EAL

Level 3

QN: 603/0926/X

Curriculum Active

EAL Level 3 Diploma in Advanced Manufacturing and Engineering - Product Design and Development Technician (Development Competence)

Official qualification regulated by Ofqual, awarded by EAL. Classified as a Occupational Qualification. Total guided learning hours: 68572 hours.

Qualification Level

Level 3

Awarding Body

EAL

Syllabus Units

129 Units

Guided Hours

68572 hrs

Instant access to interactive lessons, quizzes, and spaced revision.

Course Syllabus & Study Modules

Complete breakdown of verified curriculum topics and learning objectives.

Analysing and interpret the results of mechanical tests

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
ensure that they have the necessary test data on which toconduct the analysis
Ensure that they have all the necessary information and data required for the sample analysis andinterpretation, to include obtaining all of the following:1.1 relevant product/component information1.2 material of construction1.3 acceptance criteria to be used1.4 sample size1.5 set up parameters and testing conditions1.6 necessary data records obtained during the test
Ensure that the sample quality meets specified requirements, to include all of the following:2.1 correct dimensions2.2 correct surface finish and preparation2.3 absence of obvious significant defects
Interpret the samples properties from one of the following materials:3.1 ferrous3.2 non-ferrous3.3 alloys3.4 other specific material
Interpret the test samples and identify all of the following, as appropriate:4.1 granular structure4.2 location of any defect/flaws4.3 sample measurements
Compare their findings with the acceptance criteria, and record all of the following in the testing
report:5.1 personal data (such as details of analyser, date of test)5.2 batch/product/sample identification5.3 material of construction5.4 sample size5.5 test equipment settings and parameters5.6 sample test data/recordings5.7 defects/flaws identified5.8 comparisons with acceptance criteria5.9 conclusions reached
Follow the correct procedure to deal with products which fall into three of the following categories:6.1 samples which meet the specification6.2 samples with identified defects/flaws6.3 samples requiring further investigation6.4 samples requiring other inspection methods
solve promptly any inconsistencies in the data
analyse the data using approved methods and procedures
check that the data analysis is accurate and thorough andtakes account of the test conditions
compare the analysis against the product or assetspecification and identify any faults or variations fromspecification
record the results of the analysis in the appropriate format
Complete the analysing activities, to include carrying out all of the following:7.1marking up defective/flawed samples with all relevantinformation7.2recording all the required details of the inspection in theappropriate format7.3 handing over the inspection details to the appropriate people
Outline the specific safety precautions to be taken when carrying out testingactivities on material samples from engineering products, or structures
Describe the hazards associated with carrying out the activities (such aselectrical contact, fast moving mechanical parts, stored pressures/forces,temperatures), and how risks can be minimised
Describe the type of personal protective equipment (PPE) to be used, andhow to obtain it
Explain the importance of applying the appropriate occupational behavioursin the workplace and the implications for both the learner and the businessif these are not adhered to

Analysing and Selecting Parts for Improvement

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can analyse and select partsfor improvement. They will need to understand the principles and procedures ofanalysing and selecting parts for improvement, and their application, in adequate depth to provide a sound basisfor carrying out the activities to the required criteria.Applying safe working practices will be a key issue throughout.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment

Applying Basic Statistical Analysis

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can apply basic statisticalanalysis, by consulting with the appropriate people and gathering the relevant data for statistical analysis on aSix Sigma project.They will need to understand the principles andapplication of basic statistical analysis, in adequate depth to provide a sound basis for carrying out the activitiesto the required criteria.Applying safe working practices will be a key issue throughout.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment.

Applying Continuous Improvement Techniques (Kaizen)

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can apply continuousimprovement techniques (Kaizen) to their work activities.They will need to understand the Kaizen principles and their application, in adequate depth to provide a sound basis forcarrying out the activities to the required criteria.Applying safe working practices will be a key issue throughout.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment.

Applying Failure Modes and Effects Analysis (FMEA)

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can apply failure modes andeffects analysis (FMEA) They will need to understand the principles and application ofFMEA, in adequate depth to provide a sound basis for carrying out the activities to the required criteria.Applying safe working practices will be a key issue throughout.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment..

Applying finishes to vehicle composite mouldings

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following during the finishing activities:1.1obtain and use the appropriate documentation (such as jobinstructions, drawings, planning and quality controldocumentation, material data sheets, specifications, )1.2adhere to procedures or systems in place for risk assessment,COSHH, personal protective equipment and other relevantsafety regulations and procedures to realise a safe system ofwork1.3provide and maintain a safe working environment for thecomposite finishing activities1.4obtain the correct tools and equipment for the activity, andcheck that they are in a safe, tested and usable condition1.5follow safe practice/approved mould finishing techniques andprocedures at all times1.6return all tools and equipment to the correct location oncompletion of the mould finishing activities1.7dispose of waste materials in accordance with approvedprocedures1.8leave the work area in a safe and appropriate condition oncompletion of the activities
ensure the material surfaces to be treated are suitably preparedfor the finishing operations to be carried out
check that the finishing equipment and treatment solutions areset up and maintained at satisfactory operating conditions andlevels
Carry out all of the following activities when preparing for the finishing activity:2.1 check that mouldings are correct and complete2.2 select the correct equipment for the activity2.3 check for any defects in the mouldings2.4 check that equipment is suitable for use2.5 check availability of ancillary materials required2.6 identify and protect the moulding in the work area
carry out the treatment process in accordance with operatingprocedures and the component specification requirements
Apply finishes to composite mouldings using two of the following techniques:3.1 cloth application3.2 brush3.3 spray3.4 laying films3.5 roller
Prepare surfaces of composite mouldings, using two of the following methods:4.1 abrading4.2 bead blasting4.3 water cleaning4.4 solvent cleaning4.5 priming
Apply two types of finishes to composite mouldings from the following:5.1 surface sealers5.2 top coats5.3 UV coatings5.4 speciality coatings5.5 primers5.6 adhesive films5.7 heatproof coatings5.8 flexible coatings
Apply finishes to composite mouldings, using three of the following:6.1 one-part finishes6.2 multiple coatings6.3 solvent based6.4 water based6.5 single coatings6.6 two-part finishes6.7 combination coats6.8 adhesive based
Apply finishes to composite mouldings, using four of the following consumable materials:7.1 abrasives7.2 masking films7.3 thinners7.4 stoppers7.5 sealers7.6 cutting compounds7.7 masking tapes7.8 polishes7.9 solvents7.10 fillers7.11 primers7.12 cleaning agents
Apply finishes to composite mouldings suitable for two of the following resin types:8.1 polyester8.2 vinyl ester8.3 epoxy8.4 phenolic8.5 bismaleimide8.6 cyanate ester
Apply finishes to composite mouldings suitable for two of the following fibre types:9.1 polyethylene9.2 glass9.3 aramid9.4 carbon
ensure that the treated workpiece achieves the requiredcharacteristics and meets the finishing specification
Apply finishes to a range of mouldings which comply with one of the following quality and accuracystandards:10.1 company standards and procedures10.2 customer standards and requirements10.3have an appropriate surface finish and are free from defectsor surface blemishes
Complete the relevant paper
work, to include one from the following and pass it to the appropriatepeople:11.1 build records11.2 job cards11.3 log cards11.4 other specific recording method
deal promptly and effectively with problems within theircontrol and report those that cannot be solved
dispose of waste and excess materials in line with agreedorganisational procedures

Applying Flow Process Analysis

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can apply flow processanalysisThey will need to understand the principles and procedures offlow process analysis, and its application, in adequate depth to provide a sound basis for carrying out theactivities to the required criteria.Applying safe working practices will be a key issue throughout.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment

Applying Hypothesis Testing

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can apply hypothesis testing. They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment

Applying Lead Time Analysis

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can apply lead time analysis.They will need to understand the principles and procedures oflead time analysis, and its application, in adequate depth to provide a sound basis for carrying out the activitiesto the required criteria.Applying safe working practices will be a key issue throughout.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment.

Applying Mistake/Error Proofing (Poka Yoke)

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can apply mistake/errorproofing (Poka Yoke), which is a method of making an activity `foolproof'.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment.

Applying Policy Deployment (Hoshin Kanri, Quality Operating Systems, Business Plan Deployment)

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can apply policy deployment(Hoshin Kanri, Quality Operating Systems, Business Plan Deployment). They will need to understand the principles and procedures ofpolicy deployment, and is application, in adequate depth to provide a sound basis for carrying out the activitiesto the required criteria.Applying safe working practices will be a key issue throughout.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment.

Applying Set-up Reduction Techniques

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can apply set-up reductiontechniques.They will need to understand the principles and procedures ofset-up reduction, and its application, in adequate depth to provide a sound basis for carrying out the activities tothe required criteria.Applying safe working practices will be a key issue throughout.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment

Applying Six Sigma Methodology to a Project

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can apply a structured SixSigma methodology to a project.They will need to understand theprinciples and application of Six Sigma methodology, in adequate depth to provide a sound basis for carrying outthe activities to the required criteria.Applying safe working practices will be a key issue throughout.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment.

Applying Six Sigma Metrics to a Project

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can apply Six Sigma metricsto products and processes.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment.

Applying Total Productive Maintenance (TPM)

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can apply total productivemaintenance (TPM) principles to equipment and processes, and aims to prevent equipment problems byidentifying potential causes rather than waiting for a problem to occur.They will need to understand the principles andprocedures of TPM, and its application, in adequate depth to provide a sound basis for carrying out the activitiesto the required criteria.Applying safe working practices will be a key issue throughout.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment

Applying Value Management (Value Engineering and Value Analysis)

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can applying valuemanagement (value engineering and value analysis). They will need to understand the principles and processes ofvalue management, and its application, in adequate depth to provide a sound basis for carrying out the activitiesto the required criteria.Applying safe working practices will be a key issue throughout.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment.

Applying Workplace Organisation Techniques

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can apply a systemicapproach to continuously making improvements to the workplace organisationThey will need to understand the principles of workplace organisation and their application, in adequate depthto provide a sound basis for carrying out the activities to the required criteria.Applying safe working practices will be a key issue throughout.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment.

Assembling and disassembling electrical and electronic equipment on experimental vehicles

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Assembling and disassembling electrical and electronic equipment on experimental vehicles
Apply practical skills, procedures and techniques in Assembling and disassembling electrical and electronic equipment on experimental vehicles
Evaluate performance, standards and best practices for Assembling and disassembling electrical and electronic equipment on experimental vehicles

Assembling and disassembling mechanical equipment on experimental vehicles

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Assembling and disassembling mechanical equipment on experimental vehicles
Apply practical skills, procedures and techniques in Assembling and disassembling mechanical equipment on experimental vehicles
Evaluate performance, standards and best practices for Assembling and disassembling mechanical equipment on experimental vehicles

Assembling and fitting wiring looms to vehicles

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following during the assembly activities:1.1obtain and use the appropriate documentation (such as jobinstructions, assembly drawings, quality controldocumentation)1.2adhere to procedures or systems in place for risk assessment,COSHH, personal protective equipment and other relevantsafety regulations and procedures to realise a safe system ofwork1.3check that all cables, extension leads or air supply hoses arein a safe, tested and serviceable condition1.4check that all tools and equipment to be used are withincurrent calibration/certification dates1.5ensure that sub-assemblies and components used are freefrom damage, foreign objects, dirt or other contamination1.6use safe and approved assembly techniques and proceduresat all times1.7return all tools and equipment to the correct location oncompletion of the assembly activities1.8leave the work area in a safe and appropriate condition oncompletion of the activities
follow the relevant instructions, assembly drawings and anyother specifications
ensure that the specified components are available and thatthey are in a usable condition
Construct and assemble wiring looms and fit to the vehicle, to include all of the following:2.1 2 door/sports vehicles2.2 4/5 door vehicles2.3 special/custom-built vehicles
Select appropriate types and ratings of wire/cables to meet the loom specification, including all of thefollowing:3.1 3/4 strand3.2 special insulated3.3 multi-strand3.4 screened3.5 multiplex (as applicable)S4 Terminate wires/cables using five of the following components:4.1 multi-contact connectors4.2 soldered connectors4.3 plugs/sockets4.4 cable protection4.5 screened connectors4.6 crimped connecters4.7 terminal blocks4.8 other specific terminations
use the appropriate methods and techniques to assemble thewires and components in their correct positions
secure the components using the specified connectors andsecuring devices
Use appropriate methods and techniques in the construction of the loom, to including four of thefollowing:5.1 cable stripping/termination5.2 soldering5.3 crimping5.4 cable grouping/routing5.5 conduit assembly5.6 screw fittings5.7 other specific technique
Construct, assemble and test looms, using four of the following:6.1 jigs6.2 fixtures6.3 cutting device6.4 wire/cable stripping device6.5 measuring device6.6 testing device/meter6.7 soldering equipment6.8 computer-aided fault diagnostic device
Make five of the following types of connections during the installation:7.1 clip/push fit7.2 multi-contact connectors7.3 plugs/sockets7.4 cable ties7.5 p-clip7.6 screw fasteners7.7 other specific connection
check the completed assembly to ensure that all operationshave been completed and the finished assembly meets therequired specification
Produce assemblies which comply with all of the following quality and accuracy standards:8.1 cables are correctly routed and free from kinks8.2 pins in multi-connectors are secure8.3 loom is correctly terminated and securely mounted8.4 all components are installed correctly and to specifications
deal promptly and effectively with problems within theircontrol and report those that cannot be solved
Describe the specific safety precautions to be taken whilst carrying out theconstruction, assembly and fitting of wiring looms to vehicles (including anyspecific legislation, regulations or codes of practice relating to the activities,equipment or materials)K2 Outline the health and safety requirements of the work area in which theyare carrying out the construction, assembly and fitting of wiring looms, andthe responsibility they place on them
Describe the hazards associated with assembling vehicle wiring looms andcomponents, and how to minimise them and reduce any risks
Describe the pers

Assembling Body Sub-Assemblies to Produce a Vehicle

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can assemble various vehiclebody sub-assemblies, in accordance with approved procedures.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment.

Assembling Braking Systems to Vehicles

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can assemble brakingsystems to vehicles, in accordance with approved procedures.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment.

Assembling components for experimental vehicle engineering by resistance spot welding

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following during the welding activities:1.1obtain and use the appropriate documentation (such as jobinstructions, drawings, weld procedure specifications, qualitycontrol documentation)1.2adhere to procedures or systems in place for risk assessment,COSHH, personal protective equipment and other relevantsafety regulations and procedures to realise a safe system ofwork1.3check that all tools and equipment to be used are withincurrent calibration/certification dates1.4use safe and appropriate resistance welding methods andprocedures at all times1.5return all tools and equipment to the correct location oncompletion of the resistance welding activities1.6leave the work area in a safe and appropriate condition oncompletion of the activities1.7produce welded joints that meet the requirements of thespecification
follow the relevant joining procedure and work instructions
Ensure that the resistance spot welding equipment is fit for purpose, by carrying out all of thefollowing checks:2.1equipment range is suitable for the operations to beperformed2.2portable equipment power leads are undamaged and securelyconnected2.3 electrodes are of the correct type, size and profile2.4all mechanical and electrical systems on the equipment
operate correctly2.5 supplies of components are adequate and suitably prepared2.6 appropriate safety screens are available
confirm that the machine is set up and operating correctly,ready for the joining operations to be carried out
Set up, check, adjust and operate one of the following resistance spot welding machines:3.1 portable spot welding machines3.2 fixed, simple spot welding machines
Set up the equipment parameters, in accordance with instructions and the welding procedurespecification, to include setting all of the following:4.1 electrode tip diameter/profile4.2 welding current4.3 welding and squeeze times4.4 electrode pressure
Monitor the process operation and make adjustments to parameters, in order to produce weldedcomponents covering both of the following:5.1 two different components5.2 two different material thicknesses
check that the parent material, components, consumables andjoint preparation comply with specifications
carry out and monitor the machine operations in accordancewith specifications and job instructions
achieve joints of the required quality and specified dimensionalaccuracy
Produce welded components which meet all of the following requirements:6.1 achieve a weld quality as specified in the application standard6.2 spot welds are correctly pitched out6.3welded components meet the required dimensional accuracywithin specified tolerance
make sure that the rate of output is as specified
deal promptly and effectively with problems within theircontrol and report those that they cannot solve
shut down the equipment to a safe condition on conclusion ofthe joining activities
Describe the specific safety precautions to be taken when operatingresistance welding equipment (working with machinery, the use ofappropriate personal protective equipment (PPE); the use of safety screens;operation of machine safety devices; closing down the machine oncompletion of the welding activities; statutory requirements, riskassessment procedures and relevant requirements of HASAWA, COSHH and
Work Equipment Regulations; safe disposal of waste materials)K2 Describe the hazards associated with carrying out resistance weldingactivities and with the tools and equipment used (such as dangers from liveinternal electrical components, fumes, hot metal, expulsion of hot particles,moving parts of machines), and how to minimise them and reduce any risks
Explain the importance of applying the appropriate occupational behavioursin the workplace and the implications for both

Assembling composite vehicle components

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following during the composite assembly activities:1.1obtain and use the appropriate documentation (such as jobinstructions, drawings, planning and quality controldocumentation, material data sheets, specifications)1.2adhere to procedures or systems in place for risk assessment,COSHH, personal protective equipment and other relevantsafety regulations and procedures to realise a safe system ofwork1.3provide and maintain a safe working environment for thecomposite assembly activities1.4obtain the correct tools and equipment for the activity, andcheck that they are in a safe, tested and usable condition1.5follow safe practice/approved composite assemblytechniques and procedures at all times1.6return all tools and equipment to the correct location oncompletion of the composite assembly activities1.7dispose of waste materials in accordance with approvedprocedures1.8leave the work area in a safe and appropriate condition oncompletion of the activities
follow the relevant instructions, assembly drawings and anyother specifications
ensure that the specified components are available and thatthey are in a usable condition
Carry out all of the following when preparing for the assembly activity:2.1 check that mouldings are correct and complete2.2 select correct equipment for the activity2.3 check for any defects in the mouldings2.4 check that equipment is suitable for use2.5 check components are correct and complete2.6 check for any defects in the components2.7 check availability of ancillary materials required2.8identify and protect the moulding and components in the
use the appropriate methods and techniques to assemble thecomponents in their correct positions
Produce two of the following types of composite assembly:3.1 trial assemblies3.2 one-off assemblies3.3 batch assemblies3.4 assembly line
Produce assemblies that incorporate four of the following features:4.1 loose fit tolerances4.2 non-permanent fixing4.3 joggle joins4.4 return joins4.5 close fit tolerances4.6 shape location4.7 permanent fixing4.8 overlap joins
secure the components using the specified connectors andsecuring devices
Produce composite assemblies that require four of the following methods to be used:5.1 fettling5.2 clamping5.3 aligning5.4 assembly sequences5.5 pinning5.6 trial fitting5.7 assembly jigs
Produce composite assemblies that use three of the following joining methods:6.1 thread inserts6.2 mechanical fasteners6.3 anchor nuts6.4 rivets6.5 quick-release fasteners6.6 other specific method
Ensure that composite components include three of the following:7.1 trim7.2 body panels7.3 structural7.4 core materials7.5 inserts7.6 closing panels7.7 tubes7.8 aerodynamic7.9 sections7.10 housings
Ensure that non-composite components include three of the following:8.1 brackets8.2 fixtures8.3 fittings8.4 trim8.5 tapes8.6 memory foam8.7 films
check the completed assembly to ensure that all operationshave been completed and the finished assembly meets therequired specification
Produce assemblies which comply with all of the following quality and accuracy standards:9.1 meet company standards and procedures9.2 dimensionally accurate within specification tolerances9.3all components are mechanically secure and free fromdamage or defects
Complete the relevant paper
work, to include one from the following and pass it to the appropriatepeople:10.1 build records10.2 job cards10.3 log cards10.4 other specific recording method
check that all the required operations have been completed tospecification.
Describe the health and safety precautions to be taken, and procedures tobe used, when working with composite materials, consumables, tools andequipment in the specific work area

