EAL Level 3 Diploma in Advanced Manufacturing and Engineering - Machinist (Development Competence)

What you'll be able to do

• Demonstrate competence in bending and forming materials used in the manufacture of strip springs, using power operated equipment such as press brakes/bending machines, in accordance with approved procedures.
• Operate the appropriate bending and forming equipment in accordance with the instructions for the operations being performed.
• Ensure that all required safety devices are operating correctly on bending and forming equipment.
• Ensure that machine guards are in place and correctly adjusted on bending and forming equipment.

What you'll be able to do

• Understand the safety precautions required when working on CNC machine tools and their associated tools and equipment.
• Demonstrate safe working practices throughout the CNC machine tool programming process.
• Understand the responsibility they owe to themselves and others in the workplace when carrying out CNC machine tool programming.

What you'll be able to do

• Demonstrate competence in applying specified heat treatment processes to coil springs, wire forms or flat/strip springs, in accordance with approved procedures
• Select and prepare the appropriate equipment to use, based on the heat treatment process to be carried out
• Select and prepare the appropriate equipment to use, based on the types of material to be treated
• Carry out heat treatment activities including hardening, tempering, annealing and normalising, as applicable to the task

What you'll be able to do

• Demonstrate competence in carrying out quality control checks of spring making activities, in accordance with approved procedures.
• Obtain all relevant and current documentation for quality control checks.
• Select the appropriate inspection equipment based on the features to be checked and the accuracy to be measured.
• Check that the appropriate inspection equipment is within current test dates.
• Set up and calibrate inspection equipment ready for inspection operations.
• Check springs for dimensional and geometrical accuracy during inspection activities.
• Check springs for load and rate during inspection activities.
• Undertake inspection activities at various stages of manufacture, such as random sampling during production and final inspection.
• Inspect various types of springs, including compression, extension, torsion, wire forms, strip and flat springs.

What you'll be able to do

• Demonstrate competence in operating machinery to carry out the shot peening of springs, in accordance with approved procedures.
• Carry out checks of the machine to ensure that it is safe to use.
• Verify that the substances used during the treatment operation are available and suitable for the intended purpose and type and size of spring being treated.
• Operate the machine to control the treatment cycle and flow of abrasive substance onto the spring surfaces, in accordance with safe working practices and operating procedures.
• Monitor the machine’s performance to ensure consistent treatment of the springs.
• Check that adequate levels of abrasive substances are maintained within the machine.

What you'll be able to do

• Comply with duties and obligations as defined in the Health and Safety at Work Act.
• Demonstrate the required occupational behaviours in line with the job role and company objectives.
• Present themselves in the workplace suitably prepared for the activities to be undertaken.
• Follow organisational accident and emergency procedures.
• Recognise and control hazards in the workplace.
• Use correct manual lifting and carrying techniques.
• Apply safe working practices and procedures.
• Describe the roles and responsibilities of themselves and others under the Health and Safety at Work Act 1974 and current legislation.
• Describe the specific regulations and safe working practices and procedures that apply to their work activities.
• Describe the warning signs for the nine main groups of hazardous substances defined by Classification, Packaging and Labelling of Dangerous Substances Regulations.
• Explain how to locate relevant health and safety information for their tasks and the sources of expert assistance when help is needed.
• Explain what constitutes a hazard in the workplace.
• Explain what are their responsibilities for dealing with hazards and reducing risks in the workplace.
• Explain what are the risks associated with their working environment.

What you'll be able to do

• Understand the statutory regulations applicable to the workplace.

What you'll be able to do

• Demonstrate competence in drilling and finishing holes in spring components, using hand held and fixed drilling machines, in accordance with approved procedures
• Select the appropriate drilling equipment to use, based on the operations to be performed and the size of the component worked on
• Use appropriate workholding methods and techniques to secure the workpiece for the drilling operations
• Employ jigs, clamps, machine vice and other appropriate holding devices
• Position the drill bits accurately
• Use appropriate speeds and feeds to drill and finish the holes to the required specification
• Perform drilling and finishing operations including holes through the workpiece, blind holes, counterbored holes, countersunk holes, spot facing, reaming and tapping

What you'll be able to do

• Demonstrate competence in preparing, setting up and using single and multi-action power presses and associated equipment.
• Follow approved procedures when preparing, setting up and using power presses and associated equipment.
• Select appropriate press tools for the power press.
• Mount and position press tools to the machine in the correct location for the type of operation being carried out.
• Set up and align all associated equipment, including material positioning mechanisms and workpiece ejection mechanisms.
• Set up and align all machine safety devices and guards.

What you'll be able to do

• Demonstrate competence in forming materials used in the manufacture of strip springs, using power-operated pinch or pyramid rolls, in accordance with approved procedures
• Operate the power rolling machine, according to the operations to be performed and the thickness and size of the material to be rolled
• Set and adjust the gap between feed and forming rolls to suit material thickness
• Position side roller(s) and adjust to suit the required radius
• Check and set parallelism of rollers
• Apply suitable pressure to rollers throughout the forming operation

What you'll be able to do

• Demonstrate competence in preparing bench grinding machines for spring end grinding operations, in accordance with approved procedures.
• Demonstrate competence in preparing pedestal grinding machines for spring end grinding operations, in accordance with approved procedures.
• Demonstrate competence in preparing belt linishing machines for spring end grinding operations, in accordance with approved procedures.
• Prepare the grinding equipment to grind spring ends flat and square.
• Prepare the grinding equipment to grind spring ends to the correct dimensional requirements.
• Select the appropriate grinding machine/equipment for the spring end grinding operation.
• Select the appropriate spring holding device for the spring end grinding operation.

