EAL Level 3 Diploma in Advanced Manufacturing and Engineering - Toolmaker and Tool & Die Maintenance (Development Competence)

What you'll be able to do

• Carry out assembly operations to produce blow mould tools, in accordance with approved procedures
• Assemble and finish neck, body, punt and all ancillary parts of the mould tool
• Prepare the work area, ensuring it is safe and free from hazards
• Check that specified components are available and fit for purpose
• Obtain all relevant and current documentation, tools and equipment required for the assembly operations
• Check that tools and equipment are in a safe and usable condition
• Follow company procedures and specified assembly techniques when carrying out the assembly operations

What you'll be able to do

• Carry out assembly operations to produce dies, in accordance with approved procedures
• Assemble various types of dies, such as draw, trim, re-strike, flange, combination, pierce dies, pressure, transfer, progression, pultrusion and extrusion dies
• Prepare the work area, ensuring it is safe and free from hazards
• Check that the specified die components are available and fit for purpose
• Obtain all relevant and current documentation required for the assembly operations
• Obtain all tools required for the assembly operations
• Obtain all equipment required for the assembly operations
• Check that all tools and equipment are in a safe and usable condition
• Follow company procedures and specified assembly techniques
• Assemble the die tool

What you'll be able to do

• Carry out assembly operations to produce injection mould tools, in accordance with approved procedures.
• Assemble various types of injection mould tools, such as two-plate, three-plate, combination, split and unscrewing tools.
• Produce components with undercut or without undercut (internal and external), cores, and threaded parts.
• Prepare the work area, ensuring that it is safe and free from hazards.
• Check that specified components are available and fit for purpose.
• Obtain all relevant and current documentation required for the assembly operations.
• Obtain all tools and equipment required for the assembly operations.
• Check that tools and equipment are in a safe and usable condition.
• Follow company procedures and specified assembly techniques in order to assemble the mould tool.

What you'll be able to do

• Assemble fabricated components into jig and fixture structures, in accordance with instructions and/or approved welding procedures
• Assemble other components into jig and fixture structures, in accordance with instructions and/or approved welding procedures
• Produce fillet welds in plate, sheet, sections, pipe or tube, using a manual welding process such as manual metal arc, MIG, MAG, TIG, flux cored wire, inert shield or gas welding equipment
• Produce partial butt welds in plate, sheet, sections, pipe or tube, using a manual welding process such as manual metal arc, MIG, MAG, TIG, flux cored wire, inert shield or gas welding equipment
• Check that all the workholding equipment required is available and in a usable condition
• Check that all manipulating devices required are available and are in a usable condition
• Check the welding equipment to ensure that all the leads/cables are securely connected and free from damage
• Check the welding equipment to ensure that all the hoses are securely connected and free from damage
• Check the welding equipment to ensure that all the wire feed mechanisms are securely connected and free from damage

What you'll be able to do

• Fabricate structural components for jigs and fixtures, in accordance with approved procedures
• Select materials for fabrication
• Cut and prepare components for fabrication
• Select the appropriate equipment to use for cutting and preparing the material, using hand tools, hand power tools and machinery, as applicable

What you'll be able to do

• Carry out assembly operations to produce press tools, in accordance with approved procedures
• Assemble various single stage, multi-stage, compound, transfer, draw, extrusion and progression tooling used for blanking, forming, drawing, punching/piercing, flanging, lancing and assembly operations
• Prepare the work area, ensuring it is safe and free from hazards
• Check that the specified components are available and fit for purpose
• Obtain all relevant and current documentation, tools and equipment required for the assembly operations
• Check that tools and equipment are in a safe and usable condition
• Follow company procedures and specified assembly techniques when carrying out the assembly operations

What you'll be able to do

• Carry out assembly operations to produce vacuum forming tools, in accordance with approved procedures.
• Assemble and finish various vacuum forming tools such as male moulds, deep draw, overhead, pressure and combination forming tools.
• Prepare the work area, ensuring that it is safe and free from hazards.
• Check that the specified components are available and fit for purpose.
• Obtain all relevant and current documentation.
• Obtain the tools and equipment required for the assembly operations.
• Check that tools and equipment are in a safe and usable condition.
• Follow company procedures and specified assembly techniques in order to assemble the vacuum forming tool.