Assembling electrical and electronic equipment to vehicles

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line with thejob role and company objectives
Carry out all of the following during the assembly activities:1.1obtain and use the appropriate documentation (such as jobinstructions, assembly drawings, quality control documentation)1.2adhere to procedures or systems in place for risk assessment,COSHH, personal protective equipment and other relevant safetyregulations and procedures to realise a safe system of work1.3check that all cables, extension leads or air supply hoses are in asafe, tested and serviceable condition1.4check that all tools and equipment to be used are within currentcalibration/certification dates1.5ensure that sub-assemblies and components used are free fromdamage, foreign objects, dirt or other contamination1.6use safe and approved techniques to assemble the electrical andelectronic equipment to the vehicles1.7return all tools and equipment to the correct location oncompletion of the assembly activities1.8leave the work area in a safe and appropriate condition oncompletion of the activities
follow the relevant instructions, assembly drawings and any otherspecifications
ensure that the specified components are available and that theyare in a usable condition
Assemble five of the following electrical and electronic devices to the vehicle, and terminate to the loom:2.1 audio equipment2.2 entertainment equipment2.3 navigational equipment2.4 safety systems2.5 control systems2.6 power-up system2.7 motors2.8 other specific equipment
Terminate all electrical and electronic devices to the loom, as appropriate:3.1 fuses/f
use box3.2 fuel management system3.3 lighting system3.4 actuators3.5 sensors3.6 braking system sensors/actuators3.7 circuit boards3.8 battery3.9 circuit protection3.10 heating and ventilation system
use the appropriate methods and techniques to assemble thecomponents in their correct positions
secure the components using the specified connectors andsecuring devices
Use a variety of assembly methods and techniques, to include three of the following:4.1 threaded fastening4.2 drive/interference fits4.3 soldering4.4 clip/spring fastening4.5 adhesive4.6 cable termination4.7 multi-connection4.8 screened cable fitment4.9 plugs and sockets
Assemble and connect components to vehicles, using three of the following:5.1 jig5.2 fixture5.3 cutting device5.4 wire/cable stripping device5.5 measuring device5.6 test meter5.7 continuity tester5.8 soldering equipment5.9 computer-aided fault diagnostic device
check the completed assembly to ensure that all operations havebeen completed and the finished assembly meets the requiredspecification
Produce assemblies which comply with all of the following quality and accuracy standards:6.1loom cables are correctly connected to the device and free fromkinks6.2 pins in multi-connectors are correctly orientated and secure6.3 all equipment is correctly terminated and securely mounted6.4all components are correctly installed and comply tospecifications
deal promptly and effectively with problems within their controland report those that cannot be solved
Describe the specific safety precautions to be taken whilst carrying out theassembly and fitting of electrical components to vehicles (including anyspecific legislation, regulations or codes of practice relating to the activities,equipment or materials)K2 Outline the health and safety requirements of the work area in which theyare carrying out the assembly and fitting of electrical components, and theresponsibility these requirements place on them
Describe the hazards associated with assembling electrical and electronicequipment to a vehicle, and how to minimise them and reduce any risks
Describe the personal protective equipment and clothing (PPE) to be wornduring the assembly and fitting of electrical components
Describe the precautions t

Assembling Electrical Vehicle (EV) Power Plant Unit

Verified

Key Learning Objectives:

This unit of Competence has been developed by employers in the Advanced Manufacturing and Engineering Sector and is part of an overall development programme designed to meet the requirements of the Sector.This unit identifies the training and development required in order that the learner can assemble Electrical Vehicle (EV) power plant unit, in accordance with approved procedures. They will be required to assemble a range of different power plant components, and will also assemble associated components, pipe and cable connections, by using a variety of assembly methods and techniques. They will be expected to use a range of tools and specialist equipment associated with the assembly methods, and to check that the assembly has been completed to the level of accuracy and quality required by the specification.Their responsibilities will require them to comply with organisational policy and procedures for the assembly activities undertaken, and to report any problems with the process that they cannot resolve, or that are outside their permitted authority, to the relevant people. They will be expected to work with a minimum of supervision, taking personal responsibility for their own actions and for the quality and accuracy of the work that they carry out.Their underpinning knowledge will provide a good understanding of their work and will provide an informed approach to applying procedures appropriate to the assembly of Electrical Vehicle (EV) power plant unit. They will understand the assembly methods and techniques used, and their application, and will know about the tooling and ancillary equipment, power plant unit components and consumables, in adequate depth to provide a sound basis for carrying out the activities to the required specification.They will understand the safety precautions required when carrying out the assembly activities. They will be required to demonstrate safe working practices throughout, and will understand the responsibility they owe to themselves and others in the workplace.They will be able to apply the occupational behaviours required in the workplace to meet the job profile and overall company objectives, including logical approach, problem solving orientation, quality focus, personal responsibility and resilience, clear communicator, team player, applies lean manufacturing principles, adaptability, self-motivation, willingness to learn and commitment.

Assembling Power Plant Units

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can assemble power plantunits, in accordance with approved procedures. They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment.

Assembling structures for experimental vehicle engineering using a manual/semi-automatic welding process

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following during the welding activities:1.1obtain and use the appropriate documentation (such as jobinstructions, drawings, weld procedure specifications, qualitycontrol documentation)1.2adhere to procedures or systems in place for risk assessment,COSHH, personal protective equipment and other relevantsafety regulations and procedures to realise a safe system ofwork1.3check that all cables, welding leads and gas hoses are in a safe,tested and serviceable condition1.4check that all tools and equipment to be used are withincurrent calibration/certification dates1.5 correctly prepare the faces of the materials to be welded1.6use safe and appropriate welding methods and procedures atall times1.7return all tools and equipment to the correct location oncompletion of the welding activities1.8leave the work area in a safe and appropriate condition oncompletion of the activities1.9produce welded joints that meet the requirements of thespecification
follow the relevant joining procedure and job instructions
check that the joint preparation complies with the specification
check that joining and related equipment and consumables are asspecified and fit for purpose
Set up, check, adjust and use welding and related equipment for one of the following weldingprocesses:2.1 manual metal arc (MMA)2.2 TIG2.3 flux cored wire2.4 MIG/MAG2.5 plasma arc2.6 oxy fuel gas welding
Use consumables as specified in the welding procedure specification, covering either:two types of electrode from:3.1 rutile3.2 nickel alloy3.3 basic3.4 stainless steel3.5 cellulosic3.6 otherOR3.7two types of filler wire from different material groups, usingshielding gases (where applicable)P6make the joints as specified using the appropriate thermaljoining technique
Produce fillet welded joints and/or partial butt welds in two of the following forms of material:4.1 plate4.2 sections4.3 pipe/tube4.4 sheet4.5 other specific form
Weld joints according to approved welding procedures, in good access situations, in two of thefollowing BS EN ISO 6947 positions:5.1 flat (PA)5.2 horizontal Vertical (PB)5.3 vertical Upwards (PF)5.4 horizontal (PC)5.5 vertical Downwards (PG)5.6 overhead (PE or PD)P7produce joints of the required quality and of specifieddimensional accuracy
Produce components which comply with both of the following quality and accuracy standards:6.1achieve a minimum weld quality equivalent to the level givenin the relevant European/International Standard (such as BSEN ISO 5817 and EN30042/ISO 10042) as required by theapplication standard or specification6.2meet the required dimensional accuracy within specifiedtolerance
shut down the equipment to a safe condition on completion ofjoining activities
deal promptly with excess and waste materials and temporaryattachments, in line with approved and agreed procedures
deal promptly and effectively with problems within theircontrol and report those that cannot be solved.
Describe the safe working practices and procedures to be observed whenworking with the selected welding equipment (general workshop and sitesafety, appropriate personal protective equipment (PPE), fire prevention,protecting other workers from arc eye, safety in enclosed/confined spaces;fume control; accident procedure)K2 Outline the statutory requirements, risk assessment procedures andrelevant requirements of HASAWA, COSHH and Work EquipmentRegulations; safe disposal of waste materials
Describe the correct handling and storage of gas cylinders (manual handlingand use of cylinder trolley, leak detection procedures, relevant BCGA codesof practice, cylinder identification, gas pressures, cylinder and equipmentsafety features, emergency shutdown procedures)K4 Describe the hazards associated with using the selecte

Assembling Sub-Assembly Units to Vehicles

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can apply hypothesis testing. They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment.

Assembling the Front Suspension Sub-Assembly

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can assemble the frontsuspension sub-assembly, in accordance with approved procedures.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment.

Assembling trim components to vehicles

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following during the trim assembly activities:1.1obtain and use the appropriate documentation (such as jobinstructions, trim assembly drawings, quality controldocumentation)1.2adhere to procedures or systems in place for risk assessment,COSHH, personal protective equipment and other relevantsafety regulations and procedures to realise a safe system ofwork1.3check that all cables, extension leads or air supply hoses arein a tested and serviceable condition1.4check that all tools and equipment to be used are withincurrent calibration/certification dates1.5ensure that sub-assemblies and trim components used arefree from damage, foreign objects, dirt or othercontamination before assembling them to the vehicle1.6use safe and approved techniques to trim and assemble thecomponents to the vehicles1.7return all tools and equipment to the correct location oncompletion of the trim assembly activities1.8leave the work area in a safe and appropriate condition oncompletion of the activities
follow the relevant instructions, assembly drawings and anyother specifications
ensure that the specified components are available and thatthey are in a usable condition
Assemble trim and associated components to the vehicle, to include all of the following:2.1 hard trim (such as plastics, wood, metal)2.2 soft trim (such as carpets, linings, foams)2.3 associated fixing components
use the appropriate methods and techniques to assemble thecomponents in their correct positions
Use a variety of assembly methods and techniques, to include three of the following:3.1 staples3.2 adhesives3.3 threaded fasteners3.4 push/clip fastening3.5 rivets
secure the components using the specified connectors andsecuring devices
Assemble trim components using three of the following devices:4.1 static jigs4.2 fixtures4.3 alignment devices4.4 portable jigs4.5 bucks4.6 mechanical fastening devices4.7 templates
Assemble trim components to vehicles, to include five of the following components:5.1 door pads5.2 sound deadeners/insulation5.3 carpets5.4 door furnishings (such as handles)5.5 roof linings and fittings5.6 dash assembly5.7 front seat assemblies5.8 seat belt assemblies5.9 floor console5.10 rear squab and cushion5.11 miscellaneous hard trim (such as finishers, décor strips)P7check the completed assembly to ensure that all operationshave been completed and the finished assembly meets therequired specification
Produce assemblies which comply with all of the following quality and accuracy standards:6.1 the assembly of trim components to the vehicle is complete6.2 the assembly is free from damage, tool marks and cuts6.3surplus adhesive has been removed and components areclean6.4all quality control checks have been carried out and therequired standards achieved
deal promptly and effectively with problems within their control and
report those that cannot be solved.
Describe the specific safety precautions to be taken whilst carrying out theassembly of trim components to the vehicle (including any specificlegislation, regulations or codes of practice relating to the activities,equipment or materials)K2 Outline the health and safety requirements of the work area in which theyare carrying out the assembly of trim components to the vehicle, and theresponsibility they place on them
Describe the hazards associated with assembling trim components to thevehicle (such as using adhesives, working in confined spaces) and how tominimise them and reduce any risks
Describe the personal protective equipment and clothing (PPE) to be wornduring the assembly of trim components to the vehicle
Explain the importance of applying the appropriate occupational behavioursin the workplace and the implications for both the learner and the businessif t

Assembling Vehicle Body Sub-Assemblies

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can assemble various vehiclebody sub-assemblies, in accordance with approved proceduresThey will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment.

Bonding vehicle composite components

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following during the bonding activities:1.1obtain and use the appropriate documentation (such as jobinstructions, drawings, planning and quality controldocumentation, material/adhesive data sheets, specifications, )1.2adhere to procedures or systems in place for risk assessment,COSHH, personal protective equipment and other relevantsafety regulations and procedures to realise a safe system ofwork1.3provide and maintain a safe working environment for thecomposite bonding activities1.4obtain the correct tools and equipment for the activity, andcheck that they are in a safe, tested and usable condition1.5follow safe practice/approved composite bonding techniquesand procedures at all times1.6return all tools and equipment to the correct location oncompletion of the composite bonding activities1.7dispose of waste materials in accordance with approvedprocedures
follow the relevant bonding procedure specification and jobinstructions
check that the materials to be bonded and bonding agents
comply with the specification
correctly prepare the parent materials and bonding agents in linewith the bonding specification
Carry out all of the following when preparing for the bonding activity:2.1 check that mouldings are correct and complete2.2 check availability of ancillary materials required2.3 check for any defects in the mouldings2.4 select the correct equipment for the activity2.5 check that bonding materials are within life2.6 check that equipment is suitable for use2.7identify and protect the moulding and bonding materials inthe work area2.8 check that bonding materials are correct and complete
carry out the bonding operations using the specified processesand techniques to position and bond the materials in theircorrect locations
ensure that any equipment used to maintain surface contactduring the bonding activities is set up and used correctly
Bond composite mouldings using techniques for two of the following:3.1 one-part pastes3.2 two-part pastes3.3 film adhesives3.4 syntactic films
Prepare bonding surfaces using four of the following methods:4.1 peel plies4.2 abrading4.3 water cleaning4.4 dry fitting4.5 priming4.6 templates4.7 bead blasting4.8 solvent cleaning4.9 acid etching4.10 surface masks4.11 laser ablation
When bonding composite mouldings
use three of the following methods:5.1 dry fitting5.2 mixing adhesives5.3 laying film adhesives5.4 bonding sequences5.5 wetting-out by brush5.6 oven curing5.7 shimming materials5.8 applicator gun5.9 heated press
During the curing process, retain the bond using two of the following:6.1 weighting down6.2 pinning joins6.3 clamping6.4 press6.5 vacuum bagging6.6 bonding jigs
Bond composite mouldings using techniques for two of the following:7.1 sandwich panels7.2 butt joins7.3 overlap joins7.4 joggle joins7.5 return joins
Bond composite mouldings using techniques for two of the following:8.1 flat surfaces8.2 shaped surfaces8.3 internal surfaces8.4 external surfaces
Use techniques for bonding three of the following materials to the composite moulding:9.1 metals9.2 ceramics9.3 plastics9.4 wood-based materials9.5 other composites
Bond composite mouldings using adhesives suitable for two of the following resin types:10.1 polyester10.2 epoxy10.3 phenolic10.4 bismaleimide10.5 cyanate ester10.6 vinyl ester
Bond composite mouldings using adhesives suitable for two of the following fibre types:11.1 polyethylene11.2 glass11.3 aramid11.4 carbon11.5 other specific types

Building prototype engines for test

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Building prototype engines for test
Apply practical skills, procedures and techniques in Building prototype engines for test
Evaluate performance, standards and best practices for Building prototype engines for test

Carrying Out Capability Studies

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can carry out capabilitystudies.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment.

Carrying out condition monitoring of plant and equipment

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety and other relevant regulations and guidelines
demonstrate the required occupational behaviours in line with the job role and company objectives
carry out all of the following during the monitoring activities:1.1 plan and communicate the condition monitoring activities soas to minimise disruption to normal working as much as possible;1.2 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.1.3 ensure that the correct condition monitoring equipment is being used for the condition monitoring activity;1.4 check the calibration of the monitoring equipment before use;1.5 where applicable set up the monitoring equipment in accordance with the appropriate procedures;1.6 check that the monitoring equipment is functioning correctly.1.7 carry out the monitoring activities, using appropriate techniques and procedures;1.8 apply safe working practices and procedures at all times
correctly set up and check-calibrate the equipment required for the monitoring being carried out
carry out the monitoring activities with the minimum disruption to normal activities
use appropriate monitoring techniques to set up equipment protection systems, or predictive maintenance system monitoring techniques, on two of the following types of equipment: 2.1 engines (such as piston or turbine);2.2 rotating or reciprocating machinery (such as pumps, compressors);2.3 mechanical equipment (such as cyclic and rotational devices, gearboxes, drives and linkages);2.4 production machinery (such as machine tools, presses, transfer mechanisms);2.5 process equipment (such as furnaces, chemical baths);2.6 rotating electrical machinery (such as generators, motors).2.7 stationary electrical equipment (such as transformers, switchgear).2.8 stationary plant and equipment (such as air receivers, accumulators, tanks, piping).2.9 emergency standby or alarm/warning systems and equipment.2.10 fluid power equipment (such as pipe
work, cylinders and actuators and pumps);2.11. process controller (such as program controller, input/outputinterfacing, wiring/cabling, monitoring sensors);2.12 electrical components (such as power supplies, switchgear and distribution panels, control systems);2.13 environmental systems (such as air conditioning, fume extraction).
use two of the following condition monitoring methods:3.1 off-line/portable monitoring;3.2 protection monitoring;3.3 sampled monitoring;3.4 human sensory monitoring (sight, sound, touch, smell);3.5 continuous monitoring.
use four of the following monitoring techniques:4.1 vibration analysis;4.2 pressure analysis;4.3 temperature analysis;4.4 voltage/current analysis;4.5 flow analysis.4.6 radio telemetry analysis.4.7 particle analysis;4.8 thickness analysis;4.9 crack detection analysis;4.10 oil analysis;4.11 leak detection analysis;4.12 corrosion detection;4.13 humidity analysis;4.14 environmental pollutant analysis;4.15 photo/optical equipment;4.16 other specific monitoring equipment.
record and review the outcomes and take appropriate actions
Describe the specific health and safety precautions to be applied during themonitoring procedure, and their effects on others;K2
Describe the health and safety requirements of the area in which themonitoring activity is to take place, and the responsibility these requirements place on them
Describe the hazards associated with carrying out monitoring activities onplant and equipment (such as electrical supplies, moving machinery, processcontroller interface, using damaged or badly maintained tools and equipment, not following laid-down procedures), and how to minimise these and reduce any risks
Describe the importance of applying the occupational appropriatebehaviours in the workplace and the implications for both the apprenticeand the business if these are not adhe

Carrying out fault diagnosis on engineering plant and equipment

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Carrying out fault diagnosis on engineering plant and equipment
Apply practical skills, procedures and techniques in Carrying out fault diagnosis on engineering plant and equipment
Evaluate performance, standards and best practices for Carrying out fault diagnosis on engineering plant and equipment

Carrying out fault diagnosis on experimental vehicles

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following during the fault diagnostic activities:1.1obtain and use the appropriate documentation (such as jobinstructions, assembly drawings, vehicle documentation,quality control documentation)1.2adhere to procedures or systems in place for risk assessment,COSHH, personal protective equipment and other relevantsafety regulations and procedures to realise a safe system ofwork1.3provide and maintain safe access and working arrangementsfor undertaking the vehicle diagnostics1.4obtain the correct tools and equipment for the activity andcheck they are in a safe, tested and usable condition1.5follow safe practice/approved diagnostic techniques andprocedures at all times1.6collect vehicle fault diagnostic evidence from running andstatic vehicle systems1.7disconnect or isolate components or parts of the system,when appropriate, to confirm the diagnosis1.8 identify the fault and determine appropriate corrective action1.9return all tools and equipment to the correct location oncompletion of the diagnostic activities1.10leave the work area in a safe condition on completion of theactivities
review and use all relevant information on the symptoms andproblems associated with the products or assets
Carry out fault diagnosis, on four of the following, to sub-assembly/component level:2.1 vehicle mechanical equipment2.2 vehicle electrical/electronic systems2.3 vehicle braking systems2.4 vehicle process controllers2.5 prototype engine/power unit2.6 prototype engine test controller2.7 gearbox and transmission2.8 suspension system2.9 steering system2.10 cooling and heating system2.11 exhaust emission control system2.12 fuel system2.13 Vehicle charging system
investigate and establish the most likely causes of the faults
Collect evidence about the fault from four of the following sources:3.1 development personnel or customer who reported the fault3.2 sensory (such as sight, sound, smell, touch)3.3 monitoring equipment or gauges3.4 vehicle/manufacturer's records/history3.5 recording devices3.6 condition of the end product
use and apply diagnostic techniques, tools and aids tolocate faults
complete the fault diagnosis within the agreed time and informthe appropriate people when this cannot be achieved
Use a range of fault diagnostic techniques, to include two of the following:4.1 half-split technique4.2 emergent problem sequence4.3 unit substitution4.4 function/performance testing4.5 six point4.6 computer-aided diagnostics4.7 input/output4.8 injection and sampling4.9 unit substitution
Use a variety of diagnostic aids and equipment, to include four of the following:5.1 manufacturer's/vehicle manual5.2 logic diagrams5.3 algorithms5.4 flow charts5.5 probability charts/reports5.6 fault analysis charts (such as fault trees)5.7 equipment self-diagnostics5.8 troubleshooting guides5.9 circuit diagrams/specifications5.10 prototype engine test schedule
Use three of the following types of test equipment to help in the fault diagnosis:6.1mechanical measuring equipment (such as measuringinstruments, dial test indicators, torque instruments)6.2electrical/electronic measuring instruments (such asmultimeters, logic probes)6.3fluid power test equipment (such as test rigs, flow meters,pressure gauges)6.4 computer programmed self-assessment system6.5 prototype engine test controller6.6 Gas analyser
Find faults that have resulted in two of the following conditions:7.1 intermittent failure7.2partial failure or reduced performance/out-of-specificationproduct7.3 complete breakdown7.4 in
complete or incorrect test results
determine the implications of the fault for other work and forsafety considerations
use the evidence gained to draw valid conclusions about thenature and probable ca
use of the fault

Carrying out Health and Safety Risk Assessments on Engineering Activities

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can carry out a health andsafety risk assessment, in accordance with regulatory requirements and approved procedures within theirorganisation.They will be aware of any health, safety and environmental requirements applicable to the engineering activitiesbeing assessed. They will be required to demonstrate safe working practices throughout, and will understand theresponsibility they owe to themselves and others in the workplace.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment

Carrying Out Measurement Systems Analysis (MSA)

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can carry out measurementsystems analysis (MSA).They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment.