What you'll be able to do

• Demonstrate competence in handing over a prepared machine tool to production operators, in accordance with approved procedures.
• Check that the machine functions safely and correctly.
• Check that there are sufficient materials and consumables available for the work to be carried out.
• Check that all the required quality control instruments and gauges are available and correctly set/calibrated.
• Check that the machine is producing the components to the required specification.
• Demonstrate the operation of the machine to the operator, highlighting all the necessary key stages of performance.
• Demonstrate the operation of the machine to the operator, highlighting specific techniques to be used.
• Demonstrate the operation of the machine to the operator, highlighting aspects of safety that require particular attention.
• Ensure that the operator is operating the machine safely and correctly before leaving him/her to perform the tasks unsupervised.
• Periodically check the finished components.
• Make adjustments to settings to achieve specification.
• Solve machine-related problems during production.

What you'll be able to do

• Understand the safety precautions required when working on CNC machine tools
• Understand the safety precautions required when working with associated tools and equipment
• Demonstrate safe working practices throughout CNC machine tool operations
• Understand the responsibility they owe to themselves in the workplace
• Understand the responsibility they owe to others in the workplace

What you'll be able to do

• Demonstrate competence in carrying out broaching operations using horizontal or vertical broaching machines, in accordance with approved procedures
• Check that the broaching machine is ready for the operations to be performed
• Confirm that all the required components, materials and consumables are available for the broaching operations
• Produce a range of components that contain features such as keyways, square holes, hexagonal and octagonal holes, holes with one flat, splines, serrations, and special forms

What you'll be able to do

• Demonstrate competence in operating Computer Numerical Control (CNC) electrical discharge machines, such as spark erosion, tape erosion and wire erosion machines.
• Operate CNC electrical discharge machines in accordance with approved procedures.

What you'll be able to do

• Demonstrate competence in carrying out gear cutting operations using Computer Numerical Control (CNC) machines.
• Carry out gear cutting operations in accordance with approved procedures, using CNC machines.

What you'll be able to do

• Understand the safety precautions required when working with CNC grinding machines
• Understand the safety precautions required when working with associated tools and equipment for CNC grinding machines
• Demonstrate safe working practices when machining components using CNC grinding machines
• Understand the responsibility they owe to themselves and others in the workplace when machining components using CNC grinding machines

What you'll be able to do

• Demonstrate competence in carrying out horizontal boring operations, in accordance with approved procedures, using Computer Numerical Control (CNC) machines.

What you'll be able to do

• Demonstrate competence in carrying out cutting and profiling operations using CNC laser profiling machines, in accordance with approved procedures

What you'll be able to do

• Demonstrate competence in carrying out operations using Computer Numerical Control (CNC) machining centres, in accordance with approved procedures

What you'll be able to do

• Understand the safety precautions required when working with CNC milling machines and their associated tools and equipment.
• Demonstrate safe working practices throughout the machining process.
• Understand the responsibility they owe to themselves and others in the workplace when machining components using CNC milling machines.

What you'll be able to do

• Demonstrate competence in carrying out pressing operations, in accordance with approved procedures, using Computer Numerical Control (CNC) machines
• Demonstrate competence in carrying out punching operations, in accordance with approved procedures, using Computer Numerical Control (CNC) machines

What you'll be able to do

• Understand the safety precautions required when working with CNC turning machines
• Understand the safety precautions required when working with associated tools and equipment for CNC turning machines
• Demonstrate safe working practices when machining components using CNC turning machines
• Understand the responsibility they owe to themselves and others in the workplace when machining components using CNC turning machines

What you'll be able to do

• Demonstrate competence in carrying out vertical boring operations, in accordance with approved procedures, using Computer Numerical Control (CNC) Machines.

What you'll be able to do

• Understand the safety precautions required when working with centre lathes and their associated tools and equipment
• Demonstrate safe working practices throughout the machining process
• Understand the responsibility they owe to themselves and others in the workplace when machining components using centre lathes

What you'll be able to do

• Understand the safety precautions required when working with electro-discharge machines
• Understand the safety precautions required when working with associated tools and equipment for electro-discharge machines
• Demonstrate safe working practices when machining components using electro-discharge machines
• Understand the responsibility they owe to themselves and others in the workplace when machining components using electro-discharge machines

What you'll be able to do

• Demonstrate competence in carrying out gear cutting operations using machines such as gear hobbing, gear shaping, gear shaving, gear planing, bevel gear cutting
• Check that the machine is ready for the operations to be performed
• Ensure that all the required components/materials and consumables are available
• Produce a range of gears, such as external spur gears, internal spur gears, helical and double helical gears, bevel gears, chain sprockets, external splines and serrations

What you'll be able to do

• Demonstrate competence in carrying out gear grinding operations.
• Carry out gear grinding operations in accordance with approved procedures.
• Check that the gear grinding machine is ready for the operations to be performed.
• Ensure that all the required components, consumables and gear measuring equipment are available.
• Grind a range of gears, such as spur gears, helical and double helical gears, bevel gears, and splines.

What you'll be able to do

• Understand the safety precautions required when working with grinding machines
• Understand the safety precautions required when working with associated grinding wheels and equipment
• Demonstrate safe working practices when machining components using grinding machines
• Understand the responsibility they owe to themselves and others in the workplace when machining components using grinding machines

What you'll be able to do

• Demonstrate competence in carrying out honing and lapping operations using horizontal or vertical honing machines and lapping machines, in accordance with approved procedures.
• Check that the machine is ready for the operations to be performed.
• Ensure that all the required components, consumables and measuring equipment is available.
• Hone/lap a range of components, which will include through holes, blind holes and flat surfaces.

