TNPSC ITI Manufacturing Process Control and Automation (Code 543) Syllabus: A Comprehensive Guide

"For aspirants preparing for the Tamil Nadu Public Service Commission (TNPSC) examinations for Trade: Manufacturing Process Control and Automation (ITI Standard, Subject Code 543), a precise understanding of the official syllabus is paramount. This trade delves into the principles and practical applications of industrial automation, including Programmable Logic Controllers (PLCs), Human Machine Interfaces (HMIs), and Supervisory Control and Data Acquisition (SCADA) systems. This guide meticulously details each unit, outlining critical areas for effective preparation for the Combined Technical Services Examination (Diploma / ITI Level), as per Notification No. 10/2025. The question paper for this subject will be available in both English and Tamil."

"Associated Post and Vacancies"

• "Post Name: Junior Training Officer (Manufacturing Process Control and Automation)"
• "Post Code: 3636"
• "Number of Vacancies: 49"
• "Question Paper Language: English and Tamil"

"Key Examination Details"

• "Notification Date: June 13, 2025"
• "Online Application Last Date: July 12, 2025, at 11:59 PM."
• "Application Correction Window: July 16, 2025, 12:01 AM to July 18, 2025, 11:59 PM (three days)."
• "Paper I Examination: August 31, 2025, Forenoon (Tamil Eligibility Test, General Studies, Aptitude and Mental Ability, Subject Code 501)."
• "Paper II Examination (Subject Paper 543): Broadly scheduled between September 7, 2025, and September 15, 2025. Exact date and time to be announced on the Commission's website."
• "Application Process: Online mode only via Commission’s website, requiring One Time Registration (OTR). Subject paper selection is mandatory."
• "Mandatory Appearance: Compulsory to appear for both Paper I and Paper II. Failure to appear will lead to disqualification."

"Examination Structure and Evaluation"

• "Paper I (SSLC Standard, OMR-based):
  • "Total: 100 objective questions, 150 marks, 3 hours duration."
  • "Part A: Tamil Eligibility Test (minimum 40% or 60 marks required to qualify)."
  • "Part B: General Studies (75 questions, Degree Standard)."
  • "Part C: Aptitude and Mental Ability (25 questions, SSLC Standard)."
  "
• "Paper II (Subject Paper - Trade: Manufacturing Process Control and Automation, ITI Standard, CBT):
  • "200 objective questions, 3 hours duration, 300 marks."
  "
• "Total Marks for Final Selection: 450 marks (Part B + Part C of Paper I + Paper II)."
• "Evaluation Criteria: Paper II and Parts B and C of Paper I will be evaluated only if minimum qualifying marks in Part A of Paper I are secured."

"Eligibility Criteria for Junior Training Officer (Manufacturing Process Control and Automation) - Post Code: 3636"

• "Age Limit (as of July 1, 2025):
  • "Others: Maximum 32 years."
  • "Reserved Categories (BC, BCM, MBC/DC, SC, SCA, ST): No Maximum Age Limit."
  "
• "Educational Qualification: Must have passed SSLC or its equivalent AND possess any one of the following:
  • "A Degree in Engineering / Technology in Manufacturing / Industrial / Mechanical / Production / Mechatronics / Robotics and Automation from any institution / university recognized by AICTE / UGC."
  • "A Diploma in Manufacturing Engineering / Industrial Engineering / Mechanical Engineering / Production Engineering / Mechatronics Engineering / Robotics and Automation from any institution / university recognized by AICTE / UGC."
  • "A National Trade Certificate / National Apprenticeship Certificate in Manufacturing Process Control and Automation."
  "
• "Physical Standards: Vision Standard III or better. The post is identified as suitable for persons with benchmark disabilities of all categories."

"Official Syllabus Breakdown: TNPSC Trade - Manufacturing Process Control and Automation (Code 543)"

"The syllabus for Trade - Manufacturing Process Control and Automation at the I.T.I. Standard is structured into the following units. Aspirants should systematically cover these units for comprehensive preparation, noting that question distribution is indicative."

