FOREMEN TRAINING INSTITUTE, BANGALORE

GOVERNMENT OF INDIA

MINISTRY OF SKILL DEVELOPMENT & ENTERPRENEURSHIP :: DIRECTORATE GENERAL OF TRAINING


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COURSE CONTENTS FOR VARIOUS COURSES
Sl NoCourse NameWeeksCourse Contents
0101 CNC TURNING, PROGRAMMING, SIMULATION & OPERATION (Siemens 828 Control System) 02 Development in CNC, CNC machining concepts, part programming concepts using G code and M code contour programming, process planning , CNC Tooling, simple part programming on CNC lathe, programming on stock removal, drilling, threading, sub programming, canned cycles, verification of CNC programme by simulation by using SinuTrain 828 Siemens control system. Demo/practical’s on CNC lathe machine operation.
0102 CNC MILLING PROGRAMMING & OPERATION(Siemens 828 control system) 02 Development in CNC, CNC machining concepts, part programming concepts using G code and M code contour programming, process planning, CNC Tooling, simple part programming on CNC Milling, programming on stock removal, drilling, threading, sub programming, canned cycles, verification of CNC programme by simulation by using SinuTrain 828 Siemens control system. Demo/practical’s on CNC Milling machine operation.
0201 Designing & Detailing using AutoCAD 2016(Mech) 02

Co-ordinate systems - Introduction to AutoCAD - Draw Commands - Modify commands - Block commands - Creation of Templates & Layers,Inserting drawing - Dimensioning drawings - 3D primitives - Sweep, loft commands & draft editing of 3D drawings - Boolean operations - Setting User coordinate System - Plotting & Converting into pdf file.

0202 Part modelling designing & Detailing using Unigraphics(Nx10) 02

Types of modelling work benches - Part Designing features - Associative copy commands - Datum reference elements creation - Boolean operations - Advanced Part modelling features -Bottom up/Top down Assembly Design - Drafting work Bench.

