This standard identifies the competences you need to lead welding and fabrication activities to ensure that all the products manufactured are fit for purpose and meet the required quality specification on time and to budget. You will be required to agree and monitor departmental budgets, the review of product standards and other supplementary requirements, assess the capability to meet prescribed requirements and perform technical reviews to establish parent material specifications and welded joint properties, inspection, testing, quality and acceptance requirements in accordance with approved procedures and policies.

You will also be required to establish the required qualifications and experience for personnel and select competent welders and welding operators, welding inspectors and NDT operators. You will also select suitable welding and associated equipment, including personal protective equipment, for the production. You will be required to consider the necessary methods and actions for calibration and validation of measuring, inspection and testing equipment.

You will also be required to identify and implement a systematic approach to improving the welding and fabrication activities undertaken.

Your responsibilities will require you to comply with organisational policy and processes for the storage, handling and traceability of materials, including welding consumables.

You will be required to prepare and maintain quality records, including non-conformance and corrective actions, reporting any problems that you cannot personally resolve, or that are outside of your permitted authority, to the relevant people.  You must ensure that that all necessary data and documentation is completed accurately and legibly and stored in the correct location and format.  You will be expected to work with minimal supervision, taking personal responsibility for your own actions, and for the quality and accuracy of the welding and fabrication work carried out.

Your underpinning knowledge will provide an in depth understanding of your work, and will provide an informed approach to applying a range of leadership methods and techniques to ensure that the welding and fabrication activities undertaken are fit for purpose and meet the quality specification on time and to budget.  You will know about the welding and fabrication processes and associated quality assurance requirements in an adequate depth to provide a sound basis for leading the welding and fabrication activities.  In addition, you will have sufficient knowledge on how to develop the welding and fabrication team and how to identify and implement a systematic approach to improving the welding and fabrication activities undertaken.

You will understand the safety precautions required when carrying out the welding and fabrication activities.  You will also understand your responsibilities for safety and the importance of taking the necessary safeguards to protect yourself and others in the workplace.

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1. work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
2. develop, gain agreement and review departmental budgets
3. produce, agree and update departmental schedules and plans
4. ensure that schedules and plans are capable of meeting the required outputs
5. lead welding or fabrication activities 
6. complete and save relevant welding or fabrication data and documentation accurately
7. identify and lead on making improvements to processes and procedures
8. ensure welding or fabrication activities are carried out correctly in line with approved company processes and procedures
9. create and update visual management documentation and systems to support the activities of the department
10. report and evaluate the impact of improvement activities
11. produce and maintain departmental competency skills matrix of team members
12. provide technical advice and guidance as required