"Unit I: Workplace Safety Regulations and Computers Operations (10 Questions)"

• "Workplace Safety: Adherence to safe working practices, environment regulations, and housekeeping in industrial settings."
• "Personal Protective Equipment (PPE): Types, selection, and proper use of PPE relevant to manufacturing and automation."
• "First Aid: Basic first aid procedures for common industrial accidents."
• "Fire Safety: Types of fire extinguishers, fire prevention, and emergency response procedures."
• "Computer Operations: Basic computer literacy, operating system fundamentals (e.g., Windows), file management, and internet Browse for information retrieval relevant to automation."
• "Introduction to Industrial Automation: Overview of automation concepts and its importance in modern manufacturing."

"Unit II: Manufacturing Processes and Automation (15 Questions)"

• "Manufacturing Processes: Overview of various manufacturing processes – Batch, Discrete, and Continuous Manufacturing processes."
• "Automation Concepts: Levels of automation, benefits of automation in manufacturing."
• "Introduction to Process Control: Basic concepts of process control loops (open-loop, closed-loop)."
• "Sensors and Actuators: Basic understanding of common sensors (e.g., proximity, limit switches, temperature sensors) and actuators (e.g., motors, solenoid valves) used in automation."
• "Control Components: Relays, contactors, timers, counters – their function in control circuits."
• "Machine Tools and Operations: Basic knowledge of lathe, milling, drilling machines and their operations relevant to automated processes."

"Unit III: PLC Numbering Systems and Memory Organization (20 Questions)"

• "Numbering Systems: Application of binary, octal, decimal, and hexadecimal numbering systems in PLC programming."
• "PLC Memory Organisation: Understanding PLC memory areas (e.g., input image table, output image table, data files, program files)."
• "PLC Addressing: Input/Output addressing formats for various PLC brands (e.g., Allen-Bradley, Siemens, Mitsubishi)."
• "PLC Data Types: Basic data types used in PLCs (e.g., Boolean, Integer, Floating Point)."
• "Fundamentals of Digital Logic: Logic gates (AND, OR, NOT), Boolean algebra, truth tables."

"Unit IV: PLC Applications and Selection Criteria (15 Questions)"

• "PLC Applications: Diverse applications of PLCs in various industries (e.g., conveyor control, packaging, material handling, process control)."
• "PLC System Overview: Understanding the basic architecture and components of a PLC system (CPU, I/O modules, power supply, programming device)."
• "Selection Criteria for PLCs: Factors influencing PLC selection (e.g., number of I/O, memory size, processing speed, communication capabilities, cost)."
• "Types of PLCs: Fixed I/O PLCs, Modular PLCs, Rack-based PLCs."
• "PLC Programming Languages: Introduction to different PLC programming languages (e.g., Ladder Diagram, Function Block Diagram, Structured Text, Instruction List)."

"Unit V: PLC Input / Output Modules and Devices (25 Questions)"

• "PLC Input Modules: Types of digital input modules (e.g., DC sink/source, AC input), analog input modules (e.g., voltage, current inputs), special input modules."
• "PLC Output Modules: Types of digital output modules (e.g., relay, transistor, triac output), analog output modules, special output modules."
• "Input Devices: Wiring and operation of common input devices (e.g., push buttons, selector switches, limit switches, proximity sensors, photoelectric sensors, encoders)."
• "Output Devices: Wiring and operation of common output devices (e.g., contactors, solenoid valves, indicator lamps, motor starters, Variable Frequency Drives (VFD) interface)."
• "Interfacing: Understanding how input and output devices are interfaced with PLC modules."
• "Wiring Practices: Proper wiring techniques for industrial control panels involving PLCs."

"Unit VI: PLC Panel Wiring and VFD Operation (30 Questions)"

• "PLC Panel Wiring: Design and installation of PLC control panels, wiring diagrams, terminal blocks, wire numbering, grounding and shielding techniques."
• "Power Distribution in Panels: Circuit breakers, fuses, power supplies for PLCs and associated devices."
• "Variable Frequency Drive (VFD) Operation:
  • "Introduction to VFDs: Principle of operation, advantages in motor control."
  • "VFD components and connections (input power, motor connections, control terminals)."
  • "Basic VFD parameters and programming for motor speed control."
  • "Interfacing VFDs with PLCs for automated speed control."
  • "Troubleshooting common VFD issues."
  "
• "Motor Control Circuits: Direct Online (DOL) starters, Star-Delta starters, Forward/Reverse control using PLCs."