0301 ELECTRIC MOTORS 01 Electric Motors - construction, working principle, starting methods, speed control & applications of 3 phase induction motors, 2 speed induction motors, 1 phase motors, DC motors, Servo motor, Stepper motor & Linear motor. assembling and disassembling of motors. Plugging & Dynamic braking of motors. Trouble shooting in motors. Testing & Maintenance of motors. Testing of motors. Motor protection simulation.
0302 MOTOR CONTROLS 01 Electrical control elements like contactors, overload relays, timers etc. Logic functions in electrical controls. Power and control circuits. DOL, Forward/Reverse and Star-Delta Starters for 3 ph Induction motors. Time delay & sequential control circuits. Industrial control circuits. Trouble shooting in control/power circuits & starters. Static control of motors. Logical control of motors using PLC. Motor control using AC/DC Drives.
0303 ELECTRICAL MAINTENANCE 01 Purpose & types of Maintenance. Maintenance of Electrical power distribution system. Maintenance of Motors, transformers, starters, switchgears, Diesel generator set, Electrical Sub-station, Circuit breakers, Batteries, UPS, AC plant, Air conditioners. Power supply problems and remedy. Power factor correction. Energy conservation. Earthing- maintenance, measurement of earth resistance. DO's and DON'Ts in Electrical Maintenance.
0304ELECTRICAL SAFETY 01 Electrical Hazards: Electric Shock- Causes, effect, prevention. Burns- causes, effects & prevention. Protection against Electric shock. Earthing. Protective devices like MCB, ELCB / RCCB. Safe procedures in electrical maintenance works. Central Electricity Authority Regulations (CEAR-2010). Lockout and Tagout. Electrical Fire: Causes, prevention, fire fighting. Electrical safety. Safety precautions against electrical accidents. First aid. Case studies.
0305PROTECTIVE RELAYS 01 Protection scheme in Generation, Transmission & Distribution systems. Electro Mechanical Relays, Static or Micro-controlled based relays, Numerical Relays. PSM, TMS, Characteristic Setting / programming, fault simulation, resetting & study of characteristics of Over voltage, Under voltage Relays. Over Current, Reverse power and Earth fault relays. Frequency relay, negative sequence relay, Differential relay, Thermal Relay, Buchholz Relay. CT & PT. Protection simulation study of Generators, Motors, Transformers.
0306 CIRCUIT BREAKERS 01 Switch gears and Circuit breakers. Types of circuit breakers- MCB, MCCB, MPCB, ELCB, RCCB, ACB, ABCB, OCB, MOCB, VCB, SF6. Construction, Parts, Working principle, Arc phenomenon, Arc Extinction. Identifying parts, operating mechanism, operation & maintenance. Specification & comparison of circuit breakers. Settings on Circuit breakers, fault simulation, testing. Trouble shooting and overhauling of Circuit breakers. Tests on Circuit breakers.
0401 MICRO CONTROLLER(8051) AND APPLICATIONS02 Introduction to embedded systems, 8051 Architecture, Addressing modes:Register addressing, Immediate addressing, Direct addressing, Indirect addressing, Groups of instructions, Data transfer, Arithmetic and Logical instructions, Branching instructions, Bit Logical instructions, Programmable Perephreal Interface - 8255, Interfacing/Applications:Logic controller Interface, Traffic lights interface, relay output interface, elevator interface, stepper interface, DC motor interface, 12 bit ADC interface, Dual DAC Interface, Temperature, Transducers interface.
0402 PROGRAMMABLE LOGIC CONTROLLERS (ALLEN BRADLEY) AND APPLICATIONS 02 PLC hardware and software aspects, Allen Bradley compact logics configuration, programming using RS Logics 5000, developing ladder diagrams using different instructions like timers, counters, add, compare, equal to, greater than etc., Panel View, Variable frequency drives. Interfacing real time appliaction trainers to PLC like water level control, traffic lights control, material handling system, bottle filling system etc.,
0501 PNEUMATIC CONTROLS WITH ACTUATORS 01 Pneumatic Controls: Industrial Power syetems, pneumatic systems, Compressed air generation and distribution, FRL unit, pneumatic actuators, Directional control valves, Check Valves, roller Valves, symbols, Flow control valves, Logic Valves, time delay Valves, Pressure sequence valve, pneumatic counters, Development of typical pneumatic circuits and synchronization of multi-cylinders and software simulation of pneumatic circuits.
0502 ELECTRO PNEUMATIC CONTROLS WITH ACTUATORS01 Overview of pneumatic system, single solenoid, double solenoid valves, electrical control components - PBs, Relays, limit switches, proximity sensors, pressure switches, timers, counters, etc., Development of typical Electro-pneumatic circuits and synchronisation of multi cyclinders and software simulation of electro-pneumatic.