Carrying out mechanical testing

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
follow the appropriate procedures/techniques for use of toolsand equipment to carry out the required tests
Carry out all of the following during the testing activities:1.1obtain the required testing equipment, and ensure that it is ina safe and usable condition1.2 use appropriate personal protective equipment1.3comply with job instructions, testing inspection specifications,relevant COSHH sheets and risk assessment documentation1.4follow the defined testing procedures/techniques, and applysafe working practices and procedures at all times1.5leave the work area in a safe and tidy condition on completionof the activities
set up and carry out the tests using the correctprocedures/techniques and within agreed timescales
Obtain the correct type of equipment, as required by the testing instructions/techniques, to includeall of the following:2.1 test piece2.2 calibration blocks / pieces2.3 result conversion documents (as appropriate)S3 Carry out testing activities, using one of the following types of equipment:3.1 manual3.2 semi-automatic3.3 fully automatic
Prepare the material samples for testing, to include carrying out all of the following:4.1 checking for defects4.2 surface preparation (as appropriate)4.3 correct identification4.4 correct dimensions (as appropriate)S5 Carry out testing using one of the following types of tests:5.1 tensile5.2 compression5.3 impact5.4 hardness5.5 bending5.6 other specific mechanical test
record the results of the tests in the appropriate format
Record the test results and to include recording all of the following:6.1 sample identification6.2 sample material form6.3 date and time6.4 test criteria (such as specification, standard)6.5 test indications and interpretation (including sample defects)6.6 conclusions and recommendations6.7 personal data
review the results and carry out further tests if necessary
Complete the testing activities, to include carrying out all of the following:7.1 marking up tested samples with all relevant information7.2 disposal / storage of sample remains7.3recording all the required details of the test in the appropriateformat7.4 handing over the test report details to the appropriate people7.5turn off equipment as required and leave in a safe and tidycondition
deal promptly and effectively with problems within theircontrol and report those that cannot be solved
Outline the specific safety precautions to be taken when carrying outtesting activities on material samples from engineering products, orstructures
Describe the hazards associated with carrying out the activities (such aselectrical contact, fast moving mechanical parts, stored pressures/forces,extreme temperatures), and how they can be minimised
Describe the type of personal protective equipment (PPE) to be used, andhow to obtain it
Explain the importance of applying the appropriate occupational behavioursin the workplace and the implications for both the learner and the businessif these are not adhered to
Explain how to obtain the necessary job instructions/techniques, testingspecifications, and how to interpret their information
Explain the importance of testing product materials using mechanicaltesting methods
Explain why products may need to be tested by a range of differentmechanical testing methods (such as tensile, compression, hardness, impactand bending)K8 Describe the basic principles of mechanical testing
Outline the basic components of the testing equipment (such as displaypanel, safety devices, power sources, recording mechanisms)K10 Describe the different types of mechanical testing methods (such as tensile,compression, hardness, impact and bending) and what materialcharacteristics they are measuring

Carrying Out Problem Solving Activities

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can solve problems, inaccordance with approved procedures. They will be required to ensure that safe workingpractices are maintained throughout, and will understand the responsibility they owe to themselves and othersin the work area.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment.

Carrying out Project Management of Engineering Activities

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can project manage variousengineering activities, time and resources, in accordance with approved procedures

Carrying Out Six Sigma Process Mapping

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can carry out a Six Sigmaprocess mapping activity. They will need to understand the principles andthe application of Six Sigma process mapping, in adequate depth to provide a sound basis for carrying out theactivities to the required criteria.Applying safe working practices will be a key issue throughout.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment.

Carrying out Standard Post-Processing of Additively Manufactured Components

Verified

Key Learning Objectives:

Carrying out Standard Post-Processing of Additively Manufactured Components

Carrying Out Statistical Process Control (SPC) Procedures

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can carry out statisticalprocess control (SPC) procedures.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment.

Carrying Out Value Stream Mapping (VSM)

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can carry out value streammapping (VSM).They will need to understand the principles and procedures ofvalue stream mapping, and its application, in adequate depth to provide a sound basis for carrying out theactivities to the required criteria.Applying safe working practices will be a key issue throughout.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment.

Carrying out visual inspection of welded fabrications

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following activities during the inspection process:1.1observe all the required safety procedures for the workarea/activity1.2obtain and use the correct issue of drawings, job instructionsand welding procedure specifications1.3obtain and check the condition and calibration dates of tools,measuring instruments and equipment used1.4 follow specified or appropriate inspection procedures1.5identify and record out-of-specification features, in theappropriate format1.6mark and identify areas where non-compliance withspecification or defect indications are found1.7leave the work area in a safe and tidy condition on completionof the activities
follow the correct specification for the product or equipmentbeing inspected
use the correct equipment to carry out the inspection
Ensure that they have the required inspection equipment and that it is in good working order, toinclude six of the following, as appropriate to the operation/features being checked:2.1 weld measuring gauge2.2 CCTV viewing system2.3 rule, tape or other linear measuring device2.4 magnifying glass2.5 adjustable square/protractor2.6 mirror2.7 depth gauge2.8 portable lighting2.9 bore scope2.10 means of marking defective areas
Carry out specified prefabrication or sub-assembly inspection checks, to include all of the following:3.1 dimensional accuracy3.2 straightness3.3 security of joints3.4 squareness3.5 position/location
Carry out the inspection of two of the following types of welded fabrications:4.1 fabricated frames4.2 pipe sections4.3 transformers4.4 structures4.5 cylindrical components4.6 segmented bends4.7 square/rectangular tanks4.8 conical components4.9 modular components4.10 curved/profiled structures4.11 tubular structures4.12 other specific welded fabrications
identify and confirm the inspection checks to be made andacceptance criteria to be used
carry out all required inspections as specified
identify any defects or variations from the specification
Carry out specified inspection during fabrication, to check all of the following:5.1 condition of the weld root zone and inter-runs5.2 inter-run cleaning of weld faces and surfaces5.3distortion and shrinkage transformers segmented bendsmodular components other specific fabrications
Carry out the specified final inspection checks, to include all of the following:6.1 overall dimensional tolerances6.2 visual appearance of welds/weld profile6.3 extent of distortion, shrinkage or misalignment6.4 evidence of damage (requiring restoration)6.5 defect indications manifested on weld or parent metal surface6.6extent of excess metal, undercut, penetration or lack ofpenetration
Carry out the inspection checks to one of the following:7.1 approved construction drawings7.2 client specifications/detail drawings7.3 applicable national and international standards7.4 welding procedure specification
record the results of the inspection in the appropriate format
Complete the inspection documentation, to include one from the following, and pass to theappropriate people:8.1 weld inspection report8.2 job card8.3 customer specific documentation8.4 concession report
deal promptly and effectively with problems within theircontrol and report those that cannot be solved.
Outline the specific safety precautions to be taken when inspecting weldedfabrications (such as specific legislation or regulations governing theactivities or work area, safe working practices and procedures to beadopted, general workshop safety practice, risk assessment procedures andrelevant requirements of HASAWA, COSHH and Work EquipmentRegulations)K2 Describe the personal protective clothing and equipment (PPE) that shouldbe worn (such as leather gloves, eye protection, ear protection, safetyharness)K3 Describe th

Checking and calibrating electrical and electronic test equipment

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Prepare for the calibration activities by carrying out all of the following:1.1 ensure that the work area is in a safe and tidy condition1.2ensure that environmental conditions are suitable for thecalibration checks being made (such as temperature,cleanliness, humidity)1.3obtain and use the correct quality control documentation(such as calibration records, equipment specifications)1.4obtain and check the general condition of the instrumentationto be calibrated1.5obtain appropriate calibration/reference equipment for thejob in hand1.6leave the work area in a safe and tidy condition on completionof the activities
Carry out the calibration of electrical/electronic test instruments in both of the following types ofmeasurement:2.1 analogue2.2 digital
obtain and use the correct equipment to carry out thecalibration activities
Carry out the calibration of electrical/electronic test equipment, to include eight of the followingtypes of instruments:3.1 multimeters3.2 flash testers3.3 ammeter3.4 resistance boxes3.5 voltmeter3.6 residual current device (RCD) tester3.7 watt meters3.8 signal generators.3.9 ohmmeters3.10 portable appliance (PAT) testers3.11 oscilloscope3.12 logic probes3.13 insulation tester3.14 current injection devices3.15 loop impedance tester3.16 phase testers3.17 earth bond testers3.18 amplifiers3.19 current probes3.20 spectrum analysers3.21 chart recorders3.22 net
work analysers3.23 frequency meters and counters3.24 logic analysers3.25 other specific test equipment
identify and confirm the calibration checks to be made andacceptance criteria to be used
correctly set up, check and calibrate the equipment, usingapproved techniques and procedures
Use three of the following types of equipment during the calibration activities:4.1 reference/workshop potentiometers4.2 spectrum analysers4.3 measuring bridges4.4 net
work analysers4.5 master/reference stabilised power supplies4.6 logic analysers4.7 master/reference meters4.8 master/reference signal generators4.9 master/reference oscilloscopes4.10 other specific calibration equipment
Test and calibrate electrical/electronic test instrumentation, to include carrying out all of thefollowing:5.1 obtaining calibration parameters from data records5.2 connecting up power supplies, test and calibration equipment5.3 following specified or appropriate calibration procedures5.4ensure that any special operating conditions are taken intoaccount5.5 calibrating to manufacturer's procedures and specifications5.6 applying appropriate coding to calibrated equipment5.7recording calibration results accurately and legibly, in theappropriate format5.8 identifying and recording out-of-specification instruments5.9taking appropriate action in respect of instruments that fail tomeet calibration specifications5.10diagnosing faults during the calibration process (whereappropriate)P6record the results of the calibration checks in the appropriateformat
where appropriate
apply suitable identification to theequipment, stating current date(s) of calibration
Complete the calibration documentation, to include one from the following, and pass to theappropriate people:6.1 calibration report6.2 `equipment withdrawal from service' report6.3 job card6.4 customer specific documentation
deal promptly and effectively with problems within theircontrol and report those that cannot be solved
Outline the specific safety precautions to be taken when checking andcalibrating electrical and electronic test instrumentation (such as specificlegislation or regulations governing the activities or work area, safe workingpractices and procedures to be adopted, general workshop safety practice)K2 Describe the health and safety requirements of the work area in which theyare carrying out the calibration activit

Checking and calibrating mechanical inspection equipment

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Prepare for the calibration activities, by carrying out all of the following:1.1 ensure that the work area is in a safe and tidy condition1.2ensure that environmental conditions are suitable for thecalibration checks being made (such as temperature,cleanliness, humidity)1.3obtain and use the correct quality control documentation(such as calibration records, equipment specifications)1.4obtain and check the general condition of the measuringinstruments to be calibrated1.5obtain appropriate calibration/reference equipment for thejob in hand
Carry out the calibration of measuring instruments in both of the following systems of measurement:2.1 imperial units2.2 metric units
obtain and use the correct equipment to carry out thecalibration activities
Use five of the following types of calibration equipment:3.1 reference grade slip gauges3.2 reference/master thread gauges3.3 standard reference pieces (such as balls, blocks, wires)3.4 shadow graph3.5 angular reference gauges3.6 floating carriage micrometers3.7 standard taper gauges3.8 microscope3.9 master cylindrical square.3.10 reference/master sine bars3.11 reference/master bores (such as ring/bore)3.12 reference/master sine tables3.13 reference/master bench centres
identify and confirm the calibration checks to be made andacceptance criteria to be used
Check, and where appropriate, set and calibrate ten of the following:4.1 micrometers (to include external, internal and depth)4.2 verniers (to include length, height and depth)4.3 specialist verniers (such as gear tooth)4.4 specialist micrometers (such as thread)4.5 height micrometer4.6 spline gauges4.7 engineers' square4.8 radius/profile gauges4.9 cylindrical square4.10 workshop gauge blocks4.11 straight edge4.12 gap gauge (fixed and adjustable)4.13 engineers' levels4.14 plug/hole gauge4.15 surface tables4.16 bore gauges (fixed and telescopic)4.17 angle plates4.18 groove gauges4.19 box angle plates4.20 alignment gauges4.21 taper gauges4.22 thread plug gauge4.23 protractors4.24 thread ring gauge4.25 combination squares4.26 thread depth gauges4.27 clinometers.4.28 pneumatic gauges4.29 sine bars4.30 torque gauge/wrench4.31 sine tables4.32 bench centres4.33 dial test indicators4.34 roughness standards4.35 surface finish equipment4.36 other specific equipment
correctly set up, check and calibrate the equipment, usingapproved techniques and procedures
Check and calibrate mechanical inspection equipment, to include carrying out all of the following:5.1 obtaining calibration parameters from data records5.2 setting and using the correct calibration equipment5.3 following specified or appropriate calibration procedures5.4 calibrating the instruments to manufacturers' specifications5.5 apply appropriate coding to calibrated equipment5.6recording calibration results accurately and legibly, in theappropriate format5.7 identifying and recording out-of-specification instruments5.8taking appropriate action in respect of instruments that fail tomeet calibration specifications5.9diagnosing faults during the calibration process (whereappropriate)P6record the results of the calibration checks in the appropriateformat
where appropriate
apply suitable identification to theequipment, stating current date(s) of calibration.
Complete the calibration documentation, to include one from the following, and pass to theappropriate people:6.1 calibration report6.2 ‘equipment withdrawal from service' report6.3 job card6.4 customer specific documentation
deal promptly and effectively with problems within theircontrol and report those that cannot be solved.
Outline the specific safety precautions to be taken when checking andcalibrating mechanical measuring equipment (such as specific legislation orregulations governing the activities or

Checking and calibrating process control instrumentation

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Prepare for the calibration activities, by carrying out all of the following:1.1 ensure that the work area is in a safe and tidy condition1.2ensure that environmental conditions are suitable for thecalibration checks being made (such as temperature,cleanliness, humidity)1.3obtain and use the correct quality control documentation(such as calibration records, equipment specifications)1.4obtain and check the general condition of the instrumentationto be calibrated1.5obtain appropriate calibration/reference equipment for thejob in hand1.6leave the work area in a safe and tidy condition on completionof the activities
Carry out the calibration of process control equipment, to include four of the following types ofinstruments:2.1 pressure2.2 load/weighing/strain gauges2.3 analysers2.4 flow (fluid, gas or air)2.5 gas detection/monitoring2.6 recorders and indicators2.7 level2.8 fire detection2.9 sound/acoustic measurement2.10 temperature/humidity2.11 fiscal metering2.12 radiation detection2.13 speed measurement2.14 alarm and trip2.15 instrument controllers2.16 vibration monitoring
obtain and use the correct equipment to carry out thecalibration activities
identify and confirm the calibration checks to be made andacceptance criteria to be used
correctly set up, check and calibrate the equipment, usingapproved techniques and procedures
Use six of the following types of equipment during the calibration activities:3.1 standard test gauges3.2 speed measuring devices3.3 oscilloscope3.4 dead weight tester3.5 calibrated weights3.6 insulation testers3.7 manometer3.8 calibrated flow meter3.9 analogue and digital meters3.10 digital pressure indicators3.11 ultraviolet light source3.12 phase testers3.13 hydraulic/portable pressure pump3.14 smoke canisters3.15 current injection devices3.16 oil/water bath3.17 heat guns3.18 logic probes3.19 hydrometer3.20 appropriate test gases3.21 audio amplifiers/chambers3.22 reference/workshop potentiometers3.23 sand bath3.24 electronic weight test calibrator3.25 signal generators3.26 other specific test equipment
Test and calibrate process control instrumentation, to include carrying out all of the following:4.1 obtaining calibration parameters from data records4.2 connecting up power supplies, test and calibration equipment4.3 following specified or appropriate calibration procedures4.4ensuring that any special operating conditions are taken intoaccount (such as liquid level correction)4.5 calibrating to manufacturer's procedures and specifications4.6recording calibration results accurately and legibly in theappropriate format4.7 identifying and recording out-of-specification instruments4.8taking appropriate action in respect of instruments that fail tomeet calibration specifications4.9diagnosing faults during the calibration process (whereappropriate)P6record the results of the calibration checks in the appropriateformat
where appropriate
apply suitable identification to theequipment, stating current date(s) of calibration
Complete the calibration documentation, to include one from the following, and pass to theappropriate people:5.1 calibration report5.2 job card5.3 ‘equipment withdrawal from service' report5.4 customer specific documentation
deal promptly and effectively with problems within theircontrol and report those that cannot be solved
Outline the specific safety precautions to be taken when checking andcalibrating process control instrumentation (such as specific legislation orregulations governing the activities or work area, safe working practices andprocedures to be adopted, general workshop safety practice)K2 Describe the health and safety requirements of the work area in which theyare carrying out the calibration activities, and the responsibility theserequirements plac

Complying with statutory regulations and organisational safety

Verified

Key Learning Objectives:

Comply with their 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 theactivities to be undertaken.
Demonstrate their understanding of their duties and obligations to health and safety by carrying outall of the following:1.1 apply in principle their duties and responsibilities as anindividual under the Health and Safety at Work Act and relevantcurrent legislation; 1.2 identifying within their organisation, appropriate sources ofinformation and guidance on health and safety issues, toinclude: 1. eye protection and personal protective equipment; 2. COSHH regulations; 3. risk assessments. 1.3 identifying the warning signs and labels of the main groups of hazardous or dangerous substances; 1.4 complying with the appropriate statutory regulations at all times.
Follow organisational accident and emergency procedures.
Comply with all emergency requirements, to include: 2.1 identifying the appropriate qualified first aiders or appointedperson and the location of first aid facilities;2.2 identifying the procedures to be followed in the event of injury to self or others;2.3 following organisational procedures in the event of fire and the evacuation of premises;2.4 Identifying the procedures to be followed in the event of dangerous occurrences or hazardous malfunctions.
Recognise and control hazards in the workplace
Comply with all emergency requirements, to include:3.1 their working environment;3.2 the tools and equipment that they use;3.3 materials and substances that they use;3.4 using working practices that do not follow laid down procedures.
Use correct manual lifting and carrying techniques.
Demonstrate two of the following methods of manual lifting and carrying techniques: 4.1 lifting alone; 4.2 with assistance of others;4.3 with mechanical assistance.
Apply safe working practices and procedures.
Apply safe working practices in an industrial environment, to include all of the following: 5.1 Maintaining a tidy workplace with exits and gangways free fromobstructions;5.2 Using tools and equipment safely and only for the purposeintended.5.3 Observing organisational safety rules, signs and hazard warnings;5.4 Taking measures to protect others from harm by any work theyare carrying out.
Describe the roles and responsibilities of themselves and others under theHealth and Safety at Work Act 1974 and current legislation (such as TheManagement of Health and Safety at Work Regulations; Workplace Healthand Safety and Welfare Regulations; Personal Protective Equipment at WorkRegulations 1992; Manual Handling Operations Regulations; Provision and
Use of Work Equipment Regulations; Display Screen at Work Regulations;The Electricity at Work Regulations).
Describe the specific regulations and safe working practices and proceduresthat apply to their work activities.
Describe the warning signs for the nine main groups of hazardoussubstances defined by Classification, Packaging and Labelling of DangerousSubstances Regulations.
Explain how to locate relevant health and safety information for their tasksand the sources of expert assistance when help is needed.
Explain what constitutes a hazard in the workplace (such as moving parts ofmachinery, electricity, slippery and uneven surfaces, dust and fumes,handling and transporting, contaminants and irritants, material ejection,fire, working at height, environment, pressure/stored energy systems,volatile or toxic materials, unshielded processes).
Explain what are their responsibilities for dealing with hazards and reducingrisks in the workplace (such as hazard spotting and safety inspections; the
use of hazard check lists, carrying out risk assessments, COSHH assessmentsand safe systems of working).