What you'll be able to do

• Carry out condition monitoring of mould, press tool or die equipment, in accordance with approved procedures.
• Select the appropriate monitoring equipment to use, based on the type of mould, press tool or die equipment being monitored and the conditions that need to be checked.
• Check that the monitoring equipment is in a suitable condition to use (such as undamaged, correctly calibrated, appropriate range) and set up the equipment ready for use.
• Use the equipment to carry out diagnostic condition monitoring (fault diagnosis or prognosis) on a range of equipment such as single stage, multi-stage, compound, transfer, draw, extrusion or progression press tooling; trim, draw, re-strike, flange, combination, pierce, pressure, transfer, progression, pultrusion or extrusion dies; injection moulding dies; blow moulding dies; or vacuum tools, including material loaders and ejectors and other ancillary equipment.

What you'll be able to do

• Carry out efficient fault diagnosis on mould, press tool or die equipment.
• Carry out effective fault diagnosis on mould, press tool or die equipment.
• Diagnose faults on a range of mould, press tool or die equipment.
• Use a variety of fault diagnosis methods and techniques.
• Utilise a number of diagnostic aids and equipment.
• Identify the fault and its probable cause from the evidence gained.
• Suggest appropriate action to remedy the problem.

What you'll be able to do

• Carry out planned maintenance activities on power presses in accordance with approved procedures
• Carry out planned maintenance activities on mechanical power presses, which incorporate single and double strike, re-strike and multi-sequence actions, in order to minimise down time
• Carry out planned maintenance activities on hydraulic power presses, which incorporate single and double strike, re-strike and multi-sequence actions, in order to minimise down time
• Ensure that power presses perform at optimal level
• Ensure that power presses function to specification

What you'll be able to do

• Restore jigs or fixtures to usable condition by repair or modification, in accordance with approved procedures
• Rework a range of jig and fixture components and equipment to operational condition, by repairing or modifying assemblies, sub-assemblies and components, by reforming, reworking the surface, replacing threads or the replacement of worn parts
• Select the appropriate equipment to use, based on the nature of the repair, the operations that will need to be carried out and the accuracy to be achieved

What you'll be able to do

• Carry out checks on moulds, dies, press tools or jig and fixture assemblies.
• Prepare the work area, ensuring that it is safe and free from hazards.
• Obtain all relevant and current documentation.
• Obtain the tools and equipment required for the checking activities.
• Make sure that tools and equipment are calibrated.
• Ensure tools and equipment are in a safe and usable condition.

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

• Fabricate structural components for jigs and fixtures in accordance with approved procedures
• Select materials for fabricating structural components
• Cut and prepare components for fabrication
• Select the appropriate equipment to use for cutting and preparing the material, which will involve the use of hand tools
• Select the appropriate equipment to use for cutting and preparing the material, which will involve the use of hand power tools
• Select the appropriate equipment to use for cutting and preparing the material, which will involve the use of machinery, as applicable

What you'll be able to do

• Hand over mould, press tool or die equipment ready for production/manufacturing operations, in accordance with approved procedures.
• Confirm the completion of mould, press tool or die equipment ready for production/manufacturing operations, in accordance with approved procedures.
• Check that all try-out procedures have been carried out successfully.
• Ensure that all instruments and gauges have been set/calibrated.
• Verify that the equipment is producing the components to the required specification.

What you'll be able to do

• Hand over mould, press tool or die equipment that has been repaired or maintained.
• Confirm that the equipment is ready to return to service.
• Set up the equipment and hand it over to another person to complete start-up procedures, or complete the run-up operation.
• Check that all required equipment and safety devices are operable and correctly set and/or calibrated.
• Ensure that the equipment functions safely and correctly to the required specification.

What you'll be able to do

• Prepare to inspect components using co-ordinated measuring methods (CMM).
• Set up co-ordinated measuring methods (CMM) equipment for inspection.
• Inspect components using co-ordinated measuring methods (CMM).
• Record inspection results obtained from co-ordinated measuring methods (CMM).
• Analyse inspection results against specified tolerances.