What you'll be able to do

• Demonstrate competence in carrying out horizontal boring operations in accordance with approved procedures.
• Use horizontal boring machines and associated boring attachments effectively.
• Check that the horizontal boring machine is ready for the operations to be performed.
• Ensure that all required components, materials and consumables are available for the horizontal boring operations.
• Produce a range of components that combine different features, such as drilled and reamed holes.
• Produce components with parallel and tapered bored holes, counterbores, threads and special forms.
• Produce components with external diameters, flat, parallel and square faces, steps and slots.
• Produce components with radii and chamfers.

What you'll be able to do

• Understand the safety precautions required when working with milling machines and their associated tools and equipment
• Demonstrate safe working practices when machining components using milling machines
• Understand the responsibility they owe to themselves and others in the workplace when machining components using milling machines

What you'll be able to do

• Demonstrate competence in handing over a prepared machine tool to carry out shaping, planing or slotting operations, in accordance with approved procedures.
• Verify that the machine is ready for the operations to be performed.
• Confirm that all the required components/materials and consumables are available.
• Produce a range of components that combine a number of different features, such as flat faces, parallel faces, faces that are square to each other, angular faces, steps, slots, keyways, flat sided holes, splines and serrations.

What you'll be able to do

• Demonstrate competence in carrying out turning operations on a turret lathe, in accordance with approved procedures
• Check that the machine is ready for the operations to be performed
• Ensure that all the required components, materials and consumables are available
• Produce a range of components that combine a number of different features, such as parallel, stepped and tapered diameters
• Produce components with drilled, bored and reamed holes
• Produce components with internal and external threads
• Produce components with special forms and profiles

What you'll be able to do

• Demonstrate competence in carrying out vertical boring operations, in accordance with approved procedures, using vertical boring machines
• Demonstrate competence in carrying out vertical boring operations, in accordance with approved procedures, using associated vertical boring attachments
• Check that the vertical boring machine is ready for the operations to be performed
• Ensure that all the required components or materials are available for the vertical boring operations
• Ensure that all the required consumables are available for the vertical boring operations
• Produce a range of components that combine a number of different features, such as parallel diameters
• Produce a range of components that combine a number of different features, such as parallel bores
• Produce a range of components that combine a number of different features, such as external tapers
• Produce a range of components that combine a number of different features, such as taper bores
• Produce a range of components that combine a number of different features, such as steps
• Produce a range of components that combine a number of different features, such as faces
• Produce a range of components that combine a number of different features, such as radii
• Produce a range of components that combine a number of different features, such as threads
• Produce a range of components that combine a number of different features, such as ground diameters
• Produce a range of components that combine a number of different features, such as milled faces
• Produce a range of components that combine a number of different features, such as milled slots or profiles

What you'll be able to do

• Demonstrate competence in cold forming wire (either round, square or rectangular section) compression springs, using hand forming methods and techniques, in accordance with approved procedures
• Select the appropriate equipment to use, based on the forming operations required, the material to be formed and the accuracy to be achieved
• Utilise equipment such as coiling mandrels, coiling tools, shearing tools, hand coiling machine, fly press and pedestal grinding machines
• Produce wire compression springs including open ended right- and left-hand helix and closed end right- and left-hand helix, conical, hour glass, barrel, variable pitch and other specific spring/wire forms

What you'll be able to do

• Demonstrate competence in cold forming wire (either round, square or rectangular section) extension springs, using hand forming methods and techniques, in accordance with approved procedures
• Select the appropriate equipment to use, based on the forming operations required
• Select the appropriate equipment to use, based on the material to be formed and the accuracy to be achieved
• Use equipment such as coiling mandrels, hand coiling machine, coiling tools, shearing tools and fly presses
• Produce wire extension springs including right- and left-handed helix, garter springs and other specific extension springs

What you'll be able to do

• Demonstrate competence in cold forming wire (either round, square or rectangular section) to produce specific spring wire forms, using hand forming methods and techniques
• Select the appropriate equipment to use, based on the forming operations required, the material to be formed and the accuracy to be achieved
• Use equipment such as coiling mandrels, hand coiling machine, coiling tools, shearing tools and fly presses
• Produce wire forms including spring pins, retaining clips, key rings and other specific wire forms

What you'll be able to do

• Demonstrate competence in cutting and shaping materials used in the manufacture of strip springs, using guillotines or section cropping machines.
• Follow approved procedures when cutting and shaping materials for strip springs.
• Select appropriate equipment and machine settings to use, for the material, thickness and the accuracy to be achieved.
• Cut and shape ferrous and non-ferrous materials for strip springs.
• Produce parallel cuts, square cuts, and cuts that are at an angle.
• Work to marking out when cutting and shaping materials.
• Set the machine’s backstop when multiple cutting is required.

What you'll be able to do

• Demonstrate competence in cold forming wire torsion springs using hand forming methods and techniques, in accordance with approved procedures.
• Select appropriate equipment for cold forming wire torsion springs, based on the forming operations required.
• Select appropriate equipment for cold forming wire torsion springs, based on the material to be formed.
• Select appropriate equipment for cold forming wire torsion springs, based on the accuracy to be achieved.
• Use equipment such as coiling mandrels, hand coiling machines, coiling tools, shearing tools and fly presses.
• Produce wire torsion and tension springs including right- and left-handed helix.
• Produce single and double torsion springs.
• Produce other specific wire forms.

