ITI Manufacturing Process Control & Automation Technician (TTL) Syllabus 2026: PLC, HMI, SCADA & Official PDF ~ Nitish Atlas

ITI Manufacturing Process Control & Automation Technician (TTL) Syllabus 2026: PLC, HMI, SCADA & Official PDF

ITI Manufacturing Process Control and Automation Technician is a modern engineering trade under the Capital Goods & Manufacturing sector. The training focuses on industrial automation, programmable logic controllers (PLC), HMI, SCADA, sensors, actuators, control systems, electrical and electronic fundamentals, pneumatic systems and automated manufacturing processes.

This page explains the trade syllabus in a learner-friendly format. It does not reproduce the official DGT curriculum word-for-word. For complete learning outcomes, assessment criteria, tools and equipment, students should refer to the official DGT curriculum linked below.

Manufacturing Process Control and Automation Technician: Course at a Glance

Item	Details
Official Trade Name	Manufacturing Process Control and Automation Technician
Common Short Form	Manufacturing Process Control & Automation
Sector	Capital Goods & Manufacturing
Trade Type	Engineering
Duration	1 Year / 1200 Hours
NSQF Level	Level 3.5
Entry Qualification	10th Class examination
Unit / Batch Size	20 trainees
Year of NSQF Approval	2024

The above course information follows the current DGT CTS record for Manufacturing Process Control and Automation Technician.

What Do You Learn in This Trade?

The trade develops practical knowledge for setting up, operating, programming, checking and maintaining industrial automation systems. Students learn how sensors, controllers, actuators, electrical systems and software-based interfaces work together in an automated process.

Major learning areas include:

Industrial safety and workplace practices
Basic electrical and electronic systems
Industrial sensors and transducers
Measurement and signal concepts
Relays, contactors and control circuits
Programmable Logic Controllers (PLC)
PLC programming
Timers and counters
Digital and basic analog control
Pneumatic and electro-pneumatic systems
Hydraulic fundamentals
Human Machine Interface (HMI)
SCADA fundamentals
Industrial communication and networking concepts
Automated process control
Fault finding and preventive maintenance
Industrial automation projects
Employability skills

Trade Syllabus: Foundation and Safety

Safety is the first foundation of industrial automation training because technicians work with electrical circuits, control panels, machines, compressed air, moving equipment and automated systems.

1. Industrial Safety

Electrical safety
Personal protective equipment
Safety signs
Hazard identification
Emergency procedures
Fire safety
First-aid awareness
Safe use of tools and equipment
Housekeeping
5S workplace practices
Safe disposal of workshop waste

Basic Electrical and Electronic Skills

Automation technicians need enough electrical and electronic knowledge to understand control circuits, sensors, relays, PLC inputs and outputs.

2. Basic Electrical Concepts

Voltage
Current
Resistance
Power
AC and DC fundamentals
Series and parallel circuits
Basic electrical measurements
Electrical symbols
Wiring practices

3. Electrical Control Components

Switches
Push buttons
Relays
Contactors
Overload protection
Control transformers
Terminal blocks
Control wiring
Basic motor-control circuits

4. Basic Electronics

Diodes
Transistors
Rectification
Electronic switching
Basic digital logic
Electronic measurement
Use of multimeter

Industrial Sensors and Measurement

Sensors provide information about the physical process to the control system. Understanding the relationship between the physical quantity, sensor and controller is essential for automation work.

5. Sensors and Transducers

Students are introduced to sensors and transducers used for detecting or measuring industrial conditions.

Proximity sensors
Photoelectric sensors
Inductive sensors
Capacitive sensors
Temperature sensors
Pressure-related sensors
Level sensing
Position sensing
Basic signal concepts

6. Sensor Installation and Testing

Sensor identification
Wiring
Power-supply checking
Signal checking
Sensor alignment
Functional testing
Fault identification

PLC: The Core Automation Skill

PLC (Programmable Logic Controller) is one of the most important areas of this trade. A PLC receives input information, processes the programmed logic and controls output devices.

7. PLC Fundamentals

Purpose of PLC
PLC architecture
CPU
Power supply
Input modules
Output modules
Memory
PLC programming device/software
Digital input and output

8. PLC Programming

Students learn basic PLC programming concepts and create control logic for simple industrial automation applications.

Ladder logic fundamentals
Normally open and normally closed contacts
Coils
Logic operations
Timers
Counters
Set/reset functions
Basic sequencing
Program monitoring
Basic troubleshooting

9. PLC Input and Output Interfacing

PLC programming becomes useful only when the controller can interact correctly with real devices.

Sensor-to-input connections
PLC output connections
Relay interfacing
Contactor control
Motor-control applications
Actuator control
Input/output testing

Pneumatic and Electro-Pneumatic Systems

Pneumatic systems are widely used for movement and actuation in automated machinery. Students learn basic components and their control.