0503 ELECTRO-PNEUMATIC CONTROLS PLC with SIEMENS S7-300 02 Familiarisation with electo-pneumatic i/o devices, PBs, Relays and proximity sensors, Development of electro-pneumatic relay circuits and practical, SIEMENS S7 300 PLC - Hardware and Software aspects, simple programming instructions in STEP 7 and programming, timers, counters and memory instructions and programming, control of single-actuators and multiple-actuators using PLC. Programming, Control of single-actuators and multi-actuators systems using PLc programming techniques.
0504 ADVANCED ELCTRO-PNEUMATIC CONTROLS USING PLCs (SIEMENS S7-300 with HMI) 02 Concept of solenoid valves, proximity sensors, PLC - Hardwiring and contribution (S7-300), concept of writing programmes using ladder diagram, timers, counters, multicyclinders, Writing the programa and implementation with both analog and digital outputs using advanced trainer kit(Electronic Veneta Italy make, automation with HMI and Programme).
0505 INDUSTRIAL HYDRAULIC CONTROLS 01 Introduction including health & safety. Basics of Hydraulic Controls, Symbols used in Hydraulic Controls Hydraulic cyclinders, Pumps and Motors - types, construction, operation & their selection, directional control valves - Types, operation and their applications Pressure Control Valves - Types, operation and their applications, Flow Control Valves - Types, operation and their applications, discussion of various other accessories - Hydraulic power pack, filters, accumulators & intensivefiers, discussion of various typical circuits. Closed & opened loop circuits, Hydraulic Fluid - Functions, characteristics, requirements, additives, types, selection criteria. Contamination & its control, Maintenance of Hydraulic system.
0506 INDUSTRIAL ELECTRO HYDRAULIC CONTROLS 01 Basics & Introduction to Electro Hydraulic Controls,Symbols used in Electro Hydraulic Controls Relays & its contacts, Proximity Sensors Timers & Counters, Design of different circuits Maintenance of Electro Hydraulic Control Systems.
0601 ANALYSIS & IMPROVEMENT USING QUILITY CONTROL CIRCLES (QCC) 01 Quality Control Circles Concept - Problem Identification, Analysis, Solving methods - Application of 7QC tools - CheckSheets, Pareto Diagrams - Histogram, BrainStorming & Ishikawa Diagram - Root cause Analysis, Why- Why - Analysis - Kaizen Concepts, Stratification - Scatter Diagram, Control Charts - Examples of all Tools Exercises on usage of 7 QC tools & case studies on Quality Control Circles.
0602 TQM FOR CUSTOMER RELATIONSHIP01 Introduction to Quality and System requirement for Total Quality, Total employee involvement, Team work, Problem solving Techniques, PDCA Cycle – Deming's 14 points, 7 QC tools, Waste Elimination process, Just-in-Time concepts, House-keeping (5S), POKA YOKE, KAIZEN, SMED and 6 Sigma Concepts, Customer Relationship Management Case studies & videos on Just-in-Time concepts, 5S, POKA YOKE, KAIZEN, SMED concepts.
0603 ISO - 9001 : 2015 STANDARDS (QMS) FOR QUALITY ASSURANCE01 Quality Concepts Evolution of Quality Standards, Introduction to ISO-9000, Quality Management Principles, Process Approach, ISO-9001 Requirements, Prepration of various documentation, Corrective action & Preventive action, Ceritfication Process, Quality Audits, Internal Audits, Excercise on ISO clauses, Preparation of various documents & case studies on Audits.
0604 6 SIGMA FOR PROCESS CONTROL & IMPROVEMENT01 Introduction to Quality - Measure of central tendency and Dispersion - Normal Distribution - Statistical Quality Control Concepts - Process Capability Ratios - Out of Control & In-control processes, Six Sigma Concept Evalution, Six Sigma Deployment, Selecting Problems, DMAIC Techniques, Problem solving & Optimization case studies of Six Sigma problems, Exercises on central Tendency & dispersion measures, Process Capability study, case studies on Six Sigma problems.
0605 QUALITY CONTROL & MANAGEMENT 02 Quality Control V/s Quality Assurance, Business cycle, Market Need Analysis, Introduction to statistics, SQC Techniques for variability reduction, use of Control charts, Process Capability study & performance Analysis, QCC & 7 QC Tools, Quality Management types - ISO -9000, TQM and 6 Sigma Concepts, Vendor Development and Rating. Examples of current Market need, Exercises on control charts, Process Capability study , Case studies & videos on various Quality Management Concepts.
0701 ENGINEERING METROLOGY & ITS APPLICATION FOR QUALITY INSPECTOR02 Introduction to Inspection and Quality Control, Limits, Fits, Tolerances and limit gauges, Linear Measurements, Optical Measuring Instruments, Angular measurements, Thread measurements, Calibration Techniques, Error in Measurement process, Statistical process control techniques, Metrology Lab Pratice for understanding, handling & usage of Various Instruments listed in above categories.
0702 CALIBRATION OF VERNIER MEASURING INSTRUMENTS & GAUGES 01 Introduction to Calibration, Errors in Measuring Process, Calibration Process & Selection of Calibration of Equipment. Calibration of Instruments - Vernier Caliper, Micrometer, Dial gauges and Calibration of Limit Gauges - plug gauge, Feeler gauge, Preparation of History Card, frequency for Calibration, Uncertainty and Traceability, Laboratory practice for Calibration.