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1. the health and safety requirements of the area in which the welding or fabrication activity is to take place and the responsibility these requirements place on you
2. the information systems that are in use within your organisation and how to record data to the system
3. how to obtain and interpret legislative and regulatory documentation
4. how to obtain and interpret company policies and procedures
5. how to prioritise your own and your team's workload to ensure that targets are met
6. the process to be followed to develop and gain agreement on departmental budgets
7. the importance of regularly monitoring departmental budgets and the implications for the business if this is not carried out
8. how to communicate effectively, listen, question, support and coach others to work towards the departmental targets
9. the importance of ensuring that teams have the required skills, knowledge, experience, behaviours and where appropriate qualifications in order to weld or fabricate components to the required standards
10. how to access training and development programmes once a training need has been identified  
11. the specific health and safety precautions to be applied during the welding or fabrication and process and their effects on others
12. how to complete and review risk assessments
13. hazards associated with carrying out activities in the department and how to minimise these and reduce any risks
14. the importance of ensuring employees wear protective clothing and other appropriate safety equipment (PPE) during the welding or fabrication process
15. the importance of having access to up to date data and information such as drawings, specifications, manufacturers' manuals and other documents needed in the welding or fabrication process
16. who to contact if clarification is required on the welding or fabrication requirements
17. who should be involved in authorising any changes required to welding or fabrication activities
18. the methods used to calculate how long it should take to complete specific work outputs
19. the procedure for purchasing/obtaining materials and other consumables necessary for the welding or fabrication activities
20. the criteria for selection and application of different welding consumables
21. the classification, properties and typical applications of steels, aluminium alloys and other engineering materials in common use
22. the methods for identification of relevant materials and components
23. the characteristics and application of welding and cutting processes
24. the operation, maintenance and calibration requirements of the principal components of welding power sources and ancillary equipment
25. the characteristics and benefits of automated and mechanised welding processes
26. the terms, symbols and definitions used in weld and fabrication drawings and specifications
27. the principles of quality assurance and quality control and recognise the related standards and their application to welded fabrication as a special process
28. the requirements and function of Quality Control during manufacture, the standards related to welding operators and welding procedure qualification including joint traceability methods, the need for calibration, and monitoring of process parameters
29. the main factors affecting welding stress and distortion in welded fabrications and how these effects can be measured and minimised
30. the need for, and function of, auxiliary equipment, jigs and fixtures from the viewpoint of quality, economics and the environment
31. the methods of controlling the properties of welded joints, including strength, toughness, hardness, and corrosion resistance
32. effect of heat treatment, including normalising, annealing, preheating, quench and tempering, solution treatment and post-weld heat treatment
33. the methods and equipment used for heat treatment
34. the purpose and application of hydrostatic test methods
35. the need for and application of destructive mechanical testing
36. the purpose and application of inspection quality test plans or written schemes of examination
37. the requirements for measurement, control and recording during welding and allied operations
38. the principles of imperfections and acceptance criteria
39. the use of Non Destructive Testing (NDT) as applied to welding fabrications
40. the economics of welding operations applied to welded fabrications
41. the problems of repair welding both for in manufacture and in-service situations
42. the principles of choice of joints in reinforcing steels and their design
43. the importance of keeping up to date with new technologies, welding and fabrication methods and techniques
44. the quality assurance and control methods that are used in the department
45. the personnel involved to ensure that the quality of product outcomes are fit for purpose and their responsibilities to ensure this is achieved
46. the process and procedures to be followed when defective products are identified both during production/on completion of the welding or fabrication process
47. the organisational procedure(s) to be adopted for the safe disposal of all types of waste materials
48. how to conduct a systematic plan, do, check, act (PDCA) approach to problem-solving and business improvement
49. how to use "root cause" problem solving analysis using the 5 whys/how technique
50. how to evaluate improvement ideas in order to select those that are to be pursued
51. how improvements to the process are achieved by engaging the knowledge and experience of the people working on the process
52. how to create, review and modify Standard Operating Procedures (SOP's) and correlate work activities into them
53. the techniques required to communicate information using visual control systems (such as, card systems, colour coding, floor footprints, graphs and charts, team boards, tool/equipment shadow boards)
54. the extent of your own authority and to whom you should report if you have a problem that you cannot resolve

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1. Lead the welding and fabrication activities by carrying out all the following:

   1. interpret the Health and Safety Regulations for the welding and fabrication environment and apply controls, mitigation and protective equipment to address the risk factors associated with welding, cutting, grinding and NDT
   2. obtain accurate details of the products to be welded or fabricated
   3. review and interpret the product specification and documentation to assess their characteristics and requirements
   4. clarify any aspects of the product specification or timescales that are unclear
   5. communicate the welding, inspection, testing and fabrication activities to be undertaken with the team
   6. involve the team in planning how the welding and fabrication activities will be achieved
   7. provide clear and accurate instructions to all the relevant people
   8. advise welding personnel on welding instructions and techniques
   9. secure, monitor and control the use of resources to achieve the most effective results
   10. confirm and communicate any changes to the product specification and/or timescales required by the customer
   11. allocate specific jobs/tasks to appropriate personnel
   12. motivate the team to present their own ideas on improvements that could be made to the manufacturing process and procedures
   13. encourage the team and/or individuals to take the lead where appropriate
   14. deal efficiently and effectively with problems affecting production/inspection output
   15. produce and agree contingency plans when required

2. Carry out all the following whilst leading the welding and fabrication activities:

   1. interpret weld drawings and weld symbols, understand and apply the correct codes, standards and welding procedures for the scope of production
   2. review and verify that welder qualifications are valid for the scope of production, assign welders and control their deployment
   3. select the correct welding and associated equipment and verify that it is serviceable and calibrated
   4. select, supply and control the traceability of verified parent materials, check joint preparation, fit-up and cleanliness before welding
   5. identify welding consumables, verify welding consumables against documentation, and control their storage and supply
   6. control the welding parameters, techniques, sequences, preheating, heat input and heat treatment
   7. apply visual inspection to the control of weld finish and dimensions, and control of the shape and dimensions of the part, component or assembly
   8. assign appropriate non-destructive testing of the welds
   9. assess inspection and test reports and identify the factors affecting weld defects and apply acceptance criteria from relevant codes, standards or specifications
   10. identify the nature and extent of production problems, evaluate and select solutions, and control weld repair and rework
   11. prepare, review, maintain and archive inspection reports and weld quality records

