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DOCUMENT RESUME CE 077 666 ED 460 266 Southern Ductile Training Manual. TITLE Alabama State Dept. of Education, Montgomery. INSTITUTION Office of Vocational and Adult Education (ED), Washington, SPONS AGENCY DC. National Workplace Literacy Program. 1996-00-00 PUB DATE NOTE 390p. V198A40030 CONTRACT Classroom Guides Teacher (052) PUB TYPE MF01/PC16 Plus Postage. EDRS PRICE Adult Basic Education; Adult Literacy; Behavioral DESCRIPTORS Objectives; Competency Based Education; *Computer Literacy; Education Work Relationship; Foundries; Fringe Benefits; *Integrated Curriculum; Job Skills; Learning Activities; Lesson Plans; *Literacy Education; Mathematics Skills; Metal Industry; *Metal Working; *Numeracy; Occupational Safety and Health; Partnerships in Education; Problem Solving; Reading Skills; School Business Relationship; Skill Development; Teaching Guides; *Workplace Literacy; Writing (Composition); Writing Skills ABSTRACT This instructor's manual contains the materials required to conduct the competency-based workplace literacy program that was developed to help employees at a foundry that has evolved from a small, family-owned business into a major foundry group with several automated production systems. The workplace literacy program consists of 24 lessons in which information about the company and the tasks performed by its workers is used as the basis for helping workers develop the reading, writing, mathematics, problem-solving, and computer literacy skills required to work at the foundry. Each lesson contains some or all of the following: behavioral objectives; lesson plan containing instructor notes, lesson activities, a list of required materials, and estimates of the time required for each component of the lesson; one or more learning activities; vocabulary list; vocabulary definitions; reading material and accompanying questions; and answers to the learning activities and discussion questions. The following are among the unit topics: company history; International Standards Organization and company mission; problem solving; foundry process; coremaking I-II; grinding; pouring I-II; melting; general safety; material safety data sheets; safety--lockout/tagout and personal protective equipment; basic mathematics; statistical process control (SPC) history and principles; SPC math; form completion; job procedure; process cards; benefits; computers--introduction; computer applications; writing I-II; and bar coding. (MN) Reproductions supplied by EDRS are the best that can be made from the ori inal document. Southern Ductile Training Manual U.S. DEPARTMENT OF EDUCATION e file(' of Educational Research and Improvement UCATIONAL RESOURCES INFORMATION CENTER (ERIC) p This document has been reproduced as received from the person or organization originating it. ID Minor changes have heen made to improve reproduction quality. Points of view or opinions stated in this document do not necessarily represent official OERI position or policy. AVAILABLE BEST COPY SOUTHER\ DUCTILE November 26, 1996 Dr. Bobby Dees Alabama State Board of Education Adult Education Program 50 North Ripley Street, Room 5343 Montgomery, AL 36130-3901 Alabama Work Place Literacy Program Subject: Dear Dr. Dees: In accordance with the grant for the subject program, this is your authorization to use the generic programs developed by Southern Ductile Casting Company for distribution to other facilities, as you deem appropriate. Yours / Oavid M. Ford Human Resources Manager DMF/sr Copy: Mr. Randel Walker Southern Ductile Training Manual TABLE OF CONTENTS 1. Company History 1 2. ISO and Mission Statement 12 3. Problem Solving 21 4. Foundry Process 43 5. Coremaking - Overview I 49 6. Coremaking - Overview II 59 7. Grinding - Overview 65 8. Pouring - Overview I 72 9. Pouring - Overview H 85 93 10. Melting - Overview 11. General Safety 105 12. Safety - MSDS 128 13. Safety - Lockout/Tagout and PPE 138 14. Basic Math 141 163 15. SPC - History and Principles 16. SPC - Math 168 176 17. Form Completion 193 18. Job Procedure 247 19. Process Cards 261 20. Benefits 21. Computer - Introduction 273 22. Computer - Applications 281 23. Writing - Part I 284 22. Writing - Part II 289 23. Writing - Part III 292 24. Bar Coding -Introduction 296 Company History Upon completion of this lesson the learner will be able to: define vocabulary words relating to company history. answer comprehension questions with 90% accuracy. explain changes that have taken place and how the changes have affected the company. Instructor Notes Activities Time Materials Set Induction Have learners tell their 5-10 Minutes name and two words that describe them, using their first and last initial. Start with yourself in order to give the learners time to think. When everyone has fulished, have each group member try to remember the name of each person in the group and the two things they told about themselves. Guided Practice Introduce Vocabulary Course Content 5-10 Minutes Explain the purpose of 20-30 Minutes Pre-test Workbook the program, the course content. Give the pre- test. Have learners read the company history. Applied practice 20 Minutes Have learners answer Workbook questions about Southern Ductile. Closure 5-10 Minutes Allow learners to ask any questions they might have or to expreqq ntly concerns they might have about the training. 1 7 I-HSTORY AND FOUNDRY PROCESS S CAS TI NGATES ANDRI SERS E HCWJ CRYRUPHNVWXMJ BKN J AOEGACS MATECHNOLOGYI ORRTYQQUCAPROMDPVJ KSM B GEI BF L XPROHELEYTEGHE B ERCQLI WGOAHI ALLOYJ AC I OS EELATUCLP ATTERNBKH N NYRCUXSNXRABEEMKGREA GKSHVJ EBTZDUCTI LEI RON FETPOSTI NOCUL ATI ONJUI OTEAEOYRF I CP ZPI SNRTTZ U LMTJ CI GJ OYUNXVRMKLS A N VSCHWTWBRHBOEUWXTPDT D TAUXXLI XKLEAJUMBMBDI RLNSL XF I OGDCI HYCHF I YO YWDRVLLF DNI XQHUXMQKHN Word List POST-INOCULATION JOBBING FOUNDRY GATES AND RISERS MECHANIZATION DUCTILE IRON INSPECTION SYSTEM SAND TECHNOLOGY SHOTBLAST TREATMENT GRAY IRON SHAKEOUT GRAPHITE CASTING PATTERN CHARGE MULLER CUPOLA SCRAP ALLOY CORE TAP 9 Vocabulary Company History and Foundry Process - 1. Alloy - A metal-like material added to molten iron to change one or more of its properties. Magnesium, ferrosilicon and copper are common alloys used at Southern Ductile. 2. Casting - A metal object produced by pouring molten metal into a mold. 3 Charge - The materials placed in a melting furnace. Two common charge materials for ductile iron production are steel and foundry returns. 4 Core - A sand structure placed into a mold to create a hole or internal cavity in a casting. 5 Cupola - Stack-type melting furnace in which metal is melted in direct contact with the fuel. 6. Ductile Iron - Cast iron that has a large amount of carbon in the form of balls or nodules. These nodules are produced by adding a small amount of magnesium to the molten iron. 7. Gates and Risers - The network of extra metal attached to a casting reflecting the path of the molten metal inside the mold that must be removed at gatebreaking. 8. Graphite - A soft, black form of carbon found in gray and ductile iron. It is also used to increase the carbon content of the furnace iron. 9. Gray Iron - Cast iron that has a large amount of carbon in the form of fInke grnpliitP. 10. Inspection check castings to determine - The various procedures used to if they meet customer requirements. 11:Jobbing Foundry make a relatively small - A foundry that contracts to number of many different castings to various customers. Southern Ductile is a jobbing foundry.