10. Pneumatic Components

Compressor
Air receiver
FRL unit
Directional control valves
Flow-control valves
Pressure-control components
Pneumatic cylinders
Air tubing and fittings

11. Pneumatic Circuit Practice

Students learn to connect simple pneumatic circuits and understand the relationship between control valves and actuators.

Single-acting cylinder
Double-acting cylinder
Directional control
Speed control
Sequence operations
Basic pneumatic troubleshooting

12. Electro-Pneumatics

Electro-pneumatic systems combine electrical control with pneumatic actuation and provide an important bridge between conventional circuits and PLC-based automation.

Solenoid valves
Electrical sensors
Relay control
PLC control of pneumatic actuators
Sequence control
Fault finding

Hydraulic Fundamentals

Hydraulic systems use pressurized fluid to transmit power. Students are introduced to the components and basic applications used in industrial machinery.

Hydraulic pump
Reservoir
Pressure-control valves
Directional valves
Hydraulic actuators
Filters
Hoses and fittings
Basic hydraulic circuits
Safety during hydraulic operation

HMI: Human Machine Interface

An HMI allows an operator to monitor and interact with an automated process through a graphical interface.

13. HMI Fundamentals

Purpose of HMI
Screen layout
Buttons and indicators
Process status display
Basic alarm concepts
PLC-HMI communication
Monitoring machine conditions

A useful beginner project is a simple conveyor-control interface where the operator can start or stop the process and observe sensor or machine status.

SCADA Fundamentals

SCADA stands for Supervisory Control and Data Acquisition. It is used for monitoring and supervisory control of industrial processes.

14. SCADA Learning Areas

SCADA purpose
Supervisory monitoring
Data acquisition
Process visualization
Alarms
Trends
Basic data monitoring
Communication between control devices and supervisory systems

Students should understand the difference between a PLC performing control logic and SCADA providing higher-level monitoring and supervisory functions.

Industrial Automation System

The main objective of the trade is to connect individual components into a functioning automated process.

A simplified automation chain is:

Sensor → Input → PLC → Program Logic → Output → Actuator → Machine/Process

When HMI or SCADA is added, the operator can monitor and interact with the process:

Sensor → PLC → HMI/SCADA → Operator → Control System → Actuator

Fixed, Programmable, Flexible and Integrated Automation

Automation Type	Basic Idea
Fixed Automation	Equipment is designed for a relatively fixed sequence or dedicated production task.
Programmable Automation	Control behaviour can be changed through programming.
Flexible Automation	Systems can handle variations in products or production requirements with greater flexibility.
Integrated Automation	Multiple machines, controls and information systems work together as an integrated production system.

Industrial Networking and Communication

Modern automation systems often contain multiple controllers, HMIs, sensors, drives and supervisory systems. Communication allows these devices to exchange information.

Students should develop a basic understanding of:

Industrial communication concepts
Controller-to-device communication
PLC and HMI communication
Basic industrial networking
Addressing concepts
Communication fault diagnosis

VFD and Motor-Control Fundamentals

Variable Frequency Drives (VFDs) are commonly used for controlling the speed and operation of AC motors. Students can connect basic motor-control concepts with automation applications.

Purpose of VFD
Basic speed-control concept
Motor connection fundamentals
Control signals
Basic parameter concepts
Fault indication
Safe operation

Automation Troubleshooting

One of the most important practical skills is finding the cause of a machine or process fault systematically.

A basic troubleshooting sequence is:

Observe: Identify what has stopped working.
Check safety: Make the system safe before inspection.
Check power: Verify the required supply and protection devices.
Check inputs: Verify whether sensors and switches are providing the expected signals.
Check PLC status: Observe input/output indicators and program status.
Check outputs: Determine whether the PLC is commanding the required device.
Check actuator: Inspect the relay, contactor, solenoid, motor or other output device.
Check communication: If applicable, inspect PLC-HMI or network communication.
Verify: Test the system after correction.

Important Practical Skills

Read electrical and control diagrams.
Identify industrial automation components.
Wire basic control circuits.
Test sensors.
Use a multimeter safely.
Connect PLC inputs and outputs.
Create basic ladder-logic programs.
Use timers and counters.
Interface sensors and actuators.
Create simple pneumatic circuits.
Build electro-pneumatic sequences.
Configure basic HMI functions.
Understand SCADA monitoring.
Apply basic VFD control concepts.
Diagnose simple automation faults.
Document practical work and test results.

Practical Automation Project Example

A useful educational project can combine several trade skills into one small automated system.