What you'll be able to do

• Produce components by machining for the development of jigs and fixtures, in accordance with approved procedures.
• Perform machining activities including milling, turning, grinding, shaping/slotting, and drilling, as applicable to the components being produced.
• Produce new components or modify existing components using a range of different machines.
• Set up workholding arrangements, workpiece, and machine tooling.
• Produce components with a combination of features, such as diameters, lengths, threads, flat faces, square faces, slots, profiles, or special forms.

What you'll be able to do

• Produce toolroom components such as those used in moulds, press tools, dies, jigs and fixtures, test rigs and other experimental or developmental activities, using a variety of machines, in accordance with approved procedures.
• Perform machining activities including milling, turning, grinding, shaping/slotting, drilling, boring, spark or wire erosion, as applicable to the components being produced.
• 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 require the use of different machines and combine a number of different features.
• Produce features such as parallel, stepped and tapered diameters, drilled, bored and reamed holes, internal and external threads, flat, parallel, square and angular faces, and special forms/profiles.

What you'll be able to do

• Carry out corrective maintenance activities on mould, press tool or die equipment, in accordance with approved procedures.
• Maintain a range of mould, press tool or die equipment such as single stage, multi-stage, compound, transfer, draw, extrusion and progression press tooling; trim, draw, re-strike, flange, combination, pierce, pressure, transfer, progression, pultrusion and extrusion dies; injection moulding dies; blow moulding dies; and vacuum tools.
• Maintain mould, press tool and die material feed and ejector systems and other ancillary equipment.
• Install jacking/chocking or safety rams prior to tool or die removal.
• Dismantle, remove, and replace faulty equipment or components on a variety of different types of tool and die equipment.

What you'll be able to do

• Prepare single action power presses in accordance with approved procedures
• Prepare multi-action power presses in accordance with approved procedures
• Prepare associated equipment in accordance with approved procedures
• Set up single action power presses in accordance with approved procedures
• Set up multi-action power presses in accordance with approved procedures
• Set up associated equipment in accordance with approved procedures
• Select the appropriate press tools
• Mount press tools to the machine in the correct location for the type of operation being carried out
• 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, which will include material positioning mechanisms
• Set up and align all associated equipment, which will include workpiece ejection mechanisms
• Set up and align all associated equipment, which will include all machine safety devices and guards

What you'll be able to do

• Produce detail components for jigs and fixtures using hand fitting techniques, in accordance with approved procedures
• Select the appropriate equipment to use, based on the operations to be carried out and the accuracy required
• Use appropriate tools and equipment to mark out the material for a range of features to be produced
• Use hand tools, portable power tools, and shaping and fitting techniques that are appropriate to the type of material and operations being performed, including hand sawing, band sawing, filing, and drilling, chiselling, threading, scraping, lapping and off-hand grinding
• Produce components with features that include flat, square, parallel and angular faces, radii and curved profiles, drilled holes, internal and external threads, and sliding or mating parts

What you'll be able to do

• Carry out planned maintenance activities on mould, press tool or die equipment, in accordance with approved procedures.
• Perform planned maintenance activities on a range of mould, press tool and die equipment, such as single stage, multi-stage, compound, transfer, draw, extrusion and progression press tooling; trim, draw, re-strike, flange, combination, pierce, pressure, transfer, progression, pultrusion and extrusion dies; injection moulding dies; blow moulding dies; and vacuum tools.
• Maintain mould, press tool and die equipment material feed and ejector systems and other ancillary equipment.
• Ensure that mould, press tool and die equipment perform at optimum level and function to specification.
• Minimise downtime of mould, press tool and die equipment.

What you'll be able to do

• Produce mould, press tool or die components by manual machining, in accordance with approved procedures.
• Perform machining activities including milling, turning, grinding, shaping/slotting, drilling, boring and spark or wire erosion, as applicable to the components being produced.
• Produce new components or modify existing ones.
• Use a wide range of different machines.
• Set up the workholding arrangements, workpiece and machine tooling.
• Produce components with a combination of features such as diameters, lengths, threads, flat faces, square faces, slots, profiles/special forms.