Conducting and monitoring road tests on vehicles

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following during the testing activities:1.1obtain and use the appropriate documentation (such as jobinstructions, vehicle documentation, test schedules, testprocedures, quality control documentation)1.2adhere to procedures or systems in place for risk assessment,COSHH, personal protective equipment and other relevantsafety regulations and procedures to realise a safe system ofwork1.3provide and maintain safe access and working arrangementsfor the test area1.4obtain the correct tools and equipment for the testing activityand check that they are in a safe, tested and usable condition1.5follow safe practice/approved testing techniques andprocedures at all times1.6return all tools and equipment to the correct location oncompletion of the testing activities
follow the appropriate procedures for use of tools andequipment to carry out the required tests
set up and carry out the tests using the correct procedures andwithin agreed timescales
Prepare the vehicle for testing by carrying out all of the following, as applicable to the vehicle type:2.1fit slave wheels to the vehicle (where appropriate), and checkfor correct tyre tread depth and pressure2.2check that oil, water and other fluid levels are correct and thatthere are no leaks2.3 check that all warning devices are working correctly2.4check that all rear lights, brake lights and hazard warninglights function correctly2.5 fit monitoring or other test equipment, as appropriate2.6ensure that appropriate safety equipment is fitted to thevehicle and all driver safety equipment is available2.7 ensure that trade plates are displayed (where appropriate)2.8 ensure that seat fouling protectors are fitted2.9 inform appropriate people of the start of the test
Carry out road tests on one of the following types of vehicle:3.1 front wheel drive3.2 rear wheel drive3.3 all-wheel drive
Test vehicle on two of the following road conditions:4.1 normal road conditions4.2 salt bath4.3 wet/skid patch4.4 paved, cobble, rough road4.5 sand trench4.6 circular track4.7 country road4.8 straight speed test4.9 off-road terrain4.10 other specific conditions
Carry out road tests on the vehicle to a specific test schedule, to include nine of the following:5.1 driving the vehicle over specified distance5.2 carrying out a steering geometry check5.3 driving the vehicle at specific speeds for defined time5.4 carrying out a suspension check5.5 driving the vehicle over different road surfaces5.6 carrying out a noise and vibration check5.7 checking engine for hot and cold running temperatures5.8 carrying out an instrumentation check5.9 checking and monitoring exhaust emissions5.10 carrying out an electrical system check5.11 checking power chain through all gears5.12 carrying out a navigational system check5.13checking automatic gearbox through rapid acceleration andparking5.14 carrying out other specific tests
record the results of the tests in the appropriate format
review and analyse the results and carry out further tests ifnecessary
Review and analyse the results of the road test, using two of the following:6.1 data sheets6.2 vehicle history sheet6.3 fault records6.4 operation sheet6.5 manufacturer's specifications
Record the results of the tests, using one of the following:7.1 written records7.2 electronic records
Carry out tests which comply with one of the following standards:8.1 Ministry of Transport8.2 customer standards and requirements8.3 international standards8.4 company standards and procedures.
Describe the specific safety practices and procedures to be observed whenroad testing vehicles (including any specific legislation, regulations/codes ofpractice required for the activities, equipment or materials used)K2 Describe the health and safety requiremen

Conducting and monitoring static tests on vehicles

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following during the testing activities:1.1obtain and use the appropriate documentation (such as jobinstructions, vehicle documentation, test schedules, testprocedures, quality control documentation)1.2adhere to procedures or systems in place for risk assessment,COSHH, personal protective equipment and other relevantsafety regulations and procedures to realise a safe system ofwork1.3provide and maintain safe access and working arrangementsfor the test area1.4obtain the correct tools and equipment for the testing activityand check that they are in a safe, tested and usable condition1.5follow safe practice/approved testing techniques andprocedures at all times1.6return all tools and equipment to the correct location oncompletion of the testing activities1.7leave the work area in a safe and appropriate condition oncompletion of the activities
follow the appropriate procedures for use of tools andequipment to carry out the required tests
set up and carry out the tests using the correct procedures andwithin agreed timescales
Prepare the vehicle for testing by carrying out all of the following, as applicable to the vehicle type:2.1fit slave wheels to the vehicle (where appropriate), and checkfor correct tyre tread depth and pressure2.2check that oil, water and other fluid levels are correct, andthat there are no leaks2.3 check that all warning devices are working correctly2.4fit monitoring or other test equipment to the vehicle (whereappropriate)2.5ensure that appropriate safety equipment is fitted to thevehicle, and all driver safety equipment is available2.6ensure that test equipment is calibrated and functionscorrectly2.7ensure that seat fouling protectors are fitted (whereappropriate)S3 Carry out static tests on one of the following types of vehicle:3.1 front wheel drive3.2 rear wheel drive3.3 all-wheel drive
Undertake the vehicle tests using one of the following:4.1 rolling road4.2 computer-controlled static test4.3 computer-controlled rolling road
Carry out static tests on the vehicle to a specific test schedule, to include nine of the following:5.1 driving the vehicle for the specified time5.2 carrying out a steering geometry check5.3 driving vehicle at specified speeds through gears5.4 carrying out a suspension check5.5 carrying out braking tests5.6 carrying out noise and vibration check5.7 checking and monitoring exhaust emissions5.8 carrying out instrumentation check5.9 checking power train through all gears5.10 carrying out electrical system check5.11 carrying out tests on specific components5.12 carrying out entertainment system check5.13 carrying out engine checks for hot and cold staring5.14checking automatic gearbox through rapid acceleration andparking5.15 carrying out lighting positional/beam setting checks5.16 carrying out a complete vehicle function test5.17 carrying out other specific tests
record the results of the tests in the appropriate format
review and analyse the results and carry out further tests ifnecessary
Review and analyse the results of the static test, using two of the following:6.1 data sheets6.2 vehicle history sheet6.3 fault records6.4 operation sheet6.5 manufacturer's specifications
Record the results of the tests, using one of the following:7.1 written records7.2 electronic records
Carry out tests which comply with one of the following standards:8.1 Ministry of Transport8.2 customer standards and requirements8.3 international standards8.4 company standards and procedures
Describe the specific safety practices and procedures to be observed whencarrying out static testing of vehicles (including any specific legislation,regulations/codes of practice required for the activities, equipment ormaterials used)K2 Describe the health and safety requi

Creating Flexible Production and Manpower Systems

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can create flexible businesssystems.They will need to understand the principles and procedures ofcreating flexible production and manpower systems, and their application, in adequate depth to provide a soundbasis for carrying out the activities to the required criteria.Applying safe working practices will be a key issue throughout.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment

Creating Standard Operating Procedures

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can create standardoperating procedures (SOP) for work activitiesThey will need to understand the principles and proceduresfor creating standard operating procedures, and their application, in adequate depth to provide a sound basis forcarrying out the activities to the required criteria.Applying safe working practices will be a key issue throughout.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment

Cutting and shaping sheet metal for experimental vehicle engineering

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following during the sheet metal shaping activities:1.1obtain and use the appropriate documentation (such as jobinstructions, component drawings, quality controldocumentation)1.2adhere to procedures or systems in place for risk assessment,COSHH, personal protective equipment and other relevantsafety regulations and procedures to realise a safe system ofwork1.3check that all cables, extension leads or air supply hoses are ina safe, tested and serviceable condition1.4check that all tools and equipment to be used are withincurrent calibration/certification dates1.5 obtain appropriate materials for the work in hand1.6mark out the components accurately, using recognisedconventions1.7set up and hold the components firmly during the cutting andshaping operations1.8use safe and approved sheet metal cutting and shapingtechniques and procedures at all times1.9return all tools and equipment to the correct location oncompletion of the activities1.10leave the work area in a safe and appropriate condition oncompletion of the activities
follow relevant specifications for the component to be produced
Produce components for experimental vehicle development purposes, to include both of thefollowing:2.1Produce components for experimental vehicle developmentpurposes, to include both of the following:2.2Produce components for experimental vehicle developmentpurposes, to include both of the following:P4obtain the appropriate tools and equipment for the shapingoperations and check they are in a safe and usable condition
shape the materials using appropriate methods and techniques
Cut and shape the materials using four of the following:3.1 saws (hand or mechanical)3.2 tin snips3.3 punch/cropping machines3.4 guillotines3.5 drills and hole saws3.6 files3.7 nibblers3.8 trepanning tools3.9 abrasive discs3.10 laser/water cutting
Produce a range of components with features that include five of the following:4.1 edges/faces that are square to each other4.2 internal profiles4.3 edges/faces that are parallel4.4 external profiles4.5 edges/faces that are angled4.6 holes linearly pitched4.7 curved or circular forms4.8 holes radially pitched
Shape and form material using four of the following:5.1 bench folding machines5.2 shrinking techniques5.3 rolling machines5.4 stretching techniques5.5 presses
Produce components with a range of features that include five of the following:6.1 right-angle bend6.2 curved/circular flanges6.3 conical6.4 angled bend6.5 curved profile6.6 dished6.7 square flanges6.8 cylinder shape6.9 multi-profiled6.10 tray section and channels
Use two types of material from:7.1 mild steel7.2 stainless steel7.3 brass7.4 alloy steel7.5 aluminium7.6 composite material7.7 other specific material
check that all the required shaping operations have beencompleted to the required specification
Produce components which meet all of the following quality and accuracy standards:8.1 meet company standard requirements8.2 meets job requirements8.3 dimensionally accurate within specification tolerance8.4 free from distortion, false tool marks or damage8.5 free from sharp edges, slivers or burrs
deal promptly and effectively with problems within theircontrol and report those that cannot be solved
Describe the health and safety requirements of the area where they arecarrying out the cutting and shaping activities
Describe the personal protective clothing and equipment (PPE) to be wornwhen carrying out the fabrication activities (gloves, eye/ear protection,safety helmets)K3 Describe the correct methods of moving or lifting sheet metal
Describe the hazards associated with carrying out sheet metal fabrication
work (such as handling sheet material, using dangerous or badly maintainedtools and equipment, operating

Determining engineering requirements for the supply of products or services

Verified

Key Learning Objectives:

work safely in accordance with the regulations for their workenvironment
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following when determining the engineering requirements:1.1 use the correct issue of company information1.2check that all essential information and data needed to makevalid decisions is available1.3 determine the engineering requirements1.4check that the organisation's work and technical capacity canmeet the customer's requirements1.5maintain appropriate levels of customer communication andconfidentiality1.6record and file the engineering requirements in theappropriate format
obtain sufficient information to understand clearly thecustomer's requirements
advise the customer of relevant product or service features,and relate these to the customer's requirements
make sure that the customer requirements are accuratelyspecified
check with the customer and obtain agreement that therequirements are interpreted correctly
Determine engineering requirements for customer needs for one of the following:2.1drawing/design activities (such as mechanical,electrical/electronic, motor vehicle, aerospace, marine)2.2manufacturing activities (such as machining, detail fitting,fabrication of components, pressing)2.3material processing activities (such as heat treatment, casting,injection moulding, purification)2.4composite manufacture (such as wet lay-up, pre-preglaminating, resin infusion, blow moulding)2.5finishing activities (such as stripping finishes, painting, plating,anodising, veneering, lacquering)2.6assembly activities (such as mechanical, structural, fluidpower, electrical/electronic, woodworking)2.7installation activities (such as mechanical,electrical/electronic, avionic, structural, environmentalequipment)2.8plant and equipment (such as site preparation, plant layout,equipment changeover, equipment supply or replacement)2.9 equipment capability studies/performance measurement2.10 movement of materials, components or finished goods2.11 business improvement activities2.12 engineering safety audits or risk assessments2.13 quality control/quality assurance2.14 maintenance activities2.15 modification and repair activities2.16 testing and trialling2.17 research and development2.18 commissioning/decommissioning2.19 engineering support services
determine how their organisation can respond to therequirements in terms of workload and resources
Assess the implications of five of the following, in providing the products or services:3.1the technical capability of their organisation to provide theproducts or services requested3.2availability of resources (such as people, materials,equipment, facilities and utilities)3.3 costs and capital expenditure involved3.4 timescales to supply the products or services3.5 effects on current schedules3.6 environmental and health and safety implications3.7 legal implications (as applicable)3.8 training implications
provide the information in an appropriate format, usingrecognised and accepted conventions for terms andreferences
record and file relevant information, in accordance withorganisational requirements
Record and file product or service proposals containing all of the following:4.1 description of product or service required4.2 details of specification requirements4.3 customer requirements that may be difficult to meet4.4 delivery estimate4.5 workload schedule4.6 resources required4.7potential opportunities arising from the proposed supply ofthe product or service4.8 need vs benefit analysis
Carry out both of the following on completion of the activities:5.1 validation and evaluation of the systems and procedures used5.2identification of improvements that could be made to thesystems and procedures
Record the proposals, in accordance with organisational procedures, using one of the following:6.1 specific company documentation6.2 written or typed report6.3 electronic mail
maintain appropriate lev

Developing and Maintaining Effective Customer Relationships

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can develop and maintaineffective customer relationships, in accordance with the requirements of their organisationThey will understand the safety and environmental precautions required when carrying out their duties and theywill bear the precautions in mind when dealing with other people. They will also understand their responsibilitiesfor health and safety in their place of work, and the importance of taking the necessary safeguards to protectthemselves and others when they are working.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment.

Developing Visual Management Systems

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can develop and applying theprinciples and processes of visual management. They will need to understand the principles and procedures ofvisual management, and its application, in adequate depth to provide a sound basis for carrying out the activitiesto the required criteria.Applying safe working practices will be a key issue throughout.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment.

Diagnosing and rectifying faults in vehicle electrical and electronic systems

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following activities:1.1obtain and use the appropriate documentation (such as jobinstructions, assembly drawings, planning and quality controldocumentation)1.2adhere to procedures or systems in place for risk assessment,COSHH, personal protective equipment and other relevantsafety regulations and procedures to realise a safe system ofwork1.3obtain the correct tools and equipment for the activity andcheck they are in a safe, tested and usable condition, andwithin current calibration dates1.4follow safe practice/approved diagnostic and rectificationtechniques and procedures at all times1.5return all tools and equipment to the correct location oncompletion of the diagnostic activities1.6leave the work area and equipment in a safe and appropriatecondition on completion of the activities
review and use all relevant information on the symptoms andproblems associated with the equipment
investigate and establish the most likely causes of the faults
Carry out fault diagnosis of vehicle electrical systems, to include six of the following:2.1 safety systems2.2 heating and ventilating systems2.3 navigational systems2.4 control systems2.5 motors (such as wiper, starter)2.6 power-up systems2.7 lighting systems2.8 audio/entertainment systems2.9 braking system2.10 ignition system2.11 fuel management system2.12 ignition cut-out2.13 wheel torque instrumentation (prototype)2.14 engine calibration tools (prototype)2.15 exhaust emission control system
use and apply diagnostic techniques, tools and aids tolocate faults
Use a range of fault-diagnostic techniques, to include two of the following:3.1 emergent problem sequence3.2 signal injection and sampling3.3 input/output technique3.4 half-split technique3.5 six point technique3.6 computer-aided diagnostics3.7 function/performance3.8 equipment self-diagnostics
Use a variety of diagnostic aids and equipment, to include four of the following:4.1 manufacturers' manuals4.2 algorithms4.3 functional system check4.4 probability charts/reports4.5 audible recognition4.6 visual recognition4.7 multimeter4.8 voltage tester4.9 continuity tester4.10 ammeter4.11 computer-aided diagnostic equipment
Apply fault-diagnostic techniques to all the following type of conditions:5.1 breakdown5.2 computer indicated fault5.3 performance check
Carry out fault rectification, involving two of the following:6.1 component replacement6.2 component repair6.3 wire/loom repair
complete the fault diagnosis within the agreed time and informthe appropriate people when this cannot be achieved
use the evidence gained to draw valid conclusions about thenature and probable ca
use of the fault
rectify the identified faults using appropriate methods andtechniques
record details on the extent and location of the faults in anappropriate format
Provide a record of the outcome of fault diagnosis, using one of the following:7.1 step-by-step analytical report7.2 corrective action report7.3 record card system7.4 company-specific reporting procedure
Carry out diagnostic activities in line with one of the following standards:8.1 company standards and procedures8.2 equipment manufacturer's specifications8.3 customer standards and requirements8.4 specific system requirements
Describe the specific safety precautions to be taken whilst carrying out thevehicle electrical fault diagnosis (such as any specific legislation, regulationsor codes of practice relating to the activities, equipment or materials)K2 Outline the hazards associated with diagnosing and rectifying faults invehicle electrical and electronic systems, and how to minimise them andreduce any risks
Describe the health and safety requirements of the work area in which theyare carrying out the vehicle electrical fault diagnostic

Dressing prototype engines for test

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Dressing prototype engines for test
Apply practical skills, procedures and techniques in Dressing prototype engines for test
Evaluate performance, standards and best practices for Dressing prototype engines for test

Fabricating structural components for experimental vehicle engineering

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following during the fabrication of the structural components:1.1obtain and use the appropriate documentation (such as jobinstructions, assembly drawings, quality controldocumentation)1.2adhere to procedures or systems in place for risk assessment,COSHH, personal protective equipment and other relevantsafety regulations and procedures to realise a safe system ofwork1.3check that all cables, extension leads or air supply hoses are ina safe, tested and serviceable condition1.4check that all tools and equipment to be used are withincurrent calibration/certification dates1.5 obtain appropriate materials for the work in hand1.6mark out the components accurately, using recognisedconventions1.7set up and hold the components firmly during the fabricatingand shaping operations1.8use safe and approved fabrication techniques and proceduresat all times1.9return all tools and equipment to the correct location oncompletion of the activities1.10leave the work area in a safe and appropriate condition oncompletion of the activities
follow instructions and any relevant specifications to produce thecomponent
produce the required components using appropriatemanufacturing methods and techniques
Produce fabrications to meet one of the following experimental/development needs:2.1 new product development2.2 development of existing components2.3research into component characteristics (such asperformance, working life, response to environmentalconditions)S3 Produce fabricated components using two of the following materials:3.1 mild steel3.2 wrought iron3.3 alloy3.4 copper3.5 stainless steel3.6 brass3.7 aluminium3.8 other specific material
Produce fabrications using four of the following:4.1 section bar4.2 angle section4.3 channel section4.4 I section4.5 sheet/plate4.6 hollow section
Cut and prepare materials for fabrication, using six of the following:5.1 hand hacksaw5.2 grinder5.3 guillotine5.4 powered hacksaw5.5 files5.6 bending machine5.7 band saw5.8 punch/cropping machine5.9 tin snips5.10 hand power tool (such as sander, grinder, drill)5.11 pillar drill5.12 nibbling machine5.13 bench shears
Produce fabricated components which contain four of the following features:6.1 square/rectangular profiles6.2 curved profiles6.3 irregular profiles6.4 angled profiles6.5 bends6.6 drilled holes6.7 internal profiles6.8 box/tray sections
check that the finished component meets the requirements andmake any necessary adjustments
Produce cut and shaped components which meet all of the following quality and accuracy standards:7.1 company/customer standards/requirements7.2 dimensionally accurate (to drawing or specifications)7.3 free from distortion7.4 free from sharp edges, slivers or burrs
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 working withfabrication equipment and materials in a fabrication environment (generalworkshop and site safety, appropriate personal protective equipment,accident procedure; statutory regulations, risk assessment procedures andCOSHH regulations)K2 Describe the personal protective clothing and equipment (PPE) to be wornwhen carrying out the fabrication activities (gloves, eye/ear protection,safety helmets)K3 Describe the correct methods of moving or lifting materials
Describe the safe working practices and procedures to be observed whenusing manual and power-operated tools
Describe the hazards associated with carrying out fabrication work (such asusing dangerous or badly maintained tools and equipment, operatingguillotines and when using hand and bench shears), and how to minimisethem and reduce any risk
Explain the importance of applying the appropriate occupational beh

Flattening and Polishing Vehicle Bodies

Verified

Key Learning Objectives:

Learners will understand the safety precautions required when carrying out the flattening and polishing activities.They will be required to demonstrate safe working practices throughout and will understand the responsibilitythey owe to themselves and others in the workplace

Handing Over and Exchanging Responsibility for Control of Engineering Activities

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can hand over responsibilityand control of an engineering activity to the appropriate person, in accordance with approved procedures.They will be aware of any health, safety and environmental requirements applicable to their area ofresponsibility. They will be required to demonstrate safe working practices throughout, and will understand theresponsibility they owe to themselves and others in the workplace.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment.

