MILLWRIGHTS (MECHANICAL) 

INDUCTION
 
Organization history, mission and vision
Authority structure
Responsibilities
Documentation
Accommodation
Rules and regulations
Working hours
Leave and absence
Disciplinary procedures
Transport
Security
Sport and recreational facilities

SAFETY

Safe environment Safety attitudes 
Report safety matters
Safety inspections
Safety representatives
Unsafe acts and conditions
Injuries
First aid box
First aid officers
Personal protective clothing and equipment
Personal hygiene
Housekeeping
General house hold rules

BENCH WORK
 
Workshop safety
Understand NSD rules and procedures (read induction document)
Use of PPE
Maintain a safe working area
Maintain personal safety and safety for others according to procedures
Protect the environment according to regulations
Understand and recall driven machinery regulations
Select, use and care for engineering hand tools
Select, use and care for workshop tools
Select, use and care for power tools
Select, use and care portable power tools
Select, use and care for engineering measuring equipment
Mark off basic engineering shapes

HAND SKILLS

Make off a five holes flange
Manufacturing five holes flange
Mark off a six holes flange
Manufacturing six holes flange
Manufacturing and fit a taper key
Mark off and fit a fitting block

COUPLING AND DRIVES
 
Mount and align:
Flexible tyre coupling
Rigid flange coupling
Gear coupling
Pin and disc coupling
Universal coupling
V-belts
Chain and sprocket
Taper gauge and ruler
DTI alignment
Laser alignment

HYDRAULICS

Draw a hydraulic diagram
Build a hydraulic system on simulation panel (fault finding)
Understand applicable theory related to hydraulics (theory test)

PNEUMATICS

Draw a pneumatic diagram
Build a pneumatic system on simulation (fault finding)
Understand applicable theory related to pneumatics (theory test)

MECHANICAL DRAWINGS

Interpret mechanical drawings
Produce engineering drawings
Produce and interpret pipe isometric drawings
Produce and interpret structural sketches

MECHANICAL SYSTEM

Bearing:      
Identify difference types of bearings
Mount different types of bearings
Mount and dismount a bearing using hydraulic puller
Lubrication:  
Needs for lubricants
How lubrication works
Types of lubricants
Viscosity
Select of lubricants
Safe handling method for lubricants

Brakes:
Identify types of brakes
Align a brake drum
Set the correct torque on a brake system
Maintain a brake system   

PUMPS

Maintain pumps:
Remove and displace gland packing
Remove and displace mechanical seal
Remove and dismantle pumps:
Single stage centrifugal pump
Double diaphragm pump
Magnetic drive pump
Worm drive pumps
Find faults on pumps

BASIC ARC AND GAS WELDING (MECHNICAL)

Safety rules and regulations
Identify and explain the use of arc and gas welding equipment
Setup arc and gas welding equipment
Select and examine relevant welding rods
Prepare material for welding
Weld steel plates in basic positions
Identify welding defects and explain their causes
Arc and gas welding (mechanical)

BASIC LIFTING TECHNIQUES 

Recall overhead crane hand signals
Demonstrate overhead crane signals
Use different lifting equipment:
-Chain block
-Shackles
-Rope slings

BASIC TURNING 

Perform external parallel turning
Perform internal parallel turning
Perform external screw threads
Perform internal screw threads

BASIC MILLING

Perform milling work with: -Slot drills and end mills
Machine a flat surface
Machine a hexagon
Machine slots

MATERIALS – THERMAL APPLICATIONS
 
Identification of metals:
Ferrous metals
Nonferrous metals
Properties and characteristics of metals:
Compressive strength
Ductility strength
Malleability strength
Heat treatments:
Hardening
Tempering
Annealing
Normalizing
Case hardening

Hardness testers:
Rockwell hardness tester
Brinell hardness tester