What you'll be able to do

• Demonstrate competence in producing simple, one-off tooling for spring making activities, in accordance with approved procedures
• Produce tooling using hand fitting techniques
• Produce tooling using forming techniques
• Produce tooling using machining techniques, such as milling, turning, grinding and drilling
• Use a range of different machines and equipment to produce tooling
• Set up workholding arrangements
• Set up the workpiece
• Set up machine tooling

What you'll be able to do

• Demonstrate competence in operating computer numerically controlled (CNC) spring making machines in accordance with approved procedures.
• Follow the correct procedures for calling up the operating program on CNC spring making machines.
• Manage error messages encountered during CNC spring making operations.
• Execute CNC spring making programs safely and correctly.
• Continuously monitor spring making operations, making necessary adjustments to machine parameters.
• Maintain spring production within specification requirements.
• Meet production targets consistently.
• Maintain production records that demonstrate satisfactory performance.

What you'll be able to do

• Demonstrate competence in operating computer numerically controlled (CNC) fabrication machines, such as shearing machines, gas, laser, plasma or water jet cutting, punching, bending and forming machines.
• Operate CNC fabrication machines in accordance with approved procedures.

What you'll be able to do

• Demonstrate competence in preparing and setting up metal spinning machines and metal spinning equipment.
• Follow approved procedures when preparing and setting up metal spinning machines and equipment.
• Select appropriate workholding devices for the metal spinning machine.
• Mount and position workholding devices to the machine in the correct location for the type of operation being carried out.
• Select appropriate metal spinning tools and forming devices.
• Check metal spinning tools and forming devices for defects.
• Mount and secure metal spinning tools and forming devices to the relevant tool holding device or forming device.

What you'll be able to do

• Demonstrate competence in producing, loading and proving machine operating programs on computer numerically controlled (CNC) spring making machines, in accordance with approved procedures.
• Produce the spring program, using manual data input or by use of a remote computer.
• Save the prepared program on tape or disc, or download it directly into the machine controller from the computer.
• Check the program using single block run and program edit facilities.
• Adjust the spring making machine equipment and program, following the proving/editing activities, to achieve the component specification.
• Ensure that any edited programs are saved safely and correctly.

What you'll be able to do

• Demonstrate competence in preparing and setting up an automatic cold wire compression spring making machine for production, in accordance with approved procedures
• Set up the machine for the production of a range of compression springs, such as open and closed end springs
• Set up the machine for the production of right- and left-hand helix springs

What you'll be able to do

• Demonstrate competence in preparing and setting up automatic cold wire extension spring making machines for production, in accordance with approved procedures.
• Set up the machine for the production of a range of extension springs, such as right- and left-handed helix, garter springs and other specific extension springs.

What you'll be able to do

• Demonstrate competence in preparing and setting up automatic cold wire forming machines, to produce specific spring wire forms
• Set up for the production of a range of spring wire forms, such as spring pins, retaining clips, keyrings and other specific wire forms

What you'll be able to do

• Demonstrate competence in preparing and setting up automatic cold wire torsion spring making machines for production
• Set up for the production of a range of torsion springs, such as right- and left-handed helix, single and double torsion springs and other specific torsion spring forms

What you'll be able to do

• Demonstrate competence in preparing automatic spring end grinding machines in accordance with approved procedures.
• Demonstrate competence in setting up automatic spring end grinding machines in accordance with approved procedures.
• Set up machines to grind spring ends flat, square and to the correct dimensional requirements.
• Select appropriate workholding devices for automatic spring end grinding machines.
• Mount and position workholding devices to the machine in the correct location for the type of operation being carried out.

What you'll be able to do

• Demonstrate competence in preparing and setting up horizontal and/or vertical broaching machines for production.
• Follow approved procedures when preparing and setting up broaching machines.
• Select appropriate workholding devices for the broaching machine.
• Secure workholding devices to the broaching machine.
• Mount and set the workpiece in the correct relationship to the broaching tool.
• Select appropriate broaching tools for the task.
• Check broaching tools to ensure they are in a usable condition.
• Mount and secure broaching tools to the relevant tool holding devices.

What you'll be able to do

• Demonstrate competence in preparing and setting up computer numerically controlled (CNC) fabrication machines
• Adhere to approved procedures when preparing and setting up CNC fabrication machines
• Identify the training and development required to prepare and set up CNC fabrication machines

What you'll be able to do

• Demonstrate competence in preparing and setting up Computer Numerical Control (CNC) gear cutting machines, in accordance with approved procedures

What you'll be able to do

• Understand the safety precautions required when working with CNC grinding machines and their associated tools and equipment.
• Demonstrate safe working practices throughout the setting of CNC grinding machines.
• Understand the responsibility they owe to themselves and others in the workplace when setting CNC grinding machines.

