance.

Trade Technology - Practical

• Implement safety protocols in a maintenance workshop (e.g., lockout-tagout).

• Dismantle and assemble machine tool components (e.g., spindles, gearboxes).

• Service and test lubrication systems for machine tools.

• Maintain and troubleshoot basic electrical circuits (e.g., motors, relays).

• Inspect and repair hydraulic/pneumatic systems in a lab setup.

• Perform preventive maintenance on lathe, milling, or grinding machines.

• Diagnose mechanical faults using tools (e.g., vibration meters, alignment kits).

• Conduct quality checks on repaired machines for operational efficiency.

• Document maintenance procedures and fault reports.

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 maintenance tasks, guiding practice, and providing feedback.

Semester 2 Syllabus

Trade Technology - Theory

• Advanced Machine Tool Maintenance:

  • CNC machine maintenance: Servo motors, ball screws, and tool changers.

  • Retrofitting conventional machines to CNC systems.

• Electronics and Control Systems:

  • Programmable Logic Controllers (PLCs): Programming and diagnostics.

  • Basics of microprocessor-based machine controls.

• Diagnostics and Repair:

  • Predictive maintenance: Vibration analysis, thermography, and oil analysis.

  • Overhauling machine tools: Lathe, milling, and grinding machines.

• Automation in Maintenance:

  • IoT for real-time machine monitoring and telematics.

  • Robotics for automated maintenance tasks.

• Sustainable Practices:

  • Energy-efficient machine operation and maintenance.

  • Recycling of machine components and fluids.

• Entrepreneurship:

  • Starting a machine tool maintenance business: Business plans, budgeting, and marketing.

  • Client acquisition and service contracts.

• Industry 4.0 in MMTM:

  • AI for fault prediction and maintenance optimization.

  • Digital twins for machine performance analysis.

• Legal and Ethical Issues: Machine safety regulations, intellectual property, and ethical maintenance practices.

Trade Technology - Practical

• Maintain and troubleshoot CNC machines (e.g., servo motors, tool changers).

• Program and diagnose PLCs for machine tool control systems.

• Perform predictive maintenance using vibration analysis or thermography.

• Overhaul a machine tool (e.g., milling or grinding machine) in a workshop.

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

• Retrofit a conventional machine with basic CNC controls (if feasible).

• Apply sustainable practices: Recycle lubricants and components.

• Develop a business plan for a machine maintenance 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 maintenance projects (e.g., machine overhaul).

Additional Components

Workshop Calculation & Science

• Calculations: Tolerance calculations, motor power, and hydraulic pressure.

• Science: Mechanics, material properties, and electrical principles.

Engineering Drawing

• Drawing Basics: Detailed drawings of machine tool components.

• Schematics: Hydraulic, pneumatic, and electrical circuit diagrams.

Soft Skills & Employability Skills

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

• Leadership: Managing maintenance teams and service workflows.

• Time Management: Meeting maintenance 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 machine maintenance project (e.g., restoring a machine tool) and a teaching demonstration.