Handling, Preparing, and Recycling Materials for Additive Manufacture

Verified

Key Learning Objectives:

Handling, Preparing, and Recycling Materials for Additive Manufacture

Implementing engineering activities

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Implementing engineering activities
Apply practical skills, procedures and techniques in Implementing engineering activities
Evaluate performance, standards and best practices for Implementing engineering activities

Implementing quality control systems and procedures in an engineering environment

Verified

Key Learning Objectives:

work safely at all times, complying with health and safetylegislation, regulations, directives and other relevant guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following during the quality control activities:1.1adhere to procedures or systems in place for risk assessment,COSHH, and other relevant safety regulations1.2obtain the required quality control specifications and relateddocuments1.3 obtain approval to carry out the quality control activities1.4ensure that all appropriate personnel are fully informed oftheir intended activities1.5use appropriate personal protective equipment for the area inwhich they are carrying out the quality control1.6ensure that test results and quality records are stored, in amanner suited to future audit or investigation
Implement quality assurance procedures for one of the following engineering activities:2.1drawing/design activities (such as mechanical,electrical/electronic, motor vehicle, aerospace, marine)2.2manufacturing activities (such as machining, detail fitting,fabrication of components, pressing)2.3material processing activities (such as heat treatment, casting,injection moulding, purification)2.4composite manufacture (such as wet lay-up, pre-preglaminating, resin infusion, blow moulding)2.5finishing activities (such as stripping finishes, painting, plating,anodising, veneering, lacquering)2.6assembly activities (such as mechanical, structural, fluidpower, electrical/electronic, woodworking)2.7installation activities (such as mechanical,electrical/electronic, avionic, structural, environmentalequipment)2.8plant and equipment (such as site preparation, plant layout,equipment changeover, equipment replacement)2.9 equipment capability studies/performance measurement2.10 movement of materials, components or finished goods2.11 engineering safety audits or risk assessments2.12 business improvement activities2.13 quality control/quality assurance2.14 maintenance activities2.15 modification and repair activities2.16 commissioning/decommissioning2.17 testing and trialling2.18 research and development2.19 engineering support services
Carry out all of the following, in preparation for the quality control activity:3.1 identify the product or process requiring quality control3.2 obtain the criteria for the quality control process3.3identify suitable quality control methods, techniques andprocedures3.4obtain appropriate documentation, tools and equipment forthe quality control activities to be undertaken3.5demonstrate and recommend the quality control process tothe appropriate people
obtain accurate information on the engineering products orprocesses that are to be quality controlled
Obtain suitable information about the product or process requiring quality control, from two of thefollowing:4.1 quality assurance staff4.2 product specifications4.3 manufacturers' manuals/specifications4.4 regulations and guidelines4.5 engineering drawings4.6 international/national standards
establish clear and precise criteria for the quality controlactivities to be undertaken
Ensure that the technical sales and marketing materials comply with one of the following:5.1 organisational guidelines and procedures5.2recognised compliance agency body standards, directive orcodes of practice5.3 British, European or International standards or directives5.4 customer standards and requirements5.5 health, safety and environmental requirements5.6variations in regional/global product specification andcompliance (such as language, units of measure and currency)P7pass on the technical details to the appropriate people withinagreed timescales
Explain how to access information on health and safety regulations andguidelines relating to the technical material being produced
Describe the implications of not taking account of legislation, regulations,standards and guidelines when specifying the technical details
Explain the importance of

Inspecting and testing electrical products

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following during the testing activities:1.1obtain and use the correct issue of company and/ormanufacturers' drawings and testing documentation1.2adhere to risk assessment, COSHH and other relevant safetystandards1.3check that test equipment is correctly calibrated andappropriate for test(s) to be carried out1.4provide safe access and working arrangements for the testingarea1.5carry out the inspection and testing activities, usingappropriate techniques and procedures1.6 operate test equipment within its specification range1.7apply adjustment of inspection results for temperaturecorrection (where applicable)1.8identify and record out-of-specification features, in theappropriate format1.9report and investigate the possibility of gaining a concessionfor out-of-specification products1.10place products in the correct location on completion of theinspection activities (in and out of specification)1.11leave the work area in a safe and tidy condition on completionof the activities
follow the appropriate procedures for use of tools andequipment to carry out the required tests/inspections
set up and carry out the tests/inspections using the correctprocedures and within agreed timescales
Carry out tests on two of the following types of electrical equipment:2.1 rotating equipment (such as motors, alternators)2.2 emergency power equipment2.3 power equipment (such as transformers/inductors).2.4 electrical plant2.5control equipment (such as switchgear, distributionequipment)2.6 alarm equipment2.7 bus bar systems2.8 process control equipment2.9 electrical panels2.10 communication equipment2.11 fans/blowers2.12 wiring looms/harnesses2.13 heating equipment2.14 vehicle control equipment2.15 portable tools/equipment2.16 power supplies2.17 white goods2.18 brown goods2.19 other specific electrical equipment
Carry out two of the following inspection procedures:3.1 first/one-off3.2 in-process/sample3.3 final inspection
Carry out visual inspection of electrical products, to include ensuring all of the following:4.1 all manufacturing/assembly procedures are complete4.2all components are correctly orientated, positioned andsecured4.3 all connections are mechanically secure4.4 products are free from damage or obvious defects
Carry out tests using four of following:5.1 oscilloscope5.2 insulation resistance tester5.3 ohmmeter5.4 loop impedance tester5.5 ammeter5.6 specialist test equipment.5.7 voltmeter (such as 2-pole voltage detector)5.8 current injection tester5.9 torque tester5.10 residual current device (RCD) tester5.11 flash tester5.12 portable appliance tester (PAT)5.13 multimeter5.14 EMC meter
Use the relevant test equipment to measure and check five of the following:6.1 protective resistance values6.2 polarity6.3 insulation resistance values6.4 capacitance6.5 current levels6.6 frequency values6.7 voltage detection/levels6.8 inductance6.9 continuity6.10 safety device trip speed6.11 power rating6.12specialised tests (such as speed, sound levels, temperature,interference)6.13 resistance
record the results of the tests in the appropriate format
review the results and carry out further tests if necessary
Check that the electrical products meet one of the following quality and accuracy standards:7.1 BS or ISO standards and procedures7.2 customer standards and requirements7.3 statutory regulations7.4 company standards and procedures7.5 specific system requirements.
Complete the relevant paper
work, using one of the following, and pass it to the appropriate person:8.1 inspection report8.2 customer specific documentation8.3 concession report8.4 job card.
Outline the specific safety precautions to be taken when inspecting andtesting electrical products (such as specific legislation or regulationsgoverni

Inspecting and testing electronic products

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Inspecting and testing electronic products
Apply practical skills, procedures and techniques in Inspecting and testing electronic products
Evaluate performance, standards and best practices for Inspecting and testing electronic products

Inspecting components using co-ordinate measuring machines (CMM)

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following during the inspecting activities:1.1obtain and use the correct issue of drawings, job instructionsand specifications1.2 follow specified and appropriate inspection procedures1.3identify and record any out-of-tolerance dimensions/features,in the appropriate format1.4investigate and obtain concessions for out-of-specificationproducts (where appropriate)1.5place products in the correct location on completion of theinspection activities (in and out of specification)1.6 shut down the equipment using the correct procedure1.7leave the work area in a safe and tidy condition on completionof the inspection activities
follow the correct specification for the product or equipmentbeing inspected
use the correct equipment to carry out the inspection activities
Use one of the following types manual and/or CNC co-ordinate measuring machines:2.1 vertical2.2 gantry/bridge2.3 horizontal2.4 other specific type
identify and confirm the inspection checks to be made andacceptance criteria to be used.
carry out all required inspections as specified
identify any defects or variations from the specification
Inspect one of the following types of engineering components/equipment:3.1 machined components3.2 castings3.3 mechanical assemblies/sub-assemblies3.4 forgings3.5 pressings3.6 overhauled components/products3.7 mouldings3.8 extrusions3.9 patterns3.10 other specific components/products
Mount the workpiece in a suitable position, using two of the following:4.1 directly to the machine table4.2 on parallels4.3 on angle plates4.4 on vee blocks4.5 in special jigs4.6 other mounting methods
Carry out two of the following inspection procedures:5.1 first/one-off5.2 in-process sample inspection5.3one hundred percent final inspection of components orproducts5.4 statistical quality control
Check all of the following, as applicable to the machine type:6.1check that datums for each machine axis are set in relation toequipment, components and probes selected6.2where applicable, download the CNC program into thecontroller, safely and correctly6.3select and mount suitable inspection probes for the differentfeatures to be checked6.4 calibrate the inspection probe (where applicable)6.5enter the probe information correctly into the machinecontroller/operating system6.6ensure that probe changes are carried out safely and clearfrom obstructions6.7check that all inspection operations and probe movementsare executed safely and correctly6.8ensure that any alterations to programs are communicatedfully to the appropriate personnel (where applicable)S7Inspect components/products that have a range of different features and cover twelve of thefollowing:7.1 diameters7.2 threads7.3 recesses7.4 internal diameters/bores7.5 eccentric features7.6 slots7.7 tapered diameters7.8 angular faces7.9 holes or slots on linear/angular pitch7.10 tapered bores7.11 internal profiles/forms/surfaces7.12 holes or slots on pitch circles7.13 shoulders and steps7.14 external profiles/forms/surfaces7.15 counterbored/countersunk holes7.16 linear dimensions (lengths)7.17 grooves/undercuts7.18 special forms (such as gear, spline, serrations)7.19 depths
Check four of the following geometric features:8.1 flatness8.2 straightness8.3 parallelism8.4 alignment8.5 position/location8.6 geometry8.7 squareness8.8 concentricity8.9 distortion8.10 ovality/lobing8.11 eccentricity8.12 surface finish
record the results of the inspection in the appropriate format
Complete inspection documentation to include one from the following and pass to the appropriatepeople:9.1 inspection report9.2 concession report9.3 job card9.4 customer specific documentation
deal promptly and effectively with problems within theircontrol and report those that cannot be solved.

Inspecting fabricated components and structures

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following activities during the inspection process:1.1observe all the required safety procedures for the workarea/activity1.2obtain and use the correct issue of drawings, job instructionsand specifications1.3obtain and check the condition and calibration dates of tools,measuring instruments and equipment used1.4place and coordinate temporary survey stations, whererequired (where applicable)1.5perform the dimensional survey and determine out-oftolerancevalues1.6apply adjustment of survey results for temperature correction(where applicable)1.7produce recommendations for control of final globaldimensions, using intermediate data (where applicable)1.8report and investigate the possibility of gaining a concessionfor out-of-specification products1.9leave the work area in a safe and tidy condition on completionof the activities
follow the correct specification for the product or equipmentbeing inspected
use the correct equipment to carry out the inspection
Carry out the inspection of two of the following types of fabrications:2.1 fabricated frames2.2 pipe sections2.3 transformers2.4 structures2.5 cylindrical components2.6 reduction pieces2.7 square/rectangular tanks2.8 conical components2.9 segmented bends2.10 curved/profiled structures2.11 tubular structures2.12 modular components2.13 trunking/ducting systems2.14 panels2.15 other specific fabrication
Carry out twelve of the following checks:3.1 dimensional accuracy3.2 straightness3.3 security of joints3.4 squareness3.5 position/location3.6 weld size and profile3.7 angle3.8 freedom from distortion/damage3.9 computation of best-fit centres3.10 alignment3.11 completeness3.12 prediction of erection positions3.13 circularity or ovality3.14 flatness3.15 development of cut lines3.16 visual appearance3.17 orientation3.18computation of allowances for weld gap tolerances and weldshrinkage for attainment of global tolerances3.19 practical allowances for expansion and contraction
Use six of the following types of inspection equipment:4.1 rules and tapes4.2 protractors4.3 rafter squares4.4 squares4.5 plumb lines4.6 templates and jigs4.7 spirit levels4.8 callipers4.9 theodolites4.10 dividers4.11 vernier instruments4.12 laser equipment4.13 gauges4.14 torque instruments4.15 total station (electronic theodolite)4.16 automatic levelling equipment
identify and confirm the inspection checks to be made andacceptance criteria to be used
carry out all required inspections as specified
identify any defects or variations from the specification
Carry out the inspection checks to one of the following quality and accuracy standards:5.1 approved construction drawings5.2 applicable national and international standards5.3 client specifications/detail drawings
record the results of the inspection in the appropriate format
Complete inspection documentation, to include one from the following, and pass to the appropriatepeople:6.1 inspection report6.2 customer specific documentation6.3 job card6.4 concession report
deal promptly and effectively with problems within theircontrol and report those that cannot be solved
Outline the specific safety precautions to be taken when inspectingfabricated components (specific legislation or regulations governing theactivities or work area, safe working practices and procedures to beadopted, general workshop safety practice, relevant sections of COSHHK2 Describe the personal protective clothing and equipment (PPE) that shouldbe worn (such as leather gloves, eye protection, ear protection, safetyharness)K3 Describe the hazards associated with inspecting fabricated products (suchas working at height, handling fabricated structures, slips, trips and falls),and how they can be minimised
Explain the importance of applying the a

Inspecting mechanical products

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following during the inspecting activities:1.1obtain and use the correct issue of drawings, job instructionsand specifications1.2obtain and check the condition and calibration dates of tools,measuring instruments and equipment to be used1.3 follow specified or appropriate inspection procedures1.4use the correct and appropriate tools and equipment at alltimes1.5apply adjustment of inspection results for temperaturecorrection (where applicable)1.6identify and record out-of-specification features, in theappropriate format1.7investigate and, where appropriate, obtain a concession forout-of-specification products1.8place products in the correct location on completion of theinspection activities (in and out of specification)1.9leave the work area in a safe and tidy condition on completionof the activities
follow the correct specification for the product or equipmentbeing inspected
Inspect one of the following types of mechanical product:2.1 machined components2.2 castings2.3 extrusions2.4 mechanical assemblies/sub-assemblies2.5 forgings2.6 patterns2.7 pressings2.8 overhauled products.2.9 mouldings2.10 treated/coated components2.11 other specific mechanical product
use the correct equipment to carry out the inspection
identify and confirm the inspection checks to be made andacceptance criteria to be used
carry out all required inspections as specified
Carry out two of the following inspection procedures:3.1 first/one-off3.2one hundred percent final inspection of components orproducts3.3 in-process sample/patrol inspection3.4 random/selective sampling of finished components or product3.5 statistical quality control
Inspect mechanical products, using twelve of the following:4.1 rule or tape4.2 gap gauge4.3 surface texture comparison plates4.4 external micrometer4.5 feeler gauge4.6 surface texture measuring machines4.7 internal micrometer4.8 hole gauge4.9 optical equipment (such as shadowgraphs, microscopes)4.10 depth micrometer4.11 thread gauge4.12 height micrometer4.13 thread wires4.14 temperature gauges4.15 specialist micrometers4.16 slip gauge4.17 flow meters4.18 length vernier4.19 protractors4.20 pressure gauges4.21 depth vernier4.22 sine bar or table4.23 co-ordinate measuring machines (CMM)4.24 height vernier4.25 dial test indicator4.26 electrical measuring equipment4.27 straight edge4.28 radius/profile gauges4.29 visual checks for appearance and completion4.30 engineer's square4.31 torque wrench4.32 inclinometer4.33 other specific equipment
Use the relevant equipment to measure and check twelve of the following features:5.1 external diameters5.2 thread fit5.3 holes or slots on linear/angular pitch5.4 internal diameters/bores5.5 thread form/profile5.6 special forms (such as gear, spline, serrations)5.7 length/linear dimensions5.8 internal profiles/forms/surfaces5.9 shoulders and steps5.10 external profiles/forms/surfaces5.11 fit/working clearance5.12 depth5.13 angular faces5.14 physical properties (such as hardness)5.15 internal tapers5.16 chamfers and radii5.17 bonding strength5.18 external tapers5.19 grooves/undercuts5.20 coating thickness5.21 eccentric features5.22 counterbored/countersunk holes5.23 torque5.24 recesses5.25 holes or slots on pitch circles5.26 electrical characteristics5.27 slots
Use appropriate equipment to check eight of the following geometric features:6.1 flatness6.2 position/location6.3 verticality6.4 alignment6.5 orientation6.6 parallelism6.7 squareness6.8 concentricity6.9 geometry6.10 ovality/lobing6.11 eccentricity6.12 distortion6.13 straightness6.14 level6.15 surface finish
identify any defects/flaws or variations from the specification
record the results of the inspection in the appropriate format
Complete inspection documentation, to include one f

Installing electrical/electronic engine/transmission control units to prototype vehicles

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Installing electrical/electronic engine/transmission control units to prototype vehicles
Apply practical skills, procedures and techniques in Installing electrical/electronic engine/transmission control units to prototype vehicles
Evaluate performance, standards and best practices for Installing electrical/electronic engine/transmission control units to prototype vehicles