3. Prepare and plan welding and fabrication activities by carrying out all of the following:

   1. select materials, welding process, equipment and consumables based on weld and fabrication drawings and application standards or contract specifications
   2. compile and review welding procedures for welded components in accordance with national and international standards
   3. interpret and apply standards to the qualification of a welding procedure, recognising the main variables and its range of qualification
   4. determine the main variables for a particular welder/welding operator qualification and its range of qualification, and initiate and maintain welder qualification tests and records
   5. select and apply appropriate fixtures, jigs or positioners to improve weldability or productivity in a particular welded fabrication
   6. select and apply auxiliary equipment, and cables, heat treatment equipment and temperature controls for a particular welding procedure
   7. analyse welding production rates and costs and schedule welding and handling activities to achieve requirements

4. Lead Quality Assurance and Quality Control activities for welding and fabrication by carrying out all of the following:

   1. produce and implement effective quality control procedures
   2. interpret and apply relevant standards (such as. ISO 9000, and BS EN ISO 3834) to storage, supply, control and traceability of materials and consumables, including calibration of equipment
   3. recognise the basic factors related to personnel and equipment that influence the quality in a welded fabrication, and control them to achieve specified results
   4. apply Inspection Quality Test Plans/Written Schemes of Examination in accordance with application standards or contract specifications, and demonstrate correct use of acceptance standards for weld imperfections
   5. control welding quality, residual stresses and distortion through measurement of welding parameters and measurement and control of heat treatment operations

5. Lead one of the following activities:

Weld Repair

1.  produce a welding procedure qualification, recognising the problems of making repair welds
2.  coordinate the safety requirements for an in-service weld repair, with regard to specific needs such as hot working permit, fume control and special access or confined space training
3.  select appropriate welding personnel, equipment and consumables to be applied to a specific weld repair procedure  

Or

Welding of reinforcing steel
4. select appropriate joints for load bearing and non-load bearing
5. determine joint length and preheat for specified steel types and diameters
6. select appropriate welding processes welding of reinforcing steel to satisfy requirements of standards (such as BS EN ISO 17660 series and National Standards) and specifications

6. Create and maintain management data and information to include the following:

   1. welding or fabrication work plans/delivery schedules

plus supporting documentation associated with three of the following
2. quality records/defects
3. problem history/resolution
4. resources/materials requisitions
5. budgets
6. equipment performance
7. equipment maintenance
8. equipment downtime/failure
9. equipment utilisation
10. health and safety
11. staff development and training
12. department procedures/work instructions
13. tests and trials
14. regulatory compliance
15. justification of the purchase and/or application of innovative/new welding equipment

7. Identify and implement improvements in the manufacturing/inspection department to achieve four of the following:

   1. reduced production costs
   2. reduced lead times
   3. improved quality
   4. improved equipment/tooling efficiency
   5. improved staff utilisation
   6. improved working practices
   7. improved equipment downtime
   8. improved equipment utilisation
   9. improved use of production/inspection technologies
   10. improved use of information technology
   11. improved health and safety
   12. improved visual management systems/documentation
   13. improved resource planning
   14. improved staff development and training
   15. reduction in waste
   16. reduction in energy usage
   17. improved environmental impact
   18. improved customer service
   19. other specific improvement

8. Ensure welded or fabricated products complies with three **of the following:

   1. organisational guidelines and procedures
   2. equipment manufacturer's operating specification/range
   3. British, European or International standards or directives
   4. recognised compliance agency/body standards or directives
   5. health, safety and environmental requirements
   6. customer standards and requirements

9. Complete the relevant documentation to include one from the following:

   1. job/route cards
   2. company-specific production recording system

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​Additional Information

You will be able to apply the appropriate behaviours required in the workplace to meet the job profile and overall company objectives, such as:

• strong work ethic
• positive attitude
• team player
• dependability
• responsibility
• honesty
• integrity
• motivation
• commitment

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31 Mar 2020

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Current

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Original

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Semta

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SEMEM4-37

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Corporate Managers and Senior Officials, Engineering, Engineering and Manufacturing Technologies, Functional Managers

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1121

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Engineering; leading; design; process; maintenance; quality; customer; function; features; objectives; manufacturing; installation; commissioning; testing; carrying out; problems; specifications; quality; research; evaluate; welding; fabrication

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