Example: Automatic Conveyor Sorting System

A simple training model could contain:

Conveyor motor
Proximity or photoelectric sensor
PLC
Control relay or motor-control interface
Pneumatic cylinder
Solenoid valve
HMI

The operating sequence could be:

Object detected → PLC receives sensor input → PLC executes programmed logic → Conveyor/actuator output operates → HMI displays machine status.

This type of project helps students understand how individual components become a complete automation system.

Assessment and Training Focus

The DGT curriculum is structured around Professional Skills, Professional Knowledge and Employability Skills. The one-year course includes practical training, theory, employability development and project-related learning.

Students should therefore prepare in three connected areas:

Area	Preparation Focus
Professional Skill	Wiring, PLC, sensors, pneumatic systems, HMI, SCADA and automation projects.
Professional Knowledge	Understand why the control system and components work as they do.
Employability Skills	Communication, workplace behaviour, digital skills, safety and professional development.

Common Mistakes Automation Students Should Avoid

Memorizing PLC commands without understanding inputs and outputs.
Writing ladder logic without first defining the machine sequence.
Ignoring electrical safety while testing control circuits.
Connecting sensors without checking their voltage and wiring requirements.
Changing PLC programs without documenting the original logic.
Assuming every fault is a PLC-programming fault.
Ignoring mechanical or pneumatic causes of an automation failure.
Using HMI or SCADA only for display without understanding the underlying control system.
Skipping testing after making a change.
Working on live industrial equipment without authorized safety procedures.

How to Prepare for the Trade

Learn electrical fundamentals first. Understand voltage, current, circuits and control components.
Practise wiring. Build small relay and contactor circuits before moving to PLCs.
Understand sensors. Learn what each sensor detects and how its output reaches the controller.
Learn PLC logic step by step. Start with simple start/stop circuits and gradually add timers, counters and sequences.
Connect software with hardware. Do not learn PLC programming only on a screen.
Practise pneumatics. Understand how valves and actuators create physical movement.
Learn HMI/SCADA as monitoring tools. Always understand the underlying process.
Practise troubleshooting. Introduce simple faults and identify them systematically.
Build a project. Combine sensor, PLC, actuator and HMI functions.
Document your work. Record wiring diagrams, programs, observations and test results.

Modern Industry Connection

Industrial automation is increasingly connected with CNC machines, robotics, machine vision, production monitoring, data collection and Industry 4.0 systems.

Automation Foundation	Modern Industry Extension
PLC	Networked control and connected automation
HMI	Operator interfaces and production dashboards
SCADA	Supervisory monitoring and production data
Sensors	Machine condition and process data
Pneumatics	Automated material handling and machine actuation
PLC-controlled machine	Integrated smart manufacturing cell

This foundation can therefore support further learning in PLC programming, industrial robotics, CNC automation, machine vision, IIoT and smart manufacturing.

Official DGT Syllabus PDF

For the complete and authoritative syllabus, learning outcomes, assessment criteria and training requirements, refer to the official DGT curriculum.

Download / Open Official DGT Manufacturing Process Control and Automation Technician Curriculum PDF

View Current CTS Trade Details on Official DGT Website

How to Use the Official Syllabus

Download the official DGT curriculum.
Make a checklist of each professional skill.
Study the related professional knowledge before practical work.
Practise each PLC program on a suitable training setup or simulator.
Record sensor wiring and I/O information.
Document pneumatic and electro-pneumatic circuits.
Prepare HMI and SCADA exercises.
Practise fault-finding using a systematic method.
Build at least one integrated automation project.
Use the official learning outcomes and assessment criteria for revision.

Automation Learning Resources on Nitish Atlas

Nitish Atlas is building a connected technical-learning ecosystem covering ITI, practical skills, CNC, robotics, PLC, automation, CAD/CAM, Industry 4.0 and emerging technologies.

For automation learners, useful learning areas include:

PLC fundamentals
PLC ladder-logic practice
Sensors and industrial measurement
Pneumatic and electro-pneumatic systems
HMI and SCADA fundamentals
Industrial control panels
VFD fundamentals
Industrial robotics
CNC and automation integration
IIoT and Industry 4.0
Automation viva and practical examination preparation

Final Takeaway

The ITI Manufacturing Process Control and Automation Technician trade provides a foundation in modern industrial automation. The learner progresses from electrical and electronic fundamentals to sensors, PLCs, pneumatic systems, HMI, SCADA and automated process control.

The most useful way to understand automation is:

Sense → Input → Process Logic → Output → Actuate → Monitor → Diagnose → Improve.

Do not learn automation as isolated PLC commands. Understand how the sensor, controller, program, actuator, machine and operator interface work together as one system.

For the latest detailed syllabus, learning outcomes, assessment criteria and official training requirements, always refer to the current DGT curriculum linked above.

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