Loading and proving computer control programs

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Ensure that they apply all of the following checks and practices during the programming activities:1.1the correct operating program is obtained and checked forcurrency and validity1.2the machine controller is prepared, ready to accept theoperating program1.3 the program is loaded into the controller, safely and correctly1.4program media is stored safely and correctly, away fromcontaminants or sources of corruption
use the correct control program and ensure it is correctlyloaded into the machine controller
Load and prove programs for one of the following types of computer control equipment:2.1 CNC machine tools2.2 industrial robots2.3 co-ordinate measuring machines2.4 PLC equipment
Obtain and load programs stored on one of the following mediums:3.1 remote or networked computer terminal3.2 machine controller3.3 personal computers3.4 tape (such as punched or magnetic)3.5 handheld programmers3.6 disk3.7 other specific media
follow the correct procedures for calling up the program anddealing with any error messages or faults
confirm program integrity
Operate the controller using six of the following, as applicable to the equipment type:4.1 use single step/single block run mode of operation4.2 graphic displays4.3 full dry run4.4 search facilities4.5 program save/store facilities4.6 edit facilities4.7 program override controls (speed, feed, tool data)4.8 data input facilities4.9 data output peripherals (such as printers)4.10 speed and acceleration parameters
adjust the equipment and program operating parameters tooptimise the outcomes to be achieved
load and correctly set-up all associated equipment
check that all safety mechanisms are in place and that theequipment is set correctly for the required operations
Confirm that the equipment and program operates safely and correctly by carrying out thefollowing, as applicable to the type of equipment used:either carry out all of the following:5.1check that datums for each axis are set in relation to theequipment/component and tooling used5.2 ensure that start-up positions are safe and correctly set5.3ensure that tooling information is correctly entered into themachine controller (such as type, number, position)5.4check that tooling change positions are safe and clear of theworkpiece and other devices (such as clamps, jigs and fixtures)5.5ensure that the correct tooling is selected at the appropriatepoints in the program5.6check that tooling/operational paths are executed safely andcorrectly5.7ensure that all operations are carried out to the program coordinates5.8 save edited programs5.9 produce back-up copies of completed programs5.10ensure that any alterations to programs are communicatedfully to the appropriate personnelor carry out all of the following:5.11force contacts `on' and `off' and check for correct operation ofperipherals5.12edit, enter and remove contacts from lines of logic, whereappropriate5.13 check counter and timer settings5.14 save edited programs5.15 produce back-ups of completed programs5.16ensure that any alterations to programs are communicatedfully to the appropriate personnelor carry out all of the following:5.17confirm that the robot operates within the defined operatingenvironment/envelope/cell layout5.18 ensure that start-up positions are safe and correctly set5.19check that intrusion monitoring systems are operatingcorrectly (where appropriate)5.20 check that robot operations are executed safely and correctly5.21 monitor and review cycle times5.22ensure that all operations are carried out to program coordinates5.23 save edited programs5.24 produce back-ups of completed programs5.25ensure that any alterations to programs are communicatedfully to the appropriate personnel
Maintain appropriate records of program proving activities

Machining and hand sewing of vehicle trim components

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following during the sewing activities:1.1obtain and use the appropriate documentation (such as jobinstructions, trim assembly drawings, quality controldocumentation)1.2adhere to procedures or systems in place for risk assessment,COSHH, personal protective equipment and other relevantsafety regulations and procedures to realise a safe system ofwork1.3check that all cables, extension leads or air supply hoses arein a tested and serviceable condition1.4check that all tools and equipment to be used are withincurrent calibration/certification dates1.5ensure that trim materials and components used are freefrom damage, foreign objects, dirt or other contaminationbefore assembling them1.6use safe and approved sowing techniques to assemble thetrim components1.7return all tools and equipment to the correct location oncompletion of the sowing activities1.8leave the work area in a safe and appropriate condition oncompletion of the activities
follow the relevant instructions, assembly drawings and anyother specifications
ensure that the specified components are available and thatthey are in a usable condition
Select material, and hand/machine sew vehicle trim components, to include all of the following:2.1 straight seams2.2 curved seams2.3 pattern matching
use the appropriate methods and techniques to assemble thecomponents in their correct positions
secure the components using the specified connectors andsecuring devices
Use a variety of manufacturing methods and techniques, to include three of the following:3.1 single needle technique3.2 adhesives3.3 stretch/elasticised fabrics3.4 double needle technique3.5 fitting piping3.6 fixed edge width assemblies3.7 multi-needle technique3.8 welding plastics
Select and prepare material to be sewn, to include two of the following:4.1 leather4.2 wool4.3 velour4.4 nylon4.5 cotton4.6 linz4.7 moquette4.8 PVC4.9 foams/composites
Sew the trim components, selecting and using the appropriate equipment, to include four of thefollowing:5.1 sewing machine5.2 over lockers5.3 needles5.4 plastic welding device5.5 spools5.6 bobbins5.7 threads5.8 alignment devices5.9 cutting devices5.10 sewing feet
Sew vehicle trim components, to include two of the following:6.1 door pad covers6.2 rear cushion covers6.3 floor console covers6.4 front seat covers6.5 roof linings6.6 arm rest covers6.7 rear squab covers6.8 visor covers
check the completed assembly to ensure that all operationshave been completed and the finished assembly meets therequired specification
Produce trim assemblies which comply with all of the following quality and accuracy standards:7.1 the assembly of trim components is complete7.2 where appropriate, pattern matches are achieved7.3 the assembly is free from damage, cuts, adhesive and marks7.4 surplus material has been removed and components are clean7.5 all quality control checks have been achieved
deal promptly and effectively with problems within theircontrol and report those that cannot be solved.
Describe the specific safety precautions to be taken whilst carrying out themachine and hand sewing of vehicle trim components (including any specificlegislation, regulations or codes of practice relating to the activities,equipment or materials)K2 Outline the health and safety requirements of the work area in which theyare carrying out the machine and hand sewing of vehicle trim components,and the responsibility these requirements place on them
Describe the personal protective equipment and clothing to be worn (PPE)during the machine and hand sewing of vehicle trim components activities
Describe the specific safety requirements relating to the use of sewingmachines
Describe the hazards associated with sewing vehicle trim components (suchas using nee

Machining components for experimental vehicle engineering

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following during the machining activities:1.1obtain and use the appropriate documentation (such as jobinstructions, drawings, quality control documentation)1.2adhere to procedures or systems in place for risk assessment,COSHH, personal protective equipment and other relevantsafety regulations and procedures to realise a safe system ofwork1.3 ensure that machine guards are in place and correctly adjusted1.4 hold components securely without distortion1.5 maintain cutting tools in a suitable condition1.6 apply safe working practices at all times1.7 ensure that components produced meet specification1.8leave the work area and machine in a safe and appropriatecondition on completion of the activities
confirm that the machine is set up and ready for the machiningactivities to be carried out
Produce components for experimental vehicle development by carrying out both of the following:2.1 modifying existing components2.2 producing new components
manipulate the machine tool controls safely and correctly inline with operational procedures
Produce machined components using three of the following machining processes:3.1 turning3.2 milling3.3 grinding3.4 drilling3.5 spark/wire erosion3.6 shaping or slotting3.7 other specific process
Use a range of workholding devices, to include five of the following:4.1 3-jaw chucks4.2 vee blocks4.3 magnetic plates4.4 special fixtures4.5 4-jaw chucks4.6 clamping4.7 indexing devices4.8 collet chucks4.9 machine vices4.10 arrangements4.11 face plates4.12 angle plates
Produce machined components which cover seven of the following features:5.1 external diameters5.2 threads5.3 slots/recesses5.4 internal diameters5.5 circular/curved/radial profiles5.6 drilled/bored/reamed holes5.7 lengths/depths5.8 faces that are square to each other5.9 concave or convex forms5.10 flat faces5.11 angular/tapered surfaces5.12 special forms5.13 parallel faces5.14 steps/shoulders
Machine three different types of material from:6.1 low carbon steel6.2 aluminium6.3 plastic/synthetic6.4 high carbon steel6.5 brass6.6 composite6.7 stainless steel6.8 bronze6.9 special steels or alloys6.10 cast iron6.11 other specific material
produce components to the required quality and within thespecified dimensional accuracy
Produce components within all of the following standards, as applicable to the operations performed:7.1components to be free from false tool cuts, burrs and sharpedges7.2dimensional tolerance equivalent to BS EN 20286 or BS 1916Grade 97.3 surface finish 63 'in or 1.6'm7.4 reamed and bored holes within H87.5 screw threads BS medium fit7.6 angles within +/- 0.5 degree
carry out quality sampling checks at suitable intervals
Carry out all necessary checks for dimensional accuracy, to include four of the following:8.1 dimensions8.2 thread size and fit8.3 angles8.4 hole size/fit8.5 flatness/squareness8.6 profile8.7 concentricity8.8 quality of surface finish
deal promptly and effectively with problems within theircontrol and report those that cannot be solved
shut down the equipment to a safe condition on conclusion ofthe machining activities
Describe the health and safety requirements of the area in which they arecarrying out the machining activities
Explain the importance of wearing protective clothing and equipment (PPE),and of keeping the work area safe and tidy
Describe the specific health and safety precautions to be followed whilstcarrying out the machining activities
Describe the hazards associated with carrying out machining activities, andhow to minimise them and reduce any risk

Making vehicle trim prototypes and patterns

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following during the manufacture of the vehicle trim prototypes and patterns:1.1obtain and use the appropriate documentation (such as jobinstructions, trim/prototype pattern drawings, quality controldocumentation)1.2adhere to procedures or systems in place for risk assessment,COSHH, personal protective equipment and other relevantsafety regulations and procedures to realise a safe system ofwork1.3check that all cables, extension leads or air supply hoses arein a tested and serviceable condition1.4check that all tools and equipment to be used are withincurrent calibration/certification dates1.5ensure that trim/pattern materials and components used arefree from damage, foreign objects, dirt or othercontamination before using them1.6use safe and approved techniques to manufacture the trimprototypes and patterns1.7return all tools and equipment to the correct location oncompletion of the activities1.8leave the work area in a safe and appropriate condition oncompletion of the activities
follow instructions and any relevant specifications to producethe component
Produce patterns and prototypes to meet two of the following vehicle development needs:2.1 hard trim (such as plastics, wood, metal)2.2 soft trim (such as carpets, linings, foams)2.3 associated fixing components
produce the required components using appropriatemanufacturing methods and techniques
Use a variety of manufacture methods and techniques, to include four of the following:3.1 development of a pattern3.2 adhering3.3 cutting and preparing hard or soft trim materials3.4 stapling3.5 sewing by hand or machine3.6 plastic welding3.7 modelling/shaping fibreglass3.8 developing substrates
prepare and use a range of material in the construction, to include three of the following:4.1 paper/card4.2 foam4.3 PVC4.4 leather4.5 fibreglass4.6 composites4.7 cloth (wool, cotton, nylon)4.8 ABS plastic4.9 wood4.10 laminates
Make prototype trim components using three of the following devices:5.1 clamping devices5.2 wood machines5.3 bucks5.4 fixtures and fixings5.5 alignment devices5.6 jigs5.7 clip/stapling devices5.8 sewing machines
Produce trim prototypes for two of the following vehicle sub-assemblies:6.1 door pads6.2 carpets6.3 roof linings6.4 front seat6.5 floor console6.6 headrests6.7 rear seat6.8 door panels6.9 fibreglass substrates6.10 audio/visual housings6.11 arm rests6.12 other specific items
check that the finished component meets the requirements andmake any necessary adjustments
Produce patterns and prototypes which comply with all of the following quality and accuracystandards:7.1all components are free from damage, tool marks and cuts,and adhesives7.2 where appropriate, pattern match has been achieved7.3all quality control checks have been carried out and therequired standards achieved7.4 the prototype meets the required specification
deal promptly and effectively with problems within their control and
report those that cannot be solved
Describe the health and safety requirements of the area in which they arecarrying out the building of prototype trim assemblies
Explain the importance of wearing protective clothing and other appropriatesafety equipment (PPE), and of keeping the work area safe and tidy
Describe the specific health and safety precautions to be followed for liftingand handling trim components and other components during themanufacturing process
Describe the specific safety requirements relating to the use of trimmingassembly machines
Describe the hazards associated with making prototype trim componentsand patterns (such as using cutters, machines, staplers), and how tominimise them and reduce any risks
Explain the importance of applying the appropriate occupational behavioursin the workplace

Manufacturing vehicle composite mouldings using pre-preg laminating techniques

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Manufacturing vehicle composite mouldings using pre-preg laminating techniques
Apply practical skills, procedures and techniques in Manufacturing vehicle composite mouldings using pre-preg laminating techniques
Evaluate performance, standards and best practices for Manufacturing vehicle composite mouldings using pre-preg laminating techniques

Marking out components for experimental vehicle engineering

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following during the marking out activities:1.1obtain and use the appropriate documentation (such as jobinstructions, drawings, quality control documentation)1.2adhere to procedures or systems in place for risk assessment,COSHH, personal protective equipment and other relevantsafety regulations and procedures to realise a safe system ofwork1.3follow safe practice/approved marking out procedures at alltimes1.4check that all tools and measuring equipment are withincurrent calibration/certification dates1.5return all tools and equipment to the correct location oncompletion of the marking out activities1.6leave the work area in a safe and appropriate condition oncompletion of the activities
obtain and use the correct information for marking out
obtain the appropriate marking out equipment and check that itis in a usable condition
prepare suitable datum and marking out surfaces
Mark out a range of material forms, to include three of the following:2.1 specific vehicle components2.2 round/cylindrical sections2.3 irregular-shaped items2.4 flat or sheet materials2.5 quadrilateral section2.6 angle section2.7 machined items2.8 channel and I sections2.9 assemblies2.10 castings/forgings
mark out using appropriate methods
Use marking out methods and techniques, which include one of the following:3.1 direct marking using instruments3.2 use of templates3.3 tracing/transfer methods
Use a range of marking out equipment, to include four of the following:4.1 rules/tapes4.2 scribing blocks4.3 protractors4.4 dividers/compasses4.5 squares4.6 vernier instruments4.7 scribers4.8 depth gauges4.9 trammels4.10 angle plates4.11 laser equipment4.12 other specific equipment
Mark out workpieces which include five of the following features:5.1 datums/centre lines5.2 square/rectangular profiles5.3 angles/angular profiles5.4 radial hole positions5.5 linear hole positions5.6 simple pattern development5.7 allowances for bending
check that the marking out complies with the specification
Mark out workpieces which comply with all of the following quality and accuracy standards, asapplicable to the operation:6.1 dimensionally accurate (to drawing/specification or sketch)6.2 clearly defined for required processes6.3 use recognised marking out conventions6.4meet the requirements of the experimental/developmentprocess6.5 meet cutting out/machining requirements
deal promptly and effectively with problems within their control and
report those that cannot be resolved.
Describe the health and safety requirements of the area in which they arecarrying out the marking out process
Explain the importance of wearing protective clothing and other appropriatesafety equipment (PPE), and of keeping the work area safe and tidy
Describe the specific health and safety precautions to be followed for liftingand handling components and associated holding devices during themarking out process
Describe the hazards associated with carrying out marking out activities, andwith the equipment, materials and consumables used, and how to minimisethem and reduce any risks
Explain the importance of applying the appropriate occupational behavioursin the workplace and the implications for both the learner and the businessif these are not adhered to

Monitoring engineering activities

Verified

Key Learning Objectives:

demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following during the monitoring activities:1.1obtain the necessary specifications and documents requiredfor the monitoring process1.2 obtain approval to carry out the monitoring activities1.3ensure that all appropriate personnel are fully informed oftheir intended activities1.4use appropriate personal protective equipment for the area inwhich they are carrying out the monitoring activities1.5 apply safe working practices and procedures at all times1.6 ensure that by-products and waste are disposed of correctly1.7ensure any problems are resolved as they occur following thedefined monitoring procedures at all times
monitor the operational processes at suitable opportunities
monitor the supply and use of resources to ensure that they areeffectively used
Carry out the monitoring activities on one of the following engineering activities:2.1drawing/design activities (such as mechanical,electrical/electronic, motor vehicle, aerospace, marine)2.2manufacturing activities (such as machining, detail fitting,fabrication of components, pressing)2.3material processing activities (such as heat treatment, casting,injection moulding, purification)2.4composite manufacture (such as wet lay-up, pre-preglaminating, resin infusion, blow moulding)2.5finishing activities (such as stripping finishes, painting, plating,anodising, veneering, lacquering)2.6assembly activities (such as mechanical, structural, fluidpower, electrical/electronic, woodworking)2.7installation activities (such as mechanical,electrical/electronic, avionic, structural, environmentalequipment)2.8plant and equipment (such as site preparation, plant layout,equipment changeover, equipment replacement)2.9 equipment capability studies/performance measurement2.10 movement of materials, components or finished goods2.11 engineering safety audits or risk assessments2.12 business improvement activities2.13 quality control/quality assurance2.14 maintenance activities2.15 modification and repair activities2.16 commissioning/decommissioning2.17 testing and trialling2.18 research and development2.19 engineering support services
Obtain relevant information from the appropriate sources, to include two of the following:3.1 work orders3.2 planning documentation3.3 contracts3.4 quality standards3.5 plans/designs3.6 equipment or materials supplier information3.7 purchase orders3.8 schedules3.9 standard operating procedures3.10 production control documentation
confirm that the materials used during the operationalprocesses comply with specifications
confirm that suitable operational methods and procedureshave been used
During the monitoring activity
carry out all of the following:4.1ensure there is an effective supply and use of resources (suchas people, materials, equipment)4.2verify that materials or equipment used are withinspecification4.3evaluate the outputs of the engineering process, and comparethese with specifications4.4 record any deviations from agreed plans and schedules4.5confirm that all relevant regulations, directives and guidelinesare complied with4.6 ensure that relevant people are kept informed
Monitor the engineering activity, using two of the following techniques:5.1 scheduled5.2 random5.3 reactive
Use two of the following during the monitoring activity:6.1 resource supply (such as materials, equipment and people)6.2 observation6.3 data collection6.4 sampling
identify any variations from agreed plans and schedules
ensure that any problems with the operational processes areidentified and solved promptly
Carry out all of the following on completion of the monitoring activities:7.1validation and evaluation of the monitoring systems andprocedures used7.2suggested improvements to their process of monitoring theengineering activity7.3recommendations for improvements or changes to theengineering activities that were monitored
ensure that the outp

Obtaining and controlling materials for engineering activities

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Obtaining and controlling materials for engineering activities
Apply practical skills, procedures and techniques in Obtaining and controlling materials for engineering activities
Evaluate performance, standards and best practices for Obtaining and controlling materials for engineering activities

Obtaining resources for engineering activities

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Obtaining resources for engineering activities
Apply practical skills, procedures and techniques in Obtaining resources for engineering activities
Evaluate performance, standards and best practices for Obtaining resources for engineering activities

Operating an industrial Additive Manufacturing Machine

Verified

Key Learning Objectives:

Operating an industrial Additive Manufacturing Machine

Planning engineering activities

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Planning engineering activities
Apply practical skills, procedures and techniques in Planning engineering activities
Evaluate performance, standards and best practices for Planning engineering activities

Preparing mechanical testing equipment

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following during the preparation of the testing equipment:1.1comply with job instructions/techniques, equipment settingup documentation, testing specifications, relevant COSHHsheets and risk assessment documentation1.2 use appropriate personal protective equipment1.3follow the defined setting-up procedures/techniques, and
apply safe working practices and procedures at all times1.4leave the work area in a safe and tidy condition on completionof the activities
obtain all the required equipment and ensure that it is in safeand usable condition
Prepare one of the following types testing equipment for use:2.1 tensile2.2 compression2.3 impact2.4 hardness2.5 bending2.6 other specific type of testing equipment
carry out the necessary preparations to equipment (set up,check, adjust) in line with work requirements/techniques
Prepare one of the following types of testing equipment in readiness for use:3.1 manual3.2 semi-automatic3.3 fully automatic
make sure that required safety arrangements are in place toprotect other workers from activities likely to disrupt normalworking
Set up, check and adjust the equipment, to include carrying out all of the following:4.1 obtaining all necessary cables and fittings4.2checking that all electrical connections, cables and fittings aresecure and in a safe condition (as appropriate)4.3checking that all mechanical linkages and connections aresecure and in a safe condition4.4obtaining appropriate sample mounting clamps or fixtures (asappropriate)4.5 obtaining the necessary conversion documents4.6 functionally operate the equipment
report completion of preparations in line with organisationalprocedures
deal promptly and effectively with problems within theircontrol and report those that cannot be solved
Outline the specific safety precautions to be taken when setting up testingequipment
Describe the hazards associated with setting up the testing equipment (suchas electrical contact, fast moving mechanical parts, stored pressures/forces,temperatures) and how they can be minimised
Describe the type of personal protective equipment (PPE) to be used, andhow to obtain it
Explain the importance of applying the appropriate occupational behavioursin the workplace and the implications for both the learner and the businessif these are not adhered to
Explain how to obtain the necessary job instructions/techniques, equipmentsetting-up procedures and testing specifications, and how to interpret theirinformation
Explain the importance of testing product materials using testing methods
Explain why products may need to be tested by a range of different testingmethods (such as tensile, compression, hardness, impact and bending)K8 Describe the basic principles of testing
Outline the basic components of the testing equipment (such as displaypanel, safety devices, power sources, recording mechanisms)K10 Describe the different types of testing methods (such as tensile,compression, hardness, impact and bending) and what materialcharacteristics they are measuring

Preparing Vehicle Body Surfaces for Finishing

Verified

Key Learning Objectives:

They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment

Producing a Characteristic Selection Matrix

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can produce a characteristicselection matrix.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment.