"Unit VII: PLC Ladder Diagrams and Advanced Instructions (30 Questions)"

• "Ladder Diagram (LD) Programming:
  • "Basic Ladder Logic elements: Contacts (NO, NC), Coils (Output)."
  • "Implementing relay logic, AND/OR logic, latching circuits."
  • "Timers: ON-delay, OFF-delay, Retentive timers and their applications."
  • "Counters: Up, Down, Up/Down counters and their applications."
  "
• "Advanced PLC Instructions:
  • "Comparison instructions (EQ, NEQ, LT, LEQ, GT, GEQ)."
  • "Mathematical instructions (ADD, SUB, MUL, DIV)."
  • "Data movement instructions (MOV)."
  • "Program control instructions (JUMP, CALL, RET)."
  • "Sequencing instructions."
  • "PID (Proportional-Integral-Derivative) control concepts in PLC (basic)."
  "
• "Program Development: Developing ladder diagrams for typical industrial control applications."
• "Troubleshooting PLC Programs: Using fault indicators, force I/O, trend charts, and status bits for debugging."

"Unit VIII: HMI Installation, Configuration and PLC Interface (15 Questions)"

• "Human Machine Interface (HMI): Introduction to HMI concepts, role in automation systems."
• "HMI Hardware: Types of HMIs (e.g., panel mount, touchscreen), their features."
• "HMI Software: Installation and basic configuration of HMI application software."
• "HMI Development: Creating screens, buttons, text displays, numerical displays, graphs, and alarms in HMI."
• "Interfacing HMI with PLC: Establishing communication protocols (e.g., Ethernet/IP, Modbus TCP/RTU) between HMI and PLC."
• "Data Exchange: Tag creation, mapping PLC addresses to HMI tags for data exchange."
• "Troubleshooting HMI Issues: Common problems and their solutions in HMI-PLC communication."

"Unit IX: SCADA Operation, PLC Interface and Communication Networks (20 Questions)"

• "SCADA (Supervisory Control and Data Acquisition): Introduction to SCADA systems, architecture, and functions (e.g., data acquisition, control, monitoring, alarming, reporting)."
• "SCADA Operation: Understanding the operation of a SCADA system from an operator's perspective."
• "PLC Interface with SCADA: Establishing communication between PLCs and SCADA systems."
• "Communication Protocols: Common industrial communication protocols used in automation (e.g., Modbus, Profibus, Ethernet/IP, OPC)."
• "Communication Networks: Types of industrial networks (e.g., Fieldbus, Industrial Ethernet) and their components."
• "Data Flow in SCADA: Understanding the flow of data from field devices to SCADA central system."

"Unit X: SCADA Architecture, HMI vs SCADA and Simulation (20 Questions)"

• "SCADA Architecture: Detailed understanding of SCADA system architecture (e.g., RTUs, MTUs, communication network, HMI)."
• "HMI vs. SCADA: Key differences and similarities between HMI and SCADA systems in terms of scope, functionality, and application."
• "SCADA System Implementation: High-level process for supervisory management, control, and data acquisition."
• "Simulation in Automation: Use of simulation software for testing PLC and SCADA programs, virtual commissioning."
• "Cybersecurity in SCADA: Basic concepts of cybersecurity threats and mitigation in industrial control systems."
• "Data Historians and Reporting: Role of data historians in SCADA for trend analysis and reporting."

"Important Note for Aspirants: This comprehensive syllabus for Trade: Manufacturing Process Control and Automation (Code 543) at the ITI Standard provides a robust framework for examination preparation for the Junior Training Officer role. Aspirants are strongly advised to meticulously cover all topics, focusing on both theoretical understanding and practical applications of PLC programming, HMI development, SCADA operations, and VFD control. Consistent revision and hands-on exposure to automation concepts are essential for success in this competitive examination."

"Success in the TNPSC Manufacturing Process Control and Automation (Code 543) examination requires a disciplined and strategic approach. By gaining a strong command of industrial safety, manufacturing processes, PLC hardware and programming, HMI design, SCADA systems, and industrial communication, aspirants can significantly enhance their performance and achieve their career objectives in the field of industrial automation."

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