0801 SUPERVISORY DEVELOPMENT PROGRAMME02 Time Management: Productivity; Palnning; Motivation; Leadership Controlling of work Decision Making and Problems Solving Industrial Legislation Group Behaviour; Performance appraisal; Discipline & Morale.
0802PROJECT MANAGEMENT 02 Role of Project Manager, Project Quality, Project Scope Project schedule, Project Budget, Project procurement Project Integration Management, Hands on Using Microsoft Project management software.
0803 PRODUCTION PLANNING & CONTROL01 Functions of PPC, Planning Process; Planning Techniques, Type of Production; Forecasting; bill of materials, Material requirement Planning, Material Management, ABC Analysis; Economic Order Quantity Plant Layout, Material Handling.
0901 MACHINE TOOL MAINTENANCE03 Introduction to maintenance including health & safety. Types of maintenance - Preventive and Breakdown Maintenance management - TPM, 5s & Kaizen concepts, Bearing, Lubrication and lubricants, Use of maintenance equipment, Maintenance of Hydraulic & Pneumetic Control system, Electrical control elements, power and control circuits, DOL Starter, star delta starer, Maintenance, Reconditioning of machine tools Testing of Machine tools, Corrosion and its controls Installation and commissioning, Welding - types - application.
0902 COMPRESSOR MAINTENANCE01 Introduction to compressor including safety Types, construction, working principles, operation and their application (Reciprocating, Centrifugal, Screw, Vane, Blower & Scroll. Working principles and their application), Selection of compressor, Defect analysis and remedies.
1001 ADVANCED WELDING TECHNOLOGY02 Welding Terminology, SMAW/GMAW/GTAW/SAW/RW process applications and features. Welding power sources and classification, welding consumables, Welding safety and symbols, Welding, Metallurgy, Welding defects causes and remedy, dimensional Inspection and NDT techniques. Demonstration & practice on SMAW/GMAW/GTAW/SAW/RW process and NDT techniques.
1002WELDING INSPECTION 01 Introduction to welding, safety in welding, Welding symbols Welding defects causes and remedy, Dimensional Inspection. Features and advantages of 4 basic NDT methods. Dye penetrant and magnetic particle testing techniques demonstration & practice. Practice on weld measurement gauges.
1003NON DESTRUCTIVE TESTING(NDT)01 Introduction to welding, safety in welding, Welding symbols Welding defects causes and remedy, Dimensional Inspection and features & advantages of four basic NDT methods. DPT, MPT & UT testing techniques demonstration & practice. Radiographic film interpretation. Practice on weld measurement gauges.
1004MIG/MAG WELDING(GMAW)02 Process features, Power sources, Wire feed systems, Selection of welding parameters, Welding wire and specification, Shielding gases and its significance, welding defects, welding safety. Hands on practice of different joints on MS & SS metals.
1005TIG WELDING(GTAW) 01 Process features, Power sources, welding torch and its parts, Selection of welding parameters, Filler rods and specification, Shielding gases and its significance, welding defects, welding safety. Hands on practice of different joints on MS, Aluminium & SS metals.
1006TIG / MIG WELDING(GTAW/GMAW) 02 Process features, Power sources, welding torch and its parts, Selection of welding parameters, Filler rods and specification, Hands on practice of different joints on MS, Aluminium & SS metals. Wire feed systems, Selection of welding parameters, Welding wire and specification, Shielding gases and its significance, welding defects, welding safety. Hands on practice of different joints on MS & SS metals.
1007ROBOT WELDING (PROGRAMMING & OPERATION)01 Advantages and application of robot welding, Identification and moving of welding robot. Types of coordinate systems, Mastering and calibration, welding programming, Modifications of program. Demonstration and practice on KUKA MIG/MAG welding robot integrated with Fronius power soource.
1101DIGITAL PHOTOGRAPHY01 The Eye of the Digital Photographer, Choosing a Digital Camera, Using a Digital Camera, Digital Image Capture, Digital Imaging Systems, Color, Lighting, Choosing a Scanner, Using a Scanner. From Image Capture to Image Editing, Photoshop Installation.
1102PROFESSIONAL PHOTOGRAPHY01 Eye of the Photographer, Cameras, Lences and Filter, How to Use Your Camera, Developing Your Visual Signature, Natural and Available Light. Arificial Light - Continuous, Arificial Light - Flash.
1103PHOTOSHOP & LIGHT ROOM TECHNIQUES02 Use basic selection tools and edge refinement to isolate and edit parts of an image. Manipulate layers through ordering, positioning, scalling, rotation, and adjustments. Create composite images that demonstrate advanced selection and layering techiniques. Create adjustment layers for editable, non-destructive changes to image coloration and exposure.
1104VIDEO EDITING WITH Edius01 Understand the entire video process - Pre-production, production and post-production essentials, Lights, Camera, Action - Learn audio and lighting for video, Edit and produce final cut - Learn editing techniques, color correction, sound.