Producing Contractual Arrangements to Supply or Procure Goods or Services for Engineering Activities

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can produce contractualarrangements to supply or procure goods or services such as materials, components, services, facilities,equipment or people to customers, in accordance with approved proceduresThey will be aware of any company, legislative or regulatory health, safety and environmental requirementsapplicable to the engineering activities for which the tender is being supplied. They will be required todemonstrate safe working practices throughout, and will understand the responsibility they owe to themselvesand others in the workplace.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment.

Producing electrical engineering drawings using computer aided techniques

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Producing electrical engineering drawings using computer aided techniques
Apply practical skills, procedures and techniques in Producing electrical engineering drawings using computer aided techniques
Evaluate performance, standards and best practices for Producing electrical engineering drawings using computer aided techniques

Producing engineering drawings/models using 3D computer aided techniques.

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Producing engineering drawings/models using 3D computer aided techniques.
Apply practical skills, procedures and techniques in Producing engineering drawings/models using 3D computer aided techniques.
Evaluate performance, standards and best practices for Producing engineering drawings/models using 3D computer aided techniques.

Producing engineering systems/services drawings using computer aided techniques

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Producing engineering systems/services drawings using computer aided techniques
Apply practical skills, procedures and techniques in Producing engineering systems/services drawings using computer aided techniques
Evaluate performance, standards and best practices for Producing engineering systems/services drawings using computer aided techniques

Producing mechanical engineering drawings using computer aided techniques

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Producing mechanical engineering drawings using computer aided techniques
Apply practical skills, procedures and techniques in Producing mechanical engineering drawings using computer aided techniques
Evaluate performance, standards and best practices for Producing mechanical engineering drawings using computer aided techniques

Producing Multi-Variance Charts

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can produce multi-variancechartsThey will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment

Producing off-line programs for CNC boring machines

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Producing off-line programs for CNC boring machines
Apply practical skills, procedures and techniques in Producing off-line programs for CNC boring machines
Evaluate performance, standards and best practices for Producing off-line programs for CNC boring machines

Producing off-line programs for CNC electro-discharge machines

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Producing off-line programs for CNC electro-discharge machines
Apply practical skills, procedures and techniques in Producing off-line programs for CNC electro-discharge machines
Evaluate performance, standards and best practices for Producing off-line programs for CNC electro-discharge machines

Producing off-line programs for CNC fabrication machines

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Producing off-line programs for CNC fabrication machines
Apply practical skills, procedures and techniques in Producing off-line programs for CNC fabrication machines
Evaluate performance, standards and best practices for Producing off-line programs for CNC fabrication machines

Producing off-line programs for CNC gear cutting machines

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Producing off-line programs for CNC gear cutting machines
Apply practical skills, procedures and techniques in Producing off-line programs for CNC gear cutting machines
Evaluate performance, standards and best practices for Producing off-line programs for CNC gear cutting machines

Producing off-line programs for CNC grinding machines

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Producing off-line programs for CNC grinding machines
Apply practical skills, procedures and techniques in Producing off-line programs for CNC grinding machines
Evaluate performance, standards and best practices for Producing off-line programs for CNC grinding machines

100

Producing off-line programs for CNC laser profiling machines

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following in preparation for the CNC programming:1.1check that all the equipment is correctly connected, and is in asafe, tested and usable condition (such as cables undamaged,correctly connected, safely routed)1.2power up the equipment and activate the programmingsoftware1.3set up the computer system to be able to produce theprogram1.4ensure that they have the necessary component data andinformation to produce the program1.5identify and deal with problems (such as information basedand/or technical)P3produce computer control programs that contain all therelevant and necessary data for the engineering activity to becarried out
produce the control programs in the appropriate formats
make sure that codes and other references used in theprograms are applicable to the type of controller used
Produce programs using one of the following methods:2.1 computer aided machining (CAM)2.2 conversational code2.3 G code2.4 other specific method (such as macros)S3 Carry out all of the following, as applicable to the programming method selected:3.1import the component data file, and/or produce theshape/geometry of the component3.2 select a suitable or specified datum point3.3 select absolute and/or incremental system of measurement3.4 select imperial or metric system of measurement3.5 input the safe start position3.6 input material parameters3.7 select appropriate reference codes3.8 input required positional information3.9input cutting parameters (such as beam intensity, direction,feed in/out)3.10input preparatory commands and machinemanagement/auxiliary functions3.11use repetitive programs (sub-routines, canned cycles, labels,macros)3.12 determine the cutting path order and sequence3.13input any additional information (such as a work-shiftposition)3.14 convert the program into the correct format (post processing)S4Produce laser cutting/profiling programs, combining different operations that will produce seven ofthe following features:4.1 square/rectangular profiles4.2 circles4.3 holes radially positioned4.4 angular profiles4.5 ellipses4.6 slots and apertures4.7 curved profiles4.8 holes linearly positioned4.9 other specific features
pass on the programs to the appropriate people, withinagreed timescales
save and back up the program detail, and store securely inaccordance with organisational requirements
undertake changes to program details, within agreed controlprocedures
Carry out all of the following on completion of the programming activity:5.1 check and review the program format and content5.2edit the program using the correct procedure (whereappropriate)5.3 check that the program is correctly titled and referenced5.4ensure that programs are stored safely and correctly, in thecorrect format and location5.5ensure that the program has been checked and approvedbefore forwarding to the end user5.6send the approved program to the correct location for the enduser5.7create a separate back-up copy of the program, in case of filecorruption or accidental deletion.
Outline the specific safety precautions to be taken when working withcomputer systems (to include safety guidance relating to the use of visualdisplay unit (VDU), equipment and workstation environment (such aslighting, seating, positioning of equipment), repetitive strain injury (RSI); thedangers of trailing leads and cables; how to spot faulty or dangerouselectrical leads, plugs and connections)K2 Outline good housekeeping arrangements (such as cleaning down worksurfaces; putting media, manuals and unwanted items of equipment intosafe storage; leaving the work area in a safe and tidy condition)K3 Explain the importance of applying the appropriate occupational behavioursin the workplace and the implications for both the learner and the business

101

Producing off-line programs for CNC machining centres

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Producing off-line programs for CNC machining centres
Apply practical skills, procedures and techniques in Producing off-line programs for CNC machining centres
Evaluate performance, standards and best practices for Producing off-line programs for CNC machining centres

102

Producing off-line programs for CNC milling machines

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Producing off-line programs for CNC milling machines
Apply practical skills, procedures and techniques in Producing off-line programs for CNC milling machines
Evaluate performance, standards and best practices for Producing off-line programs for CNC milling machines

103

Producing off-line programs for CNC turning machines

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Producing off-line programs for CNC turning machines
Apply practical skills, procedures and techniques in Producing off-line programs for CNC turning machines
Evaluate performance, standards and best practices for Producing off-line programs for CNC turning machines

104

Producing off-line programs for programmable logic controller equipment

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Producing off-line programs for programmable logic controller equipment
Apply practical skills, procedures and techniques in Producing off-line programs for programmable logic controller equipment
Evaluate performance, standards and best practices for Producing off-line programs for programmable logic controller equipment

105

Producing operating programs for co-ordinate measuring machines (CMM)

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Producing operating programs for co-ordinate measuring machines (CMM)
Apply practical skills, procedures and techniques in Producing operating programs for co-ordinate measuring machines (CMM)
Evaluate performance, standards and best practices for Producing operating programs for co-ordinate measuring machines (CMM)

106

Producing operating programs for industrial robots:

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Ensure that they apply all of the following checks and practices during the robot programming activities:1.1 check that all the teach pendant/computer equipment iscorrectly connected, and is in a safe, tested and usablecondition (such as cable(s) undamaged, safely routed)1.2 power up the equipment and activate the programmingsoftware.1.3 set up the computer system to produce the program1.4 ensure that the correct process input/output and control datato produce the program is obtained and checked for currencyand validity1.5 identify and deal with problems (such as information basedand/or technical).
produce computer control programs that contain all therelevant and necessary data for the engineering activity to becarried out
produce the control programs in the appropriate formats
Prepare, load and prove programs for one of the following types of robot controller:2.1 Cartesian (gantry)2.2 SCARA2.3 jointed arm/articulated2.4 parallel2.5 other specific type
Produce operating programmes for one of the following engineering applications:3.1 welding3.2 stud welding3.3 machine loading/unloading3.4 packaging3.5 surface coating3.6 assembly3.7 gluing/sealing3.8 logistics movement/control3.9 other specific activity.
make sure that codes and other references used in theprograms are applicable to the type of controller used.
Produce process control programs, for robots with digital and analogue inputs/outputs from four ofthe following:4.1 proximity sensors4.2 hydraulic actuators4.3 pressure switches4.4 barcode scanners4.5 limit switches4.6 liquid flow switches4.7 optical sensors4.8 timer switches4.9 air flow switches4.10 control panel switches4.11 colour sensors4.12 temperature sensors4.13 liquid level sensors4.14 counters4.15 pneumatic actuators4.16 other actuator.
Develop programs which contain all of the following, as applicable to the robot type:5.1 safe start and stop positions5.2 all necessary positional information5.3 type of motion (such as joint interpolated, linear, circular)5.4 preparatory commands and process management/auxiliaryfunctions5.5 repetitive programs (sub-routines, canned cycles, labels)5.6 part programs downloaded from a computer (such as patchprogrammes)5.7 speed/acceleration parameters5.8 use of workframes (such as tool, global, joint, user)5.9 sensor information.
Prove the robot program using, four of the following:6.1 single block run6.2 full dry run6.3 search facilities6.4 edit facilities6.5 program override controls6.6 data input facilities6.7 all modes (such as auto, T1, T2 and remote).
pass on the programs to the appropriate people, within agreedtimescales
save and back up the program detail, and store securely inaccordance with organisational requirements
Carry out all of the following on completion of the programming activity:7.1 check and review program formats and contents7.2 edit programs using the correct procedure (where appropriate)7.3 check that programs are correctly titled and referenced7.4 ensure that programs are stored safely and correctly in thecorrect format7.5 ensure that programs have been checked and approved beforeforwarding to the end user7.6 create a separate back-up copy of the program, in case of filecorruption or accidental deletion
undertake changes to program details, within agreed controlprocedures.
Describe the safe working practices and procedures to be followed whenproducing and proving industrial robots operating programs
Describe the specific safety precautions to be taken when working withcomputer systems (to include safety guidance relating to the use of visualdisplay unit (VDU), equipment and workstation environment (such aslighting, seating, positioning of equipment), repetitive strain injury (RSI); thedangers of trailing leads and c

107

Producing Pattern, Corebox or Model Components using Woodworking Hand Tools

Verified

Key Learning Objectives:

Work safely at all times, complying with health and safety andother relevant regulations and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following during the hand-shaping activities:1.1obtain all the necessary information to carry out the handshapingactivities (drawings, specifications)1.2check that the hand tools are fit for purpose and are in a safeand usable condition1.3 ensure that the work area is free from hazards1.4 use safe and approved hand-shaping techniques at all times1.5 maintain the cutting tools in a serviceable condition
Follow relevant specifications for the component to beproduced
Obtain the appropriate tools and equipment for the shapingoperations and check they are in a safe and usable condition
Use hand tools to cut and shape materials, to include six of the following items:2.1 rip saws2.2 tenon saws2.3 fret/bow saws2.4 jack or smoothing planes2.5 rebating planes2.6 spokeshaves2.7 chisels/gouges2.8 drills/braces2.9 files/rasps2.10 sanding blocks/paper
Shape the materials using appropriate methods and techniques
Produce components which combine different features and cover eight of the following:3.1 flat faces3.2 parallel faces3.3 square faces3.4 angular/tapered faces3.5 stepped features3.6 rebates3.7 slots3.8 curved profiles3.9 concave profiles3.10 convex profiles3.11 circular/round profiles3.12 drilled holes
Produce components made from two of the following materials:4.1 soft woods4.2 hard woods4.3 composite4.4 resin
Check that all the required shaping operations have beencompleted to the required specification
Use appropriate measuring equipment and tools to check five of the following:5.1 dimensions5.2 flatness5.3 squareness5.4 position5.5 profile5.6 distortion/straightness5.7 alignment
Produce components which meet all of the following quality and accuracy standards:6.1 dimensionally accurate within specification tolerances6.2 free from false tool cuts and material defects6.3 appropriate surface texture6.4 meet the drawing requirements6.5 meet company and customer requirements
Deal promptly and effectively with problems within theircontrol and report those that cannot be solved
Describe the specific safety precautions to be taken whilst carrying out thewood shaping activities (including any specific legislation, regulations orcodes of practice relating to the activities, equipment or materials)K2 Describe the health and safety requirements of the work area in which theyare carrying out the wood working activities, and the responsibility theyplace on them
Describe the personal protective equipment and clothing to be worn duringthe woodworking activities
Describe the hazards associated with cutting and shaping wood andcomposite pattern or model materials, and with the tools and equipmentused, and how they can be minimised
Explain the importance of applying the appropriate occupational behavioursin the workplace and the implications for both them and the business ifthese are not adhered to
Explain how to obtain the necessary job instructions, drawings andspecifications for the woodworking activities, and how to interpret theinformation
Describe the various hand tools that are used to cut and shape thematerials, and the range of operations they are capable of performing (eg,rip saws, tenon saws, fret/bow saws; smoothing planes, jack planes,rebating planes; chisels and gouges; files and rasps; spokeshaves)K8 Explain how to check the cutting tools are in a usable and safe condition,and the procedure for sharpening and adjusting these when required
Describe the various methods to hold the components that are beingshaped, formed or dressed by hand

108

Producing Pattern, Corebox or Model Components using Woodworking Machines

Verified

Key Learning Objectives:

Work safely at all times, complying with health and safety andother relevant regulations and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following during the machining activities:1.1obtain all the necessary information to carry out themachining activities (drawings, specifications)1.2check that the machine tools are fit for purpose and are in asafe and usable condition1.3 ensure the work area is free from hazards1.4ensure all machine guards and safety devices are correctlypositioned1.5 check that dust extraction equipment is functioning correctly1.6set and adjust the machine to produce the components to therequired specification1.7 use safe and approved machining techniques at all times
Confirm that the machine is set up and ready for the machiningactivities to be carried out
Use fixed and portable machines, to include five of the following:2.1 circular saw2.2 band saw2.3 sander (eg, face, belt, bobbin)2.4 jig saw2.5 router2.6 planer/thicknesser2.7 wood miller2.8 wood lathe2.9 bench or pedestal drill
Manipulate the machine tool controls safely and correctly inline with operational procedures
Produce components which combine different features and cover all of the following:3.1 flat faces3.2 parallel faces3.3 square faces3.4 angular/tapered faces3.5 stepped features3.6 curved profiles3.7 concave profiles3.8 convex profiles3.9 circular/round profiles3.10 drilled holes
Produce components made from two of the following materials:4.1 soft woods4.2 hard woods4.3 composite4.4 resin
Carry out quality sampling checks at suitable intervals
Use appropriate measuring equipment and tools to check four of the following:5.1 dimensions5.2 flatness5.3 squareness5.4 position5.5 concentricity5.6 distortion/straightness
Produce components to the required quality and within thespecified dimensional accuracy
Produce components which meet all of the following quality and accuracy standards:6.1 dimensionally accurate within specification tolerances6.2 free from false tool cuts and material defects6.3 appropriate surface finish6.4 meet the drawing requirements6.5 meet company and customer requirements
Deal promptly and effectively with problems within theircontrol and report those that cannot be solved
Shut down the equipment to a safe condition on conclusion ofthe machining activities.
Describe the specific safety precautions to be taken whilst carrying out thewood machining activities (including any specific legislation, regulations orcodes of practice relating to the activities, equipment or materials)K2 Describe the health and safety requirements of the work area in which theyare carrying out the wood machining activities, and the responsibility theserequirements place on the them
Describe the use of machine guards and emergency stop mechanisms
Explain the importance of applying the appropriate occupational behavioursin the workplace and the implications for both them and the business ifthese are not adhered to
Explain how to set up and use dust extraction equipment, and theimportance of ensuring the equipment is operating correctly
Describe the personal protective equipment and clothing to be worn duringthe wood machining activities
Describe the hazards associated with machining wood and compositepattern or model materials, and how they can be minimised

109

Producing technical information for engineering activities

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Producing technical information for engineering activities
Apply practical skills, procedures and techniques in Producing technical information for engineering activities
Evaluate performance, standards and best practices for Producing technical information for engineering activities

110

Providing operational support for computer control programs

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Providing operational support for computer control programs
Apply practical skills, procedures and techniques in Providing operational support for computer control programs
Evaluate performance, standards and best practices for Providing operational support for computer control programs

111

Providing Technical Advice and Guidance on Engineering Activities

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can advise and guide othersin work-related engineering technical matters, in accordance with approved proceduresThey will understand the safety precautions required in the work area where they provide technical guidance.They will be required to demonstrate safe working practices throughout, and will understand the responsibilitythey owe to themselves and others in the work area.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment.