What you'll be able to do

• Demonstrate competence in preparing Computer Numerical Control (CNC) horizontal boring machines, in accordance with approved procedures
• Demonstrate competence in setting up Computer Numerical Control (CNC) horizontal boring machines, in accordance with approved procedures

What you'll be able to do

• Demonstrate competence in setting up CNC laser profiling machines
• Demonstrate competence in setting up associated equipment for CNC laser profiling machines
• Set up CNC laser profiling machines and associated equipment in accordance with approved procedures

What you'll be able to do

• Demonstrate competence in preparing and setting up Computer Numerical Control (CNC) machining centres
• Adhere to approved procedures when preparing and setting up CNC machining centres
• Identify the training and development required to prepare and set up CNC machining centres

What you'll be able to do

• Demonstrate competence in preparing CNC three axis or five axis milling machines or CNC machining centres
• Demonstrate competence in setting up CNC three axis or five axis milling machines or CNC machining centres
• Prepare and set up CNC milling machines in accordance with approved procedures

What you'll be able to do

• Demonstrate competence in preparing and setting up Computer Numerical Control (CNC) punching machines
• Adhere to approved procedures when preparing and setting up CNC punching machines
• Identify the training and development required to prepare and set up CNC punching machines

What you'll be able to do

• Demonstrate competence in preparing and setting up computer numerically controlled (CNC) spring making machines.
• Follow approved procedures when preparing and setting up CNC spring making machines.
• Select appropriate material feed and guide devices for the CNC spring making machine.
• Mount and secure material feed and guide devices to the machine.
• Select appropriate forming and cropping tools for the CNC spring making machine.
• Mount and secure forming and cropping tools to the appropriate tool holding devices.
• Place the cutting/forming tools in the relevant positions within the tool posts, slides or tool change magazine/carousel, where applicable.

What you'll be able to do

• Understand the safety precautions required when working with CNC turning machines and their associated tools and equipment.
• Demonstrate safe working practices throughout the setting of CNC turning machines.
• Understand the responsibility they owe to themselves and others in the workplace when setting CNC turning machines.

What you'll be able to do

• Demonstrate competence in preparing and setting up Computer Numerical Control (CNC) vertical boring machines.
• Prepare and set up CNC vertical boring machines in accordance with approved procedures.

What you'll be able to do

• Work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines.
• Demonstrate the required behaviours in line with the job role and company objectives.
• Obtain and use the appropriate documentation (such as job instructions, drawings, quality control documentation) during setting-up activities.
• Adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work.
• Follow safe practice/approved setting up procedures at all times.
• Confirm that the correct operating program has been loaded.
• Check that the electrode is of the correct type and in a usable condition.
• Check that the dielectric fluid is at an appropriate level.
• Ensure that the workpiece is correctly positioned and secured without distortion.
• Update the program tool data as applicable.
• Ensure that correctly adjusted machine guards are in place and safety devices are working.
• Leave the work area and machine in a safe and appropriate condition on completion of the activities.
• Follow the correct specifications for the component to be produced.
• Determine what has to be done and how the machine will be set to achieve this.
• Prepare a CNC spark erosion machine in readiness for production.
• Mount and set the required workholding devices, work piece and cutting tools.
• Position and secure work pieces to machine table, including clamping direct to machine table and using fixtures.
• Select, load and set in the appropriate tool holding device, one of the following electrode types: plain electrodes, profile electrodes, hollow electrodes.
• Set up the machine in accordance with instructions and specifications.
• Set the machine tool operating parameters to achieve the component specification.
• Check that all safety mechanisms are in place and that the equipment is set correctly for the required operations.
• Set up the machine to produce internal and external profiles.
• Machine components from ferrous or non-ferrous materials.
• Set the machine to produce components within specified quality and accuracy standards, including components free from false starts and sharp edges, and achieving a specified surface finish.
• Complete the required production documentation.
• Deal promptly and effectively with problems within their control and report those that cannot be solved.
• Describe the specific safety precautions to be taken when setting up work holding devices and tooling on CNC electrical discharge machinery.
• Explain how to start and stop the machine in normal and emergency situations.
• Explain the importance of ensuring that the machine is isolated from the power supply before mounting electrodes, cartridges/holders and work holding devices and is correctly earthed.
• Explain the importance of wearing the appropriate protective clothing (PPE) and equipment, and of keeping the work area clean and tidy.
• Describe the hazards associated with CNC electro-discharge operations (such as moving parts of machinery, electrical components), and how to minimise them and reduce any risks.
• Explain how to handle and store electrodes safely and correctly.
• Explain the importance of applying the appropriate behaviours in the work place and the implications for both the apprentice and the business if these are not adhered to.
• Explain how to save the programs in the appropriate format, and the importance of storing programs and storage devices safely and correctly, away from contaminants and possible corruption.
• Describe the methods and procedures used to minimise the chances of infecting a computer with a virus.
• Outline the implications if the programs are not saved correctly.

