Manufacturing vehicle components by acrylic moulding
Overview
This standard identifies the competences you need to mould acrylics into vehicle components, in accordance with approved procedures. You will be required to use appropriate manufacturing drawings, specifications and documentation to produce the various types of components. You will be expected to produce the acrylic components using the specified/appropriate moulding process and techniques. The equipment will include air-circulating ovens, presses, trimming and automated cutting equipment. The products produced will include deep drawn, double curvature and convex/concave shapes.
Your responsibilities will require you to comply with organisational policy and procedures for the manufacturing activities undertaken, and to report any problems with the sheet moulding activities, materials or equipment that you cannot personally resolve, or that are outside your personal 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 acrylic moulding procedures. You will understand the moulding procedure used, and its application, and will know about the moulding equipment, materials, and consumables used, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring that the finished mouldings are to the required specification.
You will understand the safety precautions required when carrying out the moulding 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 correct component drawing or any other related specifications for the component to be produced
- ensure that tools and materials are available and in a usable condition
- obtain and prepare the appropriate tools, equipment and materials
- carry out the moulding or laying-up activities using the correct methods and techniques
- produce components to the required specification
- check that all the required operations have been completed to specification
- 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 requirements
- 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 they place on you
- the personal protective equipment and clothing (PPE) to be worn during the activities
- the hazards associated with the activities, 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 moulding activity, and the currency/issue checks of the documents you are working with
- the principles of deep drawing, concave/convex moulding, positive pressure moulding and stress relieving
- the different methods of heating materials, and the temperature control methods
- the sheet profiling procedures, and material trimming methods/procedures
- the supply of acrylic sheet (colour, thickness, sheet size, surface texture, material protection)
- the use of forming aids
- the methods of sheet trimming and sheet cleaning prior to moulding
- the preparation methods and procedures applied to the moulding surface
- the material cleaning methods and procedures to be applied
- the procedures for de-moulding, and first article inspection (test samples, non-destructive testing (NDT) requirements)
- the quality control procedures to followed during the moulding operations
- the procedures for ensuring you have the correct tools and equipment
- the methods and techniques for lifting, handling and supporting the components/equipment/materials during the moulding activities
- how to recognise moulding defects (such as misalignment, distortion, contamination and surface defects)
- the tools and equipment used in the moulding activities, and their calibration, care, preparation and control procedures
- why tool/equipment control is critical, and what to do if a tool or piece of equipment is unaccounted for on completion of the activities
- the problems that can occur with the moulding 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 activities during the moulding 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 acrylic moulding activities
- obtain the correct materials for the acrylic moulding activities (such as batch number, colour, thickness, sheet size, surface texture, material protection)
- 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 acrylic moulding techniques and procedures at all times
- return all tools and equipment to the correct location on completion of the acrylic moulding 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
Carry out two of the following moulding methods and techniques:
- vacuum moulding
- deep drawing
- shape clamping
- positive pressure shaping
- stress relieving
Carry out all of the following operations during the moulding process:
- tool/equipment preparation
- stress relieving
- setting and controlling temperatures
- sheet forming
- sheet preparation
- de-moulding
- trimming
Produce a range of components with four of the following features:
- box sections
- concave shapes
- cylindrical section
- single curvatures
- convex shapes
- double curvatures
Check components comply with one of the following quality and accuracy standards:
- meets company standards and procedures
- is dimensionally accurate within specification tolerances
- has an appropriate surface finish and are free from defects or surface blemishes