112

Providing technical sales and marketing support for engineering activities

Verified

Key Learning Objectives:

demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following when developing and disseminating technical sales and marketinginformation:1.1 use the correct issue of company information1.2check that all essential information and data needed to devisethe technical sales and marketing material is available and upto date1.3produce sales and marketing material which is in keeping withcompany/organisational policy1.4ensure that health and safety regulations and safe workingpractices are taken into account1.5present the technical and marketing materials in theappropriate formats1.6 contact potential and existing customers1.7re
solve any problems as they occur, within their level ofresponsibility1.8identify improvements in content and methods ofdissemination of information
produce technical details that contain all the relevant andnecessary data for the engineering activity to be carried out
Produce technical sales and marketing material for one of the following engineering activities:2.1drawing/design activities (such as mechanical,electrical/electronic, motor vehicle, aerospace, marine)2.2manufacturing activities (such as conventional machining, CNCmachining, detail fitting, pressing)2.3fabrication activities (such as sheet metal, pipe and tube,structural steel, welding, riveting, adhering)2.4material processing activities (such as heat treatment, casting,injection moulding, purification)2.5composite manufacture (such as wet lay-up, pre-preglaminating, resin infusion, blow moulding)2.6finishing activities (such as stripping finishes, painting, plating,anodising, veneering, lacquering)2.7assembly activities (such as mechanical, structural, fluidpower, electrical/electronic, woodworking)2.8installation activities (such as mechanical,electrical/electronic, avionic, structural, environmentalequipment)2.9plant and equipment (such as site preparation, plant layout,equipment changeover, equipment replacement)2.10 equipment capability studies/performance measurement2.11maintenance activities (such as preventative maintenance,condition monitoring)2.12movement/storage of materials, components, finished goodsor waste2.13 commissioning and decommissioning2.14 quality control/quality assurance2.15 testing and trialling2.16 business improvement activities2.17 research and development services2.18 engineering support services2.19 modification and repair activities2.20 service/component supply2.21 engineering safety audits or risk assessments2.22 new product introduction to the business operation2.23 launch of an engineered product to the market2.24 logistic operations
present the technical details in the appropriate formats
Produce or contribute to the production of technical sales and marketing material, in three of thefollowing forms:3.1 technical bulletins3.2 specification sheets3.3 website3.4 technical manuals3.5 audio visual presentation3.6 billboard presentation3.7 sales flyer/leaflets3.8 media advertisement3.9 promotional items3.10 Apps/social media
record technical details and store them securely in accordancewith organisational requirements
undertake changes to technical details within agreed controlprocedures
Carry out all of the following on completion of the technical support activities:4.1validation and evaluation of the technical support systemsand procedures used4.2suggested improvements to the method used to provide thetechnical sales and marketing support4.3recommendations for improvements or changes to thetechnical support systems and procedures that are in place
make sure that codes and other references used in thetechnical details follow agreed conventions
Ensure that the technical sales and marketing materials comply with one of the following:5.1 organisational guidelines and procedures5.2recognised compliance agency body standards, directive orcodes of practice5.3 British, European or International standards or directives5.4 customer standards a

113

Removal and fitting fuel systems to prototype engines for test

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Removal and fitting fuel systems to prototype engines for test
Apply practical skills, procedures and techniques in Removal and fitting fuel systems to prototype engines for test
Evaluate performance, standards and best practices for Removal and fitting fuel systems to prototype engines for test

114

Repairing defects in vehicle composite mouldings

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following during the repair activities:1.1obtain and use the appropriate documentation (such as jobinstructions, drawings, planning and quality controldocumentation, material data sheets, specifications, )1.2adhere to procedures or systems in place for risk assessment,COSHH, personal protective equipment and other relevantsafety regulations and procedures to realise a safe system ofwork1.3provide and maintain a safe working environment for thecomposite mould repair activities1.4obtain the correct tools and equipment for the activity, andcheck that they are in a safe, tested and usable condition1.5follow safe practice/approved mould repair techniques andprocedures at all times1.6return all tools and equipment to the correct location oncompletion of the mould repair activities1.7dispose of waste materials in accordance with approvedprocedures1.8leave the work area in a safe and appropriate condition oncompletion of the activities
follow the relevant specifications for the component to berepaired
prepare the component for repair
Carry out all of the following when preparing for the repair activity:2.1 check that mouldings are correct and complete2.2 select the correct equipment for the activity2.3 identify the method of repair to be used2.4 check that equipment is suitable for use2.5 check availability of ancillary materials required2.6 identify what needs to be repaired2.7identify and protect the moulding and repair materials in the
carry out the repairs within agreed timescale using approvedmaterials and components and methods and procedures
Repair defects in six of the following types of composite mouldings:3.1 trim3.2 body panels3.3 sandwich panels3.4 moulds3.5 closing panels3.6 tubes3.7 structural3.8 jigs3.9 housings3.10 sections3.11 aerodynamic
Repair defects in composite mouldings using four of the following methods:4.1 localised curing4.2 relieving distortion4.3 resin injection4.4 core patching4.5 fettling4.6 separation of bonds4.7 wet-lay patching4.8 insert/core potting4.9 surface filling4.10 bonding4.11 pre-preg patching4.12 repair patches/kits
Repair defects using techniques/materials applicable to two of the following resins types:5.1 polyester5.2 epoxy5.3 bismaleimide5.4 cyanate ester5.5 phenolic5.6 vinyl ester
Repair defects using techniques/materials applicable to two of the following fibre types:6.1 polyethylene6.2 glass6.3 aramid6.4 carbon
Repair eight of the following types of defect in composite mouldings:7.1 in
complete curing7.2 blisters7.3 voids7.4 damaged cores7.5 dimensional7.6 bridging7.7 dis-bonds7.8 wrong inserts7.9 tolerances7.10 de-lamination7.11 dents or ‘dings'7.12 insert positions7.13 surface finish7.14 broken fibres7.15 excessive adhesive7.16 impact damage7.17 distortion
ensure that the repaired component meets the specified operatingconditions
Repair a range of mouldings which comply with all of the following quality and accuracy standards:8.1 meet company standards and procedures8.2 dimensionally accurate within specification tolerances8.3have an appropriate surface finish and are free from defectsor surface blemishes
produce accurate and complete records of all repair workcarried out
Complete the relevant paper
work, to include one from the following and pass it to the appropriatepeople:9.1 build records9.2 job cards9.3 log cards9.4 other specific recording method.
Describe the health and safety precautions to be taken, and procedures tobe used, when working with composite materials, consumables, tools andequipment in the specific work area
Describe the hazards associated with repairing composite mouldings andwith the materials, consumables, tools and equipment used, and how tominimise these and reduce any risk in the work areaK

115

Resolving engineering or manufacturing support problems

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Resolving engineering or manufacturing support problems
Apply practical skills, procedures and techniques in Resolving engineering or manufacturing support problems
Evaluate performance, standards and best practices for Resolving engineering or manufacturing support problems

116

Scheduling engineering activities

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Scheduling engineering activities
Apply practical skills, procedures and techniques in Scheduling engineering activities
Evaluate performance, standards and best practices for Scheduling engineering activities

117

Setting up and testing prototype vehicle data acquisition systems

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Setting up and testing prototype vehicle data acquisition systems
Apply practical skills, procedures and techniques in Setting up and testing prototype vehicle data acquisition systems
Evaluate performance, standards and best practices for Setting up and testing prototype vehicle data acquisition systems

118

Setting up and testing prototype vehicle electrical/electronic engine/transmission control units

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Setting up and testing prototype vehicle electrical/electronic engine/transmission control units
Apply practical skills, procedures and techniques in Setting up and testing prototype vehicle electrical/electronic engine/transmission control units
Evaluate performance, standards and best practices for Setting up and testing prototype vehicle electrical/electronic engine/transmission control units

119

Spraying Vehicle Body Surfaces

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can spray vehicle bodysurfaces, in accordance with approved procedures. They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment.

120

Stripping and rebuilding prototype engines for test

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Stripping and rebuilding prototype engines for test
Apply practical skills, procedures and techniques in Stripping and rebuilding prototype engines for test
Evaluate performance, standards and best practices for Stripping and rebuilding prototype engines for test

121

Supporting logistics operations in an engineering manufacturing environment

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Supporting logistics operations in an engineering manufacturing environment
Apply practical skills, procedures and techniques in Supporting logistics operations in an engineering manufacturing environment
Evaluate performance, standards and best practices for Supporting logistics operations in an engineering manufacturing environment

122

Testing prototype engines (fixed dynamometer)

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Testing prototype engines (fixed dynamometer)
Apply practical skills, procedures and techniques in Testing prototype engines (fixed dynamometer)
Evaluate performance, standards and best practices for Testing prototype engines (fixed dynamometer)

123

Testing prototype engines installed in vehicles

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Testing prototype engines installed in vehicles
Apply practical skills, procedures and techniques in Testing prototype engines installed in vehicles
Evaluate performance, standards and best practices for Testing prototype engines installed in vehicles

124

Trimming of body components for vehicles

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following during the trimming and assembly activities:1.1obtain and use the appropriate documentation (such as jobinstructions, drawings, quality control documentation)1.2adhere to procedures or systems in place for risk assessment,COSHH, personal protective equipment and other relevantsafety regulations and procedures to realise a safe system ofwork1.3check that all cables, extension leads or air supply hoses arein a tested and serviceable condition1.4check that all tools and equipment to be used are withincurrent calibration/certification dates1.5ensure that sub-assemblies and components used are freefrom damage, foreign objects, dirt or other contaminationbefore assembling them1.6use safe and approved techniques to trim and assemble thebody components to the vehicles1.7return all tools and equipment to the correct location oncompletion of the trimming activities1.8leave the work area in a safe and appropriate condition oncompletion of the activities
follow the relevant instructions, assembly drawings and anyother specifications
ensure that the specified components are available and thatthey are in a usable condition
Select and prepare material to be assembled, to include three of the following:2.1 leather2.2 wool2.3 velour2.4 nylon2.5 cotton2.6 linz2.7 moquette2.8 PVC2.9 foams/composites
use the appropriate methods and techniques to assemble thecomponents in their correct positions
Select material and assemble vehicle trim components, to include all of the following:3.1 pre-sewn assemblies3.2 multi-fabric/material builds3.3 pattern matching3.4 sub-frame trimming
Use a variety of manufacturing methods and techniques, to include three of the following:4.1 cutting to pattern4.2 adhering4.3 stapling4.4 hog ring fixing4.5 plastic welding4.6 hand sewing
Assemble vehicle trim components, to include three of the following:5.1 door pad assemblies5.2 rear cushion assembly5.3 arm rests assembly5.4 front seat assembly5.5 rear squab assembly5.6 floor console assembly
secure the components using the specified connectors andsecuring devices
Assemble the trim components using the appropriate equipment, to include four of the following:6.1 staple devices6.2 fixtures6.3 cutting devices6.4 hog ring machine6.5 alignment devices6.6 plastic welding device6.7 buck6.8 jigs6.9 templates
check the completed assembly to ensure that all operationshave been completed and the finished assembly meets therequired specification
Produce trim assemblies which comply with all of the following quality and accuracy standards:7.1 the assembly of trim components is complete7.2 where appropriate, pattern matches are achieved7.3 the assembly is free from damage, cuts, adhesive and marks7.4 surplus material has been removed and components are clean7.5 all quality control checks have been achieved
deal promptly and effectively with problems within theircontrol and report those that cannot be solved
Describe the specific safety precautions to be taken whilst carrying out thetrimming of body components (including any specific legislation, regulationsor codes of practice relating to the activities, equipment or materials)K2 Outline the health and safety requirements of the work area in which theyare carrying out the trimming of body components, and the responsibilitythey place on them
Describe the hazards associated with carrying out trimming activities, andhow to minimise them and reduce any risks
Describe the personal protective equipment and clothing (PPE) to be wornduring the trimming of body components
Explain the importance of applying the appropriate occupational behavioursin the workplace and the implications for both the learner and the businessif these are not adhered to
Outline the procedures for

125

Trimming vehicle composite mouldings using hand tools

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following during the trimming activities:1.1obtain and use the appropriate documentation (such as jobinstructions, drawings, planning and quality controldocumentation, material data sheets, specifications)1.2adhere to procedures or systems in place for risk assessment,COSHH, personal protective equipment and other relevantsafety regulations and procedures to realise a safe system ofwork1.3provide and maintain a safe working environment for thecomposite mould trimming activities1.4obtain the correct tools and equipment for the activity, andcheck that they are in a safe, tested and usable condition1.5follow safe practice/approved mould trimming techniques andprocedures at all times1.6return all tools and equipment to the correct location oncompletion of the mould trimming activities1.7dispose of waste materials in accordance with approvedprocedures
follow relevant specifications for the component to be produced
obtain the appropriate tools and equipment for the shapingoperations and check they are in a safe and usable condition
Carry out all of the following activities when preparing for the trimming activity:2.1 check the moulding is correct and complete2.2 check equipment is suitable for use2.3 check for any defects in the moulding2.4 identify and protect the moulding in the work area2.5 select the correct equipment for the activity
Mark out mouldings using all of the following methods:3.1 scriber3.2 height gauge3.3 moulded scribe lines3.4 centre punch3.5 trimming templates
shape the materials using appropriate methods and techniques
Cut mouldings using two of the following methods:4.1 cutting wheels/discs4.2 saws4.3 routers4.4 trim jigs
Sand mouldings using three of the following methods:5.1 rubbing blocks5.2 diamond files5.3 pencil grinders5.4 disc sanders5.5 belt sanders
Use a hand drill or pedestal drill to drill mouldings, using three of the following methods:6.1 drill jigs6.2 hole saws6.3 counterbores6.4 countersinks6.5 drill bits
Polish mouldings using four of the following methods:7.1 wet sanding7.2 polishing compound7.3 orbital sander7.4 polisher7.5 cutting compound7.6 rubbing block
Trim mouldings using techniques for two of the following resins types:8.1 polyester8.2 vinyl ester8.3 epoxy8.4 phenolic8.5 bismaleimide8.6 cyanate ester
Trim mouldings using techniques for two of the following fibre types:9.1 polyethylene9.2 glass9.3 aramid9.4 carbon
Trim mouldings that require, or incorporate, eight of the following features:10.1 straight edges10.2 radius corners10.3 multiple holes10.4 inserts to be drilled10.5 curved edges10.6 returns10.7 multiple hole sizes10.8 inserts to be tapped10.9 flat surfaces10.10 nett edges10.11 countersinks10.12 solid cores10.13 polished surfaces10.14 joggle details10.15 counterbores10.16 honeycomb cores10.17 shaped surfaces10.18 removal of join lines10.19 further lay-up stages10.20 edge filling
check that all the required shaping operations have beencompleted to the required specification
Trim a range of mouldings which comply with all of the following quality and accuracy standards:11.1 meet company standards and procedures11.2 dimensionally accurate within specification tolerances11.3 free from false tool cuts, defects or damage
Complete the relevant paper
work, to include one from the following and pass it to the appropriatepeople:12.1 build records12.2 job cards12.3 log cards12.4 other specific recording method
deal promptly and effectively with problems within theircontrol and report those that cannot be solved.

126

Using and interpreting engineering data and documentation

Verified

Key Learning Objectives:

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 ofthe following:1.1 check the currency and validity of the documentation used;1.2 exercise care and control over the documentation at all times;1.3 correctly extract all necessary data in order to carry out the required tasks.1.4 seek out additional information where there are gaps or deficiencies in the information obtained.1.5 deal with and/or report any problems found with the data and documentation.1.6 make valid decisions based on the evaluation of the information extracted from the documentation.1.7 return all documentation to the approved location on completion of the work.1.8 complete all necessary work related documentation such asproduction 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 ofthe following:2.1 drawings (such as component drawings, general assemblydrawings, modification drawings, repair drawings, welding/fabrication drawings, distribution and installation drawings).2.2 Diagrams (such as schematic, fluid power diagrams, piping, wiring/circuit, layout diagrams).2.3 manufacturers manuals/drawings.2.4 approved sketches.2.5 technical illustrations.2.6 photographic images/representations.2.7 visual display screen information.2.8 technical sales/marketing documentation.2.9 contractual documentation.2.10 other specific drawings/documents.
Use information extracted from related documentation to include three from the following:3.1 standard operating procedures.3.2 instructions (such as job instructions, drawing instructions, manufacturer’s instructions).3.3 specifications (such as material, finish, process, contractual, calibration).3.4 reference materials (such as manuals, tables, charts, fault diagnosis guides).3.5 schedules;3.6 operation sheets;3.7 maintenance log reports;3.8 service/test information/schedules/results;3.9 planning documentation;3.10 quality control documents;3.11 company specific technical instructions;3.12 national, international and organisational standards;3.13 health and safety standards relating to the activity (such as COSHH);3.14 environmental requirements/information;3.15 other specific related documentation
Extract information that includes three of the following: 4.1 materials or components required;4.2 dimensions;4.3 tolerances;4.4 quality requirements;4.5 installation requirements;4.6 customer requirements;4.7 time scales;4.8 financial information;4.9 operating parameters;4.10 surface texture requirements;4.11 location/orientation of parts;4.12 process or treatments required.4.13 dismantling/assembly sequence;4.14 inspection/testing requirements;4.15 number/volumes required;4.16 repair/service methods;4.17 method of manufacture;4.18 weld type and size;4.19 operations required. 4.20 connections to be made;4.21 surface finish required;4.22 shape or profiles.4.23 fault finding procedures;4.24 test points;4.25 safety/risk factors;4.26 environmental controls;4.27 technical data (such as component data, maintenance data, electrical data, fluid data);4.28 resources (such as tools, equipment, personnel);4.29 utility supply details (such as electricity, water, gas, air).4.30 location of services, including standby and emergency backup systems;4.31 circuit characteristics (such as pressure, flow, current, voltage, speed);4.32 protective arrangements and equipment (such as containment,environmental controls, warning and evacuation systems and equipment);4.33 other specific related information (suc

127

Using and Maintaining Business Procedures and Protocols in an Engineering Environment

Verified

Key Learning Objectives:

This unit identifies the training and development required in order that the learner can use and maintainbusiness systems and protocols in an engineering environment, in accordance with approved proceduresThey will be aware of any health, safety and environmental requirements applicable to the products andprocesses, and to the business activities. They will be required to demonstrate safe working practicesthroughout, and will understand the responsibility they owe to themselves and others in the workplace.They will be able to apply the occupational behaviours required in the workplace to meet the job profile andoverall company objectives, including logical approach, problem solving orientation, quality focus, personalresponsibility and resilience, clear communicator, team player, applies lean manufacturing principles,adaptability, self-motivation, willingness to learn and commitment.

128

Using hand fitting techniques to produce components for experimental vehicle engineering

Verified

Key Learning Objectives:

work safely at all times, complying with health and safety andother relevant regulations, directives and guidelines
demonstrate the required occupational behaviours in line withthe job role and company objectives
Carry out all of the following during the hand fitting activities:1.1obtain and use the appropriate documentation (such as jobinstructions, assembly drawings, quality controldocumentation)1.2adhere to procedures or systems in place for risk assessment,COSHH, personal protective equipment and other relevantsafety regulations and procedures to realise a safe system ofwork1.3check that all cables, extension leads or air supply hoses are ina safe, tested and serviceable condition1.4check that all tools and equipment to be used are withincurrent calibration/certification dates1.5 use safe and approved fitting techniques at all times1.6return all tools and equipment to the correct location oncompletion of the fitting activities1.7leave the work area in a safe and appropriate condition oncompletion of the activities
follow relevant specifications for the component to be produced
Produce components for experimental vehicle development activities, to include both of thefollowing:2.1 modify existing components2.2 produce new components
obtain the appropriate tools and equipment for the shapingoperations and check they are in a safe and usable condition
shape the materials using appropriate methods and techniques
Use a range of hand-fitting methods, to include seven of the following:3.1 hand sawing3.2 band/power sawing3.3 filing3.4 drilling3.5 chiselling3.6 threading external3.7 reaming3.8 riveting3.9 offhand grinding3.10 tapping3.11 scraping3.12 lapping
Produce or modify components which combine several features and cover eight of the following:4.1 flat datum faces4.2 faces which are parallel to each other4.3 faces which are square to each other4.4 faces at an angle to each other4.5 curved profiles4.6 radii4.7 drilled holes (through; to a depth)4.8 counterbored/countersunk/spotfaced holes4.9 reamed holes4.10 external threads4.11 internal threads4.12 sliding or mating parts4.13 chamfers and radii
Cut and shape three different types of material from the following:5.1 low carbon steel5.2 plastic/synthetic5.3 high carbon steel5.4 aluminum5.5 stainless steel5.6 brass/bronze5.7 cast iron5.8 composite5.9 other specific material
check that all the required shaping operations have beencompleted to the required specification
Produce experimental components within all of the following standards, as applicable to theoperations performed:6.1 surface finish 63'in or 1.6 'm6.2 screw threads to BS Medium fit6.3 reamed and bored holes within H86.4flatness and squareness 0.001? per inch or 0.025mm per25mm
deal promptly and effectively with problems within theircontrol and report those that cannot be solved.
Describe the health and safety requirements, and safe working practices andprocedures required for the hand fitting activities undertaken
Explain the importance of wearing appropriate protective clothing andequipment (PPE), and of keeping the work area safe and tidy
Describe the hazards associated with the carrying out hand-fittingtechniques (such as use of power tools, trailing leads or hoses, damaged orbadly maintained tools and equipment, using files with damaged or poorfitting handles), and how to minimise them and reduce any risks
Explain the importance of applying the appropriate occupational behavioursin the workplace and the implications for both the learner and the businessif these are not adhered to
Outline the procedure for obtaining the required drawings, sketch,development sheets, job instructions and other related specifications
Explain how to extract and use information from engineering drawings andrelated specifications (to include symbols and conventions to appropriateBS, ISO or BSEN standards) in relation to work undertaken
Explain how to interpret first and third angle drawings, imperial an

129

Working efficiently and effectively in advanced manufacturing and engineering

Verified

Key Learning Objectives:

Understand key principles, terminology and concepts of Working efficiently and effectively in advanced manufacturing and engineering
Apply practical skills, procedures and techniques in Working efficiently and effectively in advanced manufacturing and engineering
Evaluate performance, standards and best practices for Working efficiently and effectively in advanced manufacturing and engineering

Regulatory & Verification Details

Qualification Number (QN): 603/0926/X
Regulated Status: Available to learners
Awarding Body: EAL
Qualification Type: Occupational Qualification
Operational Start: Jan 2017