What you'll be able to do

• Work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines.
• Demonstrate the required behaviours in line with the job role and company objectives.
• Obtain and use the appropriate documentation (such as job instructions, drawings, quality control documentation) during the setting-up activities.
• Adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work during the setting-up activities.
• Follow safe practice/approved setting up procedures at all times.
• Confirm that the correct operating program has been loaded.
• Check that the wire is of the correct type and in a usable condition.
• Check that the dielectric fluid is at an appropriate level.
• Ensure that the workpiece is correctly positioned and secured without distortion.
• Update the program tool data as applicable.
• Ensure that correctly adjusted machine guards are in place and safety devices are working.
• Leave the work area and machine in a safe and appropriate condition on completion of the activities.
• Follow the correct specifications for the component to be produced.
• Determine what has to be done and how the machine will be set to achieve the required outcome.
• Prepare a CNC wire erosion machine in readiness for production.
• Mount and set the required workholding devices, workpiece and cutting tools.
• Position and secure workpieces using clamping direct to machine table.
• Position and secure workpieces using fixtures.
• Select, load and set the wire.
• Check electrical conditions (such as earthing, voltage) as applicable to the machine type.
• Set wire tension as applicable to the machine type.
• Set linear feeds and speeds as applicable to the machine type.
• Ensure correct threading of wire through wire guides and feed mechanisms as applicable to the machine type.
• Set wire speeds as applicable to the machine type.
• Check filtration equipment as applicable to the machine type.
• Check ventilation and fume extraction as applicable to the machine type.
• Check safety mechanisms/devices as applicable to the machine type.
• Enter all wire data to the operating program (such as wire type and size, material thickness) as applicable to the machine type.
• Enter all relevant tooling data to the operating program (such as wire position, offsets) as applicable to the machine type.
• Set wire datum point as applicable to the machine type.
• Save changes to programme (as appropriate).
• Set the machine tool operating parameters to achieve the component specification.
• Check that all safety mechanisms are in place and that the equipment is set correctly for the required operations.
• Set up the machine to produce internal and external profiles.
• Machine components from ferrous material.
• Machine components from non-ferrous material.
• Set the machine to produce components to be free from false starts and sharp edges, as applicable to the operations performed.
• Set the machine to produce components with a surface finish of 32µin/0.8µm, 18VDI, as applicable to the operations performed.
• Set the machine to produce angles within +/- 0.5 degree, as applicable to the operations performed.
• Set the machine to produce machined holes within H8, as applicable to the operations performed.
• Complete the required production documentation.
• Deal promptly and effectively with problems within their control and report those that cannot be solved.
• Describe the specific safety precautions to be taken when setting up work holding devices and tooling on CNC electrical discharge machinery.
• Explain how to start and stop the machine in normal and emergency situations.
• Explain the importance of ensuring that the machine is isolated and correctly earthed from the power supply before mounting the wire.
• Explain the importance of wearing the appropriate protective clothing (PPE) and equipment, and of keeping the work area clean and tidy.
• Describe the hazards associated with CNC electro-discharge operations (such as moving parts of machinery, electrical components, handling dielectrics, fumes), and how to minimise them and reduce any risks.
• Explain how to handle and store dielectrics safely and correctly.

What you'll be able to do

• Understand the safety precautions required when working with centre lathes and their associated tools and equipment
• Demonstrate safe working practices when setting centre lathes
• Understand the responsibility they owe to themselves and others in the workplace when setting centre lathes

What you'll be able to do

• Demonstrate competence in preparing and setting up gear cutting machines, such as gear hobbing, gear shaping, gear shaving, gear planning and bevel gear cutting machines, in accordance with approved procedures
• Select the appropriate workholding devices
• Mount and position workholding devices to the machine in the correct location for the type of operation being carried out
• Select the appropriate cutters to use
• Mount and secure cutters to the appropriate tool holding devices

What you'll be able to do

• Demonstrate competence in preparing and setting up gear grinding machines, which cover gear grinding using formed wheels and gear grinding using generation methods, and will include the grinding of spur gears, helical, bevel gears and splines, in accordance with approved procedures.
• Select the appropriate workholding devices.
• Mount and position workholding devices to the machine in the correct location for the type of operation being carried out.
• Select the appropriate grinding wheels to use.
• Check grinding wheels for defects.
• Balance grinding wheels when appropriate.
• Mount and secure grinding wheels to the machine spindle.
• Mount the gears to be ground.
• Check that gears are running true and concentric before starting the grinding operations.

What you'll be able to do

• Understand the safety precautions required when working with grinding machines and their associated tools and equipment
• Demonstrate safe working practices when setting grinding machines
• Understand the responsibility they owe to themselves and others in the workplace when setting grinding machines

What you'll be able to do

• Demonstrate competence in preparing and setting up honing and lapping machines, such as horizontal, vertical honing machines, rotary and reciprocal lapping machines, in accordance with approved procedures.
• Select the appropriate workholding devices.
• Mount and position workholding devices to the machine in the correct location for the type of operation being carried out.
• Select the appropriate honing mandrels, stones, discs and grit to use.
• Check honing mandrels, stones, discs and grit for defects.
• Mount and secure honing mandrels, stones, discs and grit to the machine spindle.
• Mount the workpiece.
• Check that the workpiece is correctly positioned and aligned before starting the honing or lapping operations.

What you'll be able to do

• Demonstrate competence in preparing and setting up horizontal boring machines, and horizontal boring attachments, in accordance with approved procedures.
• Select appropriate workholding devices.
• Mount and position workholding devices to the machine in the correct location for the type of operation being carried out.
• Select appropriate horizontal boring tools and cutters.
• Check tools and cutters for defects.
• Mount and secure tools and cutters to the relevant tool holding devices and machine spindle.

What you'll be able to do

• Demonstrate competence in preparing metal spinning machines in accordance with approved procedures.
• Demonstrate competence in setting up metal spinning machines in accordance with approved procedures.
• Demonstrate competence in setting up metal spinning equipment in accordance with approved procedures.

What you'll be able to do

• Understand the safety precautions required when working with milling machines
• Understand the safety precautions required when working with associated tools and equipment for milling machines
• Demonstrate safe working practices when setting milling machines
• Understand the responsibility they owe to themselves and others in the workplace when setting milling machines

What you'll be able to do

• Demonstrate competence in preparing and setting up shaping, planing or slotting machines for production
• Select appropriate workholding devices and secure them to the machine table
• Mount and set the workpiece in correct relationship to the cutting tools
• Select appropriate shaping/slotting tools
• Check that shaping/slotting tools are in a usable condition
• Mount and secure shaping/slotting tools to the relevant tool holding devices

What you'll be able to do

• Demonstrate competence in preparing and setting up special-purpose machines for production, in accordance with approved procedures
• Select the appropriate work holding devices
• Secure work holding devices to the machine spindle
• Select and set suitable collects or chuck jaws
• Bore out soft jaws (where applicable)
• Mount work pieces in jigs or fixtures
• Select the appropriate tooling
• Check that tooling is in a usable condition
• Mount and secure tooling to the relevant tool holding devices

What you'll be able to do

• Demonstrate competence in preparing and setting up vertical boring machines and vertical boring attachments, in accordance with approved procedures.
• Select appropriate workholding devices.
• Mount and position workholding devices to the machine in the correct location for the type of operation being carried out.
• Select appropriate boring tools and cutters.
• Check tools and cutters for defects.
• Mount and secure tools and cutters to the relevant tool holding devices and machine spindle.

