Checking that toolroom assemblies comply with specification
Overview
This standard identifies the competences you need to carry out checks on moulds, dies, press tools or jig and fixture assemblies, in accordance with approved procedures. You will be required to prepare the work area, ensuring that it is safe and free from hazards, and to obtain all relevant and current documentation. You will also need to obtain the tools and equipment required for the checking activities, and to make sure that they are calibrated and are in a safe and usable condition.
You will be responsible for confirming that the assembly is complete, meets all dimensional and geometric tolerances, is fit for purpose, and meets the operational performance required by the specification. In order to do this, you will be expected to carry out all necessary inspection checks and manual operational checks and, where appropriate, oversee trials of the die, mould, press tool or jig and fixture. You will also be required to complete any relevant inspection documentation, accurately and legibly.
Your responsibilities will require you to comply with organisational policy and procedures for checking the tool room assemblies, and to report any problems with the assemblies that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to ensure that all tools and equipment used in checking the assemblies are correctly accounted for on completion of the activities and returned to the correct location. 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 demonstrate a good understanding of your work, and will provide an informed approach to applying quality control techniques and procedures including, where appropriate, British, European and International standards. You will understand the assemblies being checked, and their application, and will know about the tools and equipment used to check the assemblies, in adequate depth to provide a sound basis for carrying out the activities to the required specification. You will understand the types of defect that can be found on the assemblies, and how critical these defects are in determining the satisfactory performance of the completed product.
You will understand the safety precautions required when carrying out the checking activities. 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 and make appropriate use of the specifications for the product or asset being checked
- use all the correct tools and inspection equipment and check that they are in useable condition
- carry out the checks in an appropriate sequence using approved methods and procedures
- identify and assess any defects or variations from the specification and take appropriate action
- report completion of compliance activities in line with organisational procedures
Knowledge and Understanding
You need to know and understand:
- the specific safety precautions to be taken while carrying out the die, mould, press tool or jig and fixture assembly checks (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials)
- the health and safety requirements of the work area in which you are carrying out the assembly checking activities, and the responsibility these requirements place on you
- COSHH regulations with regard to the substances used in the assembly or checking process
- the hazards associated with checking die, mould, press tool or jig and fixture assemblies, and how they can be minimised
- the personal protective equipment and clothing (PPE) to be worn during the assembly checking activities
- how to use and extract information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS or ISO standards) in relation to work undertaken
- how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing
- the use of British, European and International standards in determining if components and assemblies are fit for purpose
- the general principles of quality assurance, control systems and procedures
- the various stages when the assembly should be checked, and to what level
- preparations to be undertaken before the assembly is checked
- the application of the various tools and equipment used to check the assembly
- the importance of ensuring that tools and equipment are set up correctly and are in a safe and useable condition
- the procedure and methods used to check that tools and equipment are within calibration date
- the quality control procedures to be followed when checking the assembly
- how to conduct any necessary checks to ensure the safety, accuracy, position, security, function and completeness of the assembly
- the types of defect that can be found in the die, mould, press tool or jig and fixture assemblies, and why they occur
- how to detect assembly defects, and what to do to rectify them
- the documentation to be completed to confirm that the assembly has been properly checked
- the importance of ensuring that all tools and equipment are returned to their correct location on completion of the assembly checking activities
the extent of your own responsibility and whom you should report to if you have problems that you cannot resolve
Scope/range
Scope Performance
1. Carry out all of the following during the checking activities:
- use the correct issue of drawings, job instructions and specifications
- check the calibration dates of tools and measuring instruments to be used
- ensure that all exposed openings are free from foreign objects, dirt or other contamination
- use appropriate and safe inspection and checking techniques at all times
- complete all relevant documentation on completion of the checking activities
- leave the work area in a safe condition
2. Carry out checks on one of the following assemblies:
- injection moulds
- blow moulds
- die tools
- press tools
- jigs and fixtures
- other specific toolroom assemblies
3. Use six of the following instruments and gauges whilst checking the assembly:
- micrometers
- verniers
- squares
- straight edges
- levels
- dial test indicator
- feeler gauges
- templates
- slip gauges
- protractors
- surface finish devices
- profile gauges
- torque wrench
- pressure gauge
- temperature gauges
- electrical measuring equipment
- optical equipment
- co-ordinate measuring equipment
- other specific checking equipment
4. Use the relevant equipment to measure and check eight of the following features:
- dimensions
- position/location
- flatness
- alignment
- squareness
- parallelism
- level
- verticality
- concentricity
- fit/working clearance
- angles
- profile
- surface finish
- freedom from distortion
- torque
5. Check the operational functions of the assembly, to include all of the following, as appropriate to the equipment being checked:
- freedom of all moving parts
- distance/travel of moving parts
- correct operation of material ejection system
- material clamping arrangements are satisfactory
- moving parts operate at the correct time/sequence
- correct operation of material loading/feed system
- operation of heating/cooling system
- operation of safety mechanisms
- assembly is free from damage, and check for completeness
- securing/mounting facilities are to specifications
- connections/arrangements for service supplies (such as water, air, electrical supply)
6. Oversee two of the following types of check to ensure that the completed assembly meets the specification:
- trial
- under power
- fully operational
- manual check
7. Check that toolroom assemblies comply with one of the following quality and accuracy standards:
- BS or ISO standards and procedures
- customer standards and requirements
- company standards and procedures
- specific system requirements