What you'll be able to do

• Prepare computer numerically controlled (CNC) electro-discharge machines, such as spark erosion and wire erosion machines, in accordance with approved procedures, to produce toolroom components.
• Set up computer numerically controlled (CNC) electro-discharge machines, such as spark erosion and wire erosion machines, in accordance with approved procedures, to produce toolroom components.
• Run computer numerically controlled (CNC) electro-discharge machines, such as spark erosion and wire erosion machines, in accordance with approved procedures, to produce toolroom components.
• Select the appropriate workholding devices.
• Mount and secure workholding devices to the machine table in the designated or appropriate position, as required by the machine operating program.
• Select the appropriate electrode cartridge holders or wires.
• Mount and secure electrode cartridge holders or wires to the appropriate machine head/slide and/or tool change holder mechanism, where this is applicable.
• Ensure that all electrode cartridges/holders and/or wires have been allocated a relevant tool number.
• Ensure that the relevant data on their co-ordinates and datum positions is entered into the operating program of the machine controller.
• Follow the correct procedures for running the operating program.
• Deal with any error messages.
• Execute the program activities safely and correctly.

What you'll be able to do

• Prepare computer numerically controlled (CNC) grinding machines, such as CNC universal grinding machines, CNC surface/profile grinding machines, CNC gear grinding machines, and CNC grinding machining centre, in accordance with approved procedures
• Set up computer numerically controlled (CNC) grinding machines, such as CNC universal grinding machines, CNC surface/profile grinding machines, CNC gear grinding machines, and CNC grinding machining centre, in accordance with approved procedures
• Run computer numerically controlled (CNC) grinding machines, such as CNC universal grinding machines, CNC surface/profile grinding machines, CNC gear grinding machines, and CNC grinding machining centre, in accordance with approved procedures, to produce toolroom components used in moulds, press tools, dies, jigs and fixtures, test rigs and other experimental or developmental activities
• Select appropriate workholding devices
• Mount and secure workholding devices to the machine table or spindle in the designated or appropriate position, as required by the machine operating program
• Select appropriate grinding wheels
• Balance grinding wheels
• Dress grinding wheels
• Mount and secure grinding wheels to the appropriate machine spindles and/or tool change magazine/carousel, where this is applicable
• Allocate a relevant tool number to all grinding wheels
• Enter relevant data on grinding wheel co-ordinates and datum positions into the operating program and machine controller
• Follow the correct procedures for running the operating program
• Deal with any error messages
• Execute the program activities safely and correctly

What you'll be able to do

• Prepare computer numerically controlled (CNC) laser profiling machines and associated equipment, in accordance with approved procedures, to produce toolroom components.
• Set up computer numerically controlled (CNC) laser profiling machines and associated equipment, in accordance with approved procedures, to produce toolroom components.
• Run computer numerically controlled (CNC) laser profiling machines and associated equipment, in accordance with approved procedures, to produce toolroom components.
• Select the appropriate workholding devices.
• Mount and secure workholding devices to the machine table in the correct relationship to the operating program and machine parameters.
• Set up the machine conditions and adjust/edit program parameters, controlling the setting of the optical system, laser characteristics, laser alignment, electrical parameters, and the laser cutting speed.
• Follow the correct procedures for running the operating program.
• Deal with any error messages.
• Execute the program activities safely and correctly.

What you'll be able to do

• Prepare computer numerically controlled (CNC) three axis or five axis milling machines or CNC machining centres.
• Set up computer numerically controlled (CNC) three axis or five axis milling machines or CNC machining centres.
• Run computer numerically controlled (CNC) three axis or five axis milling machines or CNC machining centres.
• Select appropriate workholding devices.
• Mount and position workholding devices to the machine table.
• Select appropriate milling cutters to use.
• Mount and secure milling cutters to the appropriate tool holding devices.
• Place the tools in the relevant positions within the tool change magazine or carousel.
• Ensure that all the tools have been allocated a relevant tool number.
• Ensure that the relevant data on tool co-ordinates and datum positions are entered into the operating program and machine.
• Follow the correct procedures for running the operating program.
• Deal with any error messages.
• Execute the program activities safely and correctly.