What you'll be able to do

• Demonstrate competence in preparing CNC laser cutting and profiling machines for the cutting and shaping of components used in strip/flat spring manufacturing activities, in accordance with approved procedures.
• Produce and load the machine operating program.
• Set up the laser cutting parameters.
• Follow correct procedures for calling up the machine-operating program.
• Deal with any error messages.
• Execute the program activities safely and correctly.

What you'll be able to do

• Demonstrate competence in setting and using a fly press for bending and forming materials used in the manufacture of strip and coil springs, in accordance with approved procedures
• Select the correct bending and forming tools for the operations being performed when setting up the fly press
• Mount, align and secure bending and forming tools to the appropriate points on the fly press bed and spindle
• Set the fly press to perform required operations, including punching holes, punching slots and profiles, bending, forming spring ends such as loops, and setting/adjusting spacing in spring coils

What you'll be able to do

• Work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines.
• Demonstrate the required behaviours in line with the job role and company objectives.
• Obtain and use the appropriate documentation (such as job instructions, drawings, quality control documentation) during setting up.
• Adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work during setting up.
• Follow safe practice/approved setting up procedures at all times.
• Ensure that correctly adjusted machine guards are in place.
• Check that cutting tools are in a suitable condition.
• Hold components securely without distortion.
• Leave the work area and machine in a safe and appropriate condition on completion of the activities.
• Follow the correct specifications for the component to be produced.
• Determine what has to be done and how the machine will be set to achieve this.
• Prepare a spark erosion electro-discharge machine in readiness for production.
• Mount and set the required workholding devices, workpiece and cutting tools.
• Position and secure workpieces to machine table.
• Select and mount electrodes for roughing and finishing.
• Set the machine tool operating parameters to achieve the component specification.
• Check that all safety mechanisms are in place and that the equipment is set correctly for the required operations.
• Set up the machine in accordance with instructions and specifications.
• Set up the machine to produce internal and external profiles.
• Machine components made from ferrous material.
• Machine components made from non-ferrous material.
• Set the machine to produce components to be free from false starts, and sharp edges, as applicable to the operations performed.
• Set the machine to produce components with a surface finish of 32 µin; 0.8 µm; 18VDI, as applicable to the operations performed.
• Complete the required production documentation.
• Deal promptly and effectively with problems within their control and report those that cannot be solved.
• Describe the specific safety precautions to be taken when setting up workholding devices and electrodes on electro-discharge machines.
• Describe the hazards associated with setting electro-discharge machines (such as moving parts of machinery, electrical components, handling dielectrics, fumes, fire), and how to minimise them and reduce any risks.
• Explain how to start and stop the machine in normal and emergency situations.
• Explain the importance of ensuring that the machine is isolated from the power supply before mounting electrodes and workholding devices.
• Explain the importance of ensuring that the machine is earthed before starting work.
• Explain the importance of wearing the appropriate protective clothing (PPE) and equipment, and of keeping the work area clean and tidy.
• Explain the importance of applying the appropriate behaviours in the workplace and the implications for both the apprentice and the business if these are not adhered to.
• Describe the basic principles of operation of the various electro-discharge machines, and typical operations that they can perform.
• Explain how to handle and store electrodes safely and correctly.
• Explain how to extract and use information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS, ISO or BSEN standards) in relation to work undertaken.
• Explain how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing.
• Outline the terminology used in electro-discharge machining in relation to the activities undertaken.
• Outline the range of eroded features that are produced on the electro- discharge machines.
• Outline the range of workholding devices that are used.

What you'll be able to do

• Work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines.
• Demonstrate the required behaviours in line with the job role and company objectives.
• Obtain and use the appropriate documentation (such as job instructions, drawings, quality control documentation) during setting up.
• Adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work.
• Follow safe practice/approved setting up procedures at all times.
• Ensure that correctly adjusted machine guards are in place.
• Check that tooling is in a suitable condition.
• Hold components securely without distortion.
• Leave the work area and machine in a safe and appropriate condition on completion of the activities.
• Follow the correct specifications for the component to be produced.
• Determine what has to be done and how the machine will be set to achieve this.
• Prepare a wire erosion electro-discharge machine in readiness for production.
• Mount and set the required workholding devices, workpiece and wire.
• Position and secure workpieces to machine table using clamping direct to machine table.
• Position and secure workpieces to machine table using fixtures.
• Select and mount the wire.
• Set the machine tool operating parameters to achieve the component specification.
• Check that all safety mechanisms are in place and that the equipment is set correctly for the required operations.
• Set up the machine in accordance with instructions and specifications.
• Set up the machine to produce internal and external profiles.
• Machine components made from ferrous material.
• Machine components made from non-ferrous material.
• Set the machine to produce components to be free from false starts, and sharp edges, as applicable to the operations performed.
• Set the machine to produce angles within +/- 0.5 degree, as applicable to the operations performed.
• Set the machine to produce components with a surface finish of 32 µin; 0.8 µm; 18VDI, as applicable to the operations performed.
• Complete the required production documentation.
• Deal promptly and effectively with problems within their control and report those that cannot be solved.
• Describe the specific safety precautions to be taken when setting up work holding devices and wire on electro-discharge machines.
• Describe the hazards associated with setting electro-discharge machines (such as moving parts of machinery, electrical components, handling dielectrics, fumes), and how to minimise them and reduce any risks.
• Explain how to start and stop the machine in normal and emergency situations.
• Explain the importance of ensuring that the machine is isolated from the power supply before mounting wire and workholding devices and the importance of earthing.
• Explain the importance of wearing the appropriate protective clothing (PPE) and equipment, and of keeping the work area clean and tidy.
• Explain the importance of applying the appropriate behaviours in the workplace and the implications for both the apprentice and the business if these are not adhered to.
• Describe the basic principles of operation of the various electro-discharge machines, and typical operations that they can perform.
• Explain how to handle and store wire safely and correctly.
• Explain how to extract and use information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS, ISO or BSEN standards) in relation to work undertaken.
• Explain how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing.
• Outline the terminology used in electro-discharge machining in relation to the activities undertaken.
• Outline the range of eroded features that are produced on the electro- discharge machines.
• Outline the range of workholding devices that are used.

