Manufacturing vehicle components by vacuum forming
Overview
This standard identifies the competences you need to manufacture automotive components using vacuum forming, in accordance with approved procedures. You will be required to use appropriate manufacturing drawings and specifications, together with other quality documentation, to produce the various types of components from thermoplastic sheet, fibre reinforced sheet and structural foam, using air circulating ovens, vacuum forming machines, trimming equipment and assorted tooling. The components produced will have a range of features, such as male shapes, female shapes, double curvatures and stiffened mouldings.
Your responsibilities will require you to comply with organisational policy and procedures for the vacuum forming activities undertaken, and to report any problems with the moulding activities, equipment, materials or consumables that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.
Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying vacuum forming procedures. You will understand the vacuum forming procedures used, and their application, and will know about the vacuum moulding techniques, materials, tooling and consumables used, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring that the work output is to the required specification.
You will understand the safety precautions required when carrying out the vacuum forming operations. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- follow the relevant instructions, assembly drawings and any other specifications
- ensure that the specified tools and materials are available and that they are in a usable condition
- produce components to specification using appropriate methods and techniques
- carry out quality sampling checks at suitable intervals
- deal promptly and effectively with problems within your control and report those that cannot be solved
- ensure that work records are completed, stored securely and available to others as per organisational policy
- leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements
Knowledge and Understanding
You need to know and understand:
- the specific safety precautions to be taken whilst carrying out the activities (including any specific legislation, regulations/codes of practice for the activities, equipment or materials)
- the health and safety requirements of the work area and the activities, and the responsibility these requirements place on you
- the personal protective equipment and clothing (PPE) to be worn during activities the hazards associated with the activities, and with the materials, tools and equipment used, and how to minimise them and reduce any risks
- the procedure for the correct separation and safe disposal of waste materials
- the layout of the area to give maximum throughput
- the interpretation of drawings, standards, quality control procedures and specifications used for the vacuum forming activity, and the currency/issue checks of the documents you are working with
- the methods and techniques to be used during tool preparation
- the reasons for the use of intensifiers and the robber system
- equipment checks, and the stores and kitting functions
- the methods of sheet trimming and sheet cleaning, prior to forming
- the principles of deep drawing, concave/convex moulding, positive pressure moulding and stress relieving
- the sheet profiling procedures and material trimming methods/procedures
- the supply and storage of stock material (such as colour, thickness, sheet size, surface texture, material protection)
- the preparation methods and procedures applied to the moulding surface
- the merits of male/female moulding, de-moulding techniques, and temperature control procedures
- the methods and techniques for carrying out the de-moulding procedures and first article inspection (test samples; non-destructive testing (NDT) requirements)
- the methods and techniques for lifting, handling and supporting the components/equipment/materials during the vacuum forming activities
- how to recognise vacuum forming defects (misalignment, distortion, damage, contamination and surface defects)
- the quality control procedures to followed during the vacuum forming operations
- the procedures for ensuring you have the correct tools and equipment
- the tools and equipment used in the vacuum forming activities, and their calibration, care, preparation and control procedures
- the problems that can occur with the vacuum forming operations, and how these can be overcome
- the importance of identifying and marking specific vacuum forming work on recording documents
- the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
- how to access, use and maintain information to comply with organisational requirements and legislation
Scope/range
Scope Performance
Carry out all of the following during the vacuum forming activities:
- obtain and use the appropriate documentation (such as job instructions, drawings, material data sheets, planning and quality control documentation, material data sheets, specifications, )
- adhere to procedures or systems in place for risk assessment, hazardous substances, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
- provide and maintain a safe working environment for the resin casting activities
- obtain the correct materials for the vacuum forming activities (such as colour, size, composition)
- obtain the correct tools and equipment for the activity, and check that they are in a safe, tested and usable condition (such as part marked, undamaged, cleared inspection)
- follow safe practice/approved vacuum forming techniques and procedures at all times
- return all tools and equipment to the correct location on completion of the vacuum forming activities
- dispose of waste materials in accordance with approved procedures
- leave the work area in a safe and appropriate condition on completion of the activities
Use three of the following types of equipment :
- air circulating ovens
- wood tooling
- vacuum forming machines
- trimming equipment
- tufnol tooling
- composite tooling
- metal tooling
Carry out four of the following operations:
- bubble blowing to minimize webbing
- positioning of robbers
- tooling cleaning
- temperature control
- trimming techniques
- drying of sheet
- use of intensifiers
- sheet cleaning
Produce a range of components with three of the following features:
- double curvatures
- female shapes
- male shapes
- stiffened mouldings
Produce a range of components using all the following materials:
- thermoplastic sheet (such as polycarbonate, polysulphone, acrylic, polyvinyl chloride, ABS)
- fibre-reinforced thermoplastic sheet
- structural foams (polyvinyl chloride (PVC), polymethate (Rohacell))
Check components comply with all of the following quality and accuracy standards:
- meet company standards and procedures
- dimensionally accurate within specification tolerances
- have an appropriate surface finish and are free from defects or surface blemishes