What you'll be able to do

• Prepare computer numerically controlled (CNC) turning machines or CNC machining centres, in accordance with approved procedures, to produce toolroom components.
• Set up computer numerically controlled (CNC) turning machines or CNC machining centres, in accordance with approved procedures, to produce toolroom components.
• Run computer numerically controlled (CNC) turning machines or CNC machining centres, in accordance with approved procedures, to produce toolroom components.
• Select the appropriate workholding devices.
• Mount and secure workholding devices to the machine spindle.
• Select the appropriate cutting tools.
• Mount and secure cutting tools to the appropriate tool holding devices.
• Place the cutting tools in the relevant positions within the tool posts, turrets, slides or tool change magazine/carousel, where this is applicable.
• Ensure that all the tools have been allocated a relevant tool number.
• Ensure that the relevant data on their co-ordinates and datum positions are entered into the operating program.
• Follow the correct procedures for running the operating program.
• Deal with any error messages.
• Execute the program activities safely and correctly.

What you'll be able to do

• Produce/finish mould, press tool or die components using hand fitting techniques, in accordance with approved procedures.
• Select the appropriate equipment to use, based on the operations to be carried out and the accuracy required.
• Use appropriate tools and equipment to mark out the material for a range of features to be produced.
• Use hand tools, portable power tools, shaping and fitting techniques that are appropriate to the type of material and operations being performed, including activities such as hand sawing, band sawing, filing, and drilling, chiselling, threading, scraping, lapping and off-hand grinding.
• Produce components with features that include flat, square, parallel and angular faces, radii and curved profiles, drilled holes, internal and external threads, and sliding or mating parts.

What you'll be able to do

• Restore mould, press tool or die components to usable condition by repair or modification, in accordance with approved procedures.
• Rework a range of tool and die assemblies, sub-assemblies, components and equipment to operational condition, by reforming, reworking the surface, replacing threads or replacing worn parts.
• Select the appropriate equipment to use, based on the nature of the repair, the operations that will need to be carried out, and the accuracy to be achieved.

What you'll be able to do

• Prepare a variety of machines in accordance with approved procedures
• Set up a variety of machines in accordance with approved procedures to produce toolroom components such as those used in moulds, press tools, dies, jigs and fixtures, test rigs and other experimental or developmental activities
• Determine the machining operations to be carried out
• Select the appropriate machine for the machining operations
• Select appropriate workholding devices for the machining operations
• Select appropriate tooling required for the machining operations
• Mount and position the workholding devices on the machine in the correct location for the type of operations being carried out
• Mount and position the tooling on the machine in the correct location for the type of operations being carried out

What you'll be able to do

• Undertake try-out and proving activities on dies, in accordance with approved procedures.
• Perform try-out and proving activities on dies such as draw, trim, re-strike, flange, combination, pierce dies, pressure, transfer, progression, puttrusion and extrusion dies.
• Check that the designated die has been positioned and set up correctly.
• Ensure that any handover or permit-to-work procedures have been completed.
• Ensure that the machines have safe access and are free from hazards.
• Ensure that any necessary lifting and handling equipment, try-out/proving tools, consumables and site services are available, so that the try-out/proving can be carried out safely and efficiently.

What you'll be able to do

• Carry out try-out activities on injection moulding equipment, in accordance with approved procedures
• Carry out proving activities on injection moulding equipment, in accordance with approved procedures
• Check that the designated mould has been positioned correctly in the injection moulding machine
• Check that the designated mould has been set up correctly in the injection moulding machine
• Check that any permit-to-work procedures have been completed
• Ensure that the machine has safe access and is free from hazards
• Ensure that any necessary lifting and handling equipment is available
• Ensure that try-out/proving tools are available
• Ensure that consumables are available
• Ensure that site services are available, so that the tryout/proving can be carried out safely and efficiently

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.