What you'll be able to do

• Demonstrate competence in bending and forming strip and section materials used in the manufacture of strip and coil springs, in accordance with approved procedures.
• Interpret drawings for spring components.
• Form materials to the required shape using appropriate equipment and techniques.
• Produce leaf springs using appropriate equipment and techniques.
• Form bends and loops in strip materials for flat springs using appropriate equipment and techniques.
• Apply heat to assist with the forming of coil springs using appropriate equipment and techniques.

What you'll be able to do

• Use the approved source to obtain the required data, documentation or specifications.
• Demonstrate the required occupational behaviours in line with the job role and company objectives.
• Use approved sources to obtain the necessary drawings and related specifications, and carry out all of the following: 3.1. Check the currency and validity of the documentation used. 3.2. Exercise care and control over the documentation at all times. 3.3. Correctly extract all necessary data in order to carry out the required tasks. 3.4. Seek out additional information where there are gaps or deficiencies in the information obtained. 3.5. Deal with and/or report any problems found with the data and documentation. 3.6. Make valid decisions based on the evaluation of the information extracted from the documentation. 3.7. Return all documentation to the approved location on completion of the work. 3.8. Complete all necessary work related documentation such as production documentation, installation documentation, maintenance documentation, planning documentation.
• Extract and interpret the required information from the data, documentation or specifications.
• Use the information obtained to establish work requirements.
• Use information extracted from engineering drawings and related documentation, to include two of the following: 6.1. Drawings (such as component drawings, general assembly drawings, modification drawings, repair drawings, welding/fabrication drawings, distribution and installation drawings). 6.2. Diagrams (such as schematic, fluid power diagrams, piping, wiring/circuit, layout diagrams). 6.3. Manufacturers manuals/drawings. 6.4. Approved sketches. 6.5. Technical illustrations. 6.6. Photographic images/representations. 6.7. Visual display screen information. 6.8. Technical sales/marketing documentation. 6.9. Contractual documentation. 6.10. Other specific drawings/documents.
• Use information extracted from related documentation to include three from the following: 7.1. Standard operating procedures. 7.2. Instructions (such as job instructions, drawing instructions, manufacturer’s instructions). 7.3. Specifications (such as material, finish, process, contractual, calibration). 7.4. Reference materials (such as manuals, tables, charts, fault diagnosis guides). 7.5. Schedules. 7.6. Operation sheets. 7.7. Maintenance log reports. 7.8. Service/test information/schedules/results. 7.9. Planning documentation. 7.10. Quality control documents. 7.11. Company specific technical instructions. 7.12. National, international and organisational standards. 7.13. Health and safety standards relating to the activity (such as COSHH). 7.14. Environmental requirements/information. 7.15. Other specific related documentation.
• Extract information that includes three of the following: 8.1. Materials or components required. 8.2. Dimensions. 8.3. Tolerances. 8.4. Quality requirements. 8.5. Installation requirements. 8.6. Customer requirements. 8.7. Time scales. 8.8. Financial information. 8.9. Operating parameters. 8.10. Surface texture requirements. 8.11. Location/orientation of parts. 8.12. Process or treatments required. 8.13. Dismantling/assembly sequence. 8.14. Inspection/testing requirements. 8.15. Number/volumes required. 8.16. Repair/service methods. 8.17. Method of manufacture. 8.18. Weld type and size. 8.19. Operations required. 8.20. Connections to be made. 8.21. Surface finish required. 8.22. Shape or profiles. 8.23. Fault finding procedures. 8.24. Test points. 8.25. Safety/risk factors. 8.26. Environmental controls. 8.27. Technical data (such as component data, maintenance data, electrical data, fluid data). 8.28. Resources (such as tools, equipment, personnel). 8.29. Utility supply details (such as electricity, water, gas, air). 8.30. Location of services, including standby and emergency backup systems. 8.31. Circuit characteristics (such as pressure, flow, current, voltage, speed). 8.32. Protective arrangements and equipment (such as containment, environmental controls, warning and evacuation systems and equipment). 8.33. Other specific related information.

What you'll be able to do

• Apply effective communication skills in advanced manufacturing and engineering environments.
• Manage time effectively to meet deadlines and targets.
• Work collaboratively with colleagues to achieve common goals.
• Demonstrate problem-solving skills in advanced manufacturing and engineering contexts.
• Maintain a safe and organised working environment.