Trying out and proving dies

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This standard identifies the competences you need to undertake try-out and proving activities on dies, in accordance with approved procedures.  This will include dies such as draw, trim, re-strike, flange, combination, pierce dies, pressure, transfer, progression, puttrusion and extrusion dies.  You will be required to check that the designated die has been positioned and set up correctly, and that any handover or permit-to-work procedures have been completed.  You will also be required to ensure that the machines have safe access and are free from hazards, and that any necessary lifting and handling equipment, try-out/proving tools, consumables and site services are available, so that the try-out/proving can be carried out safely and efficiently.

You will be expected to apply a range of try-out and proving methods and techniques, such as spotting, grinding, finishing and polishing.  You will also be required to make off-load checks, aligning and adjusting components before making a full die strike.

Your responsibilities will require you to comply with organisational policy and procedures for the try-out/proving activities undertaken, and to report any problems with these activities or with the tools and equipment used, that you cannot personally resolve or are outside your permitted authority, to the relevant people.  You must ensure that all tools, equipment, and materials used in the try-out/proving activities are removed from the work area on completion of the activities, and that all necessary job/task documentation is completed accurately and legibly.  You will be expected to work with minimum 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 try-out and proving procedures for die tool equipment.  You will understand the die try-out and proving methods and procedures, and their application.  You will know how the machine and die functions, the purpose of the individual components and associated defects, in adequate depth to provide a sound basis for carrying out the try-out/proving activities, correcting faults and ensuring that the die functions and produces components to the required specification.

You will understand the safety precautions required when carrying out the try-out and proving activities, especially those associated with delivery and collection systems and for isolating the equipment.  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. confirm that the equipment is set up correctly and ready for the activities to be carried out
3. maintain an adequate supply of base/raw material
4. manipulate the machine controls safely and correctly, in line with operational procedures
5. produce trial components and check that they meet the required specification
6. report any instances where the activities cannot be fully met or where there are identified defects
7. complete relevant trial records accurately, and pass them on to the appropriate person
8. shut down the equipment to a safe condition on conclusion of the activities
9. deal safely with excess materials, in line with organisational procedures

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1. the health and safety requirements of the area in which the die try-out and proving activity is to take place
2. the hazards, and specific safety precautions to be taken, when carrying out die try-out and proving activities, (such as weight, press stored pressure/force, misuse of tools, press jacking/chocking, isolation procedures or appropriate lock-off procedures), and how they can be minimised 
3. the emergency procedures that are in place to deal with a machine malfunction when working with die equipment 
4. the COSHH regulations relating to materials used in the die try-out/proving activities
5. the importance of wearing protective clothing and other appropriate safety equipment (PPE) during the die try-out and proving process
6. how to obtain and interpret drawings, specifications, manufacturers' manuals and other documents needed in the process
7. the procedure for obtaining consumables necessary for the die try-out activities
8. the various types of die tools that are used, and their typical applications
9. why it is important to check the dies for damage or other non-conformance, prior to try-out
10. the principle of operation of the dies and equipment being used, and the working purpose of individual components and how they interact
11. how to check that tools and equipment are free from damage or defect, are in a safe and usable condition, and are configured correctly for the intended purpose
12. the methods and techniques involved in the die try-out and proving activities
13. the application of compressed air equipment used in die try-out
14. how to make adjustments to components/assemblies to ensure that they function correctly
15. how to identify panel/components faults caused by the action of the die, and how specific part control can be applied to overcome them
16. the generation of die try-out documentation and/or reports following try-out activity
17. how to use lifting and handling equipment in the try-out activity
18. the various machine operating parameters that require setting up (such as pressure, speed/timings and distance/stroke), and how these are achieved
19. the effects that changes to these settings will have on the quality of the components produced
20. preparations to be carried out on the materials, in order to ensure that the completed components meet the required specification
21. methods of checking the finished components to ensure that they are to the required specification
22. identification of component defects, their causes, and methods of prevention
23. why it is important to keep the die equipment clean and free from damage, to practice good housekeeping of tools and equipment, and to maintain a clean and unobstructed working area
24. the problems associated with die try-out/proving activity, and how they can be overcome
25. the procedure to be adopted for the safe disposal of waste of all types of materials
26. the extent of your own authority and whom you should report to if you have problems that you cannot resolve

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1. Carry out all of the following during the die try-out and proving activities:

1. use the correct issue of company and/or manufacturer's drawings and documentation
2. adhere to risk assessment, COSHH and other relevant safety standards
3. use appropriate personal protective equipment
4. provide safe access and working arrangements for the die try-out/proving area
5. ensure that all guards, screens and safety mechanisms are in place and operate correctly
6. carry out the die try-out/proving activities using appropriate techniques and procedures
7. adhere to component inspection procedures throughout the die try-out/proving
8. leave the work area in a safe and tidy condition on completion of the activities
   
    

2. Carry out die try-out and proving activities on two of the following types of die:

1. draw die (such as cushion, single action, double action, inverted double action)
2. trim
3. re-strike
4. stamping
5. flange
6. pressure (high or low)
7. progression
8. combination
9. transfer
10. extrusion
11. pierce
12. pultrusion
    
     

3. Prepare the machine for use, to include carrying out all of the following checks prior to commencing die proving:

1. appropriate work permit/handover documentation has been issued
2. ensure that correct press/die pressure can be achieved
3. check that the dies are free from damage or defects, and are correctly and securely mounted
4. inspect the die for completeness
5. check the freedom of all moving parts
6. check the movement of ejector mechanisms
7. all die securing devices are activated and effective
8. die faces have been correctly prepared
9. check all working clearances
10. ensure that all machine services are connected and operational (such as water, electrical, pneumatic, hydraulic)
11. ensure that die stops are engaging correctly
12. set and check that the material feed systems are operating correctly
13. set and check that all machine safety mechanisms and features are operating correctly (such as guards, emergency stop)
14. check and adjust the machine operating conditions to suit the components being produced
    
     

4. Try out and prove dies using appropriate methods and techniques, to include three of the following:

1. surface blueing
2. hand grinding
3. hand finishing
4. polishing/stoning up
5. material movement control
6. specific part control
   
    

5. Ensure that the completed die complies with all of the following:

1. the die meets the manufacturer's specification
2. organisational guidelines and codes of practice
3. the dies comply with appropriate regulations
4. components produced meet their specification requirements
   
    

6. Complete the try-out/proving operations, and carry out all of the following:

1. completing all relevant documentation
2. disposing of surplus material, in line with company procedures
3. closing down the machine and checking that all systems are safe

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2

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2018

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Current

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Original

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Semta

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SEMET15

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Metal Machining, Fitting and Instrument Making Trades

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5222

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Engineering; toolmaking; tryout; proving; dies; draw; trim; pierce; flange; restrike

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