ITI Stone Processing Machines Operator Syllabus (English)

Course Overview

• Trade Name: Stone Processing Machines Operator

• Duration: 1 Year (2 Semesters)

• NSQF Level: Level 4

• Eligibility: 10th Grade Pass with Science and Mathematics

• Objective: To train candidates in operating and maintaining stone processing machinery for cutting, shaping, and polishing stones like marble, granite, and limestone, preparing them for roles in stone processing industries, quarries, or self-employment in stone fabrication services.

• Certification: National Trade Certificate (NTC) by NCVT

Detailed Syllabus

Semester 1

Trade Theory

• Introduction to Stone Processing: Types of stones (marble, granite, sandstone, limestone), their properties, and applications in construction/decor.

• Safety Practices: PPE (helmets, gloves, safety goggles), dust control, machine guarding, first aid in workshops.

• Stone Processing Tools: Hand tools (chisels, hammers), power tools (angle grinders, polishers), their uses and maintenance.

• Measurement Instruments: Vernier calipers, spirit levels, laser measures; ensuring precision (±0.5 mm).

• Basic Machines: Circular saws, gang saws, edge cutters; components, functions, and setup.

• Stone Characteristics: Hardness, porosity, grain structure; impact on cutting and polishing.

• Workshop Management: Material handling, waste disposal, inventory tracking for stone slabs.

Trade Practical

• Safety Drills: Wearing PPE, practicing dust mask usage, conducting emergency stops on machines.

• Tool Handling: Using vernier calipers for slab measurements, leveling surfaces with spirit levels.

• Machine Setup: Aligning circular saw blades, calibrating edge cutters, checking coolant systems.

• Cutting Practice: Cutting granite/marble slabs to specified sizes (±1 mm accuracy).

• Grinding Tasks: Grinding stone edges using hand grinders, achieving smooth finishes.

• Maintenance: Cleaning machines, checking belt tension, lubricating moving parts.

• Project Work: Cut and grind a 1x1 m marble slab to a specified thickness, ensuring flatness.

Hours: Theory: 160 hours | Practical: 240 hours

Semester 2

Trade Theory

• Advanced Machinery: CNC stone cutting machines, waterjet cutters, polishing lines; automation basics.

• Cutting Techniques: Multi-blade cutting, contour cutting, miter cuts; achieving precision (±0.2 mm).

• Polishing and Finishing: Types of abrasives, polishing compounds, achieving mirror finishes.

• Quality Control: Inspecting surface defects, checking dimensional accuracy, hardness testing.

• Electrical Systems: Motors, inverters, wiring in stone processing machines; troubleshooting basics.

• Environmental Practices: Water recycling in cutting, dust suppression, eco-friendly processing.

• Entrepreneurship: Starting a stone processing unit, market trends (e.g., custom countertops).

Trade Practical

• CNC Operation: Programming basic shapes (e.g., circles, rectangles) on CNC machines, cutting stone slabs.

• Waterjet Cutting: Operating waterjet cutters for intricate designs, maintaining nozzle alignment.

• Polishing Practice: Polishing granite surfaces to mirror finish using automated polishing lines.

• Quality Inspection: Measuring finished slabs with laser tools, identifying cracks or chips.

• Electrical Maintenance: Checking motor connections, replacing fuses, testing machine circuits.

• Waste Management: Recycling water from cutting, segregating stone waste for reuse.

• Project Work: Fabricate a polished granite countertop (1.5x0.6 m) with precise edges and sink cutout.

Hours: Theory: 160 hours | Practical: 240 hours

Additional Components

• Workshop Calculation and Science

  • Calculations: Cutting speed, slab volume, abrasive consumption, power requirements.

  • Science: Friction in cutting, heat generation, properties of stone under stress.

  • Hours: 80 hours/year

• Engineering Drawing

  • Drawings: Machine layouts, stone slab designs, cutting patterns, workshop floor plans.

  • Hours: 80 hours/year

• Employability Skills

  • Communication: Coordinating with supervisors, documenting production logs, client interactions.

  • IT Literacy: Using CNC software, inventory management tools, online stone catalogs.

  • Soft Skills: Time management, teamwork, resume writing, interview preparation.

  • Hours: 60 hours/year

Assessment and Certification

• Exams:

  • Theory: Written exams per semester (MCQs, descriptive questions).

  • Practical: Operating machines, cutting/polishing tasks, quality inspections, maintenance checks.

• Evaluation Criteria: Precision in cutting, surface finish quality, safety adherence, machine handling efficiency.

• Certification: NCVT National Trade Certificate (NTC), globally recognized.

Career Opportunities

• Employment: Machine operator, quality inspector, or technician in stone processing units, construction firms, or export houses.

• Self-Employment: Stone fabrication workshop, custom stone design services, consultancy for quarries.

• Further Studies: Diploma in Mechanical Engineering, certifications in CNC programming or stone technology.