Solving welding problems in production
Overview
This standard identifies the competences you need to solve welding related problems that arise in production, in accordance with approved procedures. You will be required to evaluate available evidence, to identify the source of the problem and to recommend/agree solutions, seeking specialist help from others if required. Your proposed solution will take into account the effects on both the welding process and on the people involved.
Your responsibilities will require you to comply with organisational policy and procedures for the welding activities undertaken, and to report any problems with those activities 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 problem solving techniques and procedures to welding production situations. You will understand the relevant welding technology and its application, and will know about the technology in adequate depth to provide a sound basis for carrying out the activities to the required standard.
You will be aware of any company/customer, legislative or regulatory health, safety and environmental requirements applicable to the welding process used. You will understand the specific safety precautions required when carrying out the problem solving activities, especially those for isolating the equipment. You will be required to demonstrate safe working practices throughout, and will understand your responsibility for taking the necessary safeguards to protect yourself and others in the work area.
Performance criteria
You must be able to:
- take prompt action to solve engineering problems and keep all relevant people informed of progress
- obtain all relevant information relating to the engineering problems
- identify correctly the nature and extent of any engineering problems that arise
- evaluate all realistic engineering solutions to solve engineering problems
- identify the most effective engineering solution for solving engineering problems
- ensure that engineering solutions are implemented correctly and promptly
- update the quality assurance system in accordance with organisational procedures
- ensure that solutions to engineering problems comply with all relevant regulations and guidelines
Knowledge and Understanding
You need to know and understand:
- the specific safety precautions to be taken when working with production welding and related equipment (such as specific legislation or regulations governing the activities or work area, safe working practices and procedures to be adopted, general workshop safety practice, risk assessment procedures and relevant requirements of HASAWA, COSHH and Work Equipment Regulations)
- the personal protective clothing and equipment (PPE) that should be worn (such as eye protection, ear protection, safety clothing)
- the hazards associated with the production welding and related processes (such as arc flashes, fumes and gases, safety in enclosed/confined spaces, handling hot welded components/structures), and how they can be minimised
- how to access information on health and safety regulations and guidelines relating to the welding production activities to be implemented
- the implications of not taking account of legislation, regulations, standards and guidelines when determining solutions to the welding problems
- the welding production processes being used, and their technology (such as basic principles of fusion welding, AC and DC power sources, power ranges, manual metal arc (MMA), MIG, MAG or flux cored-wire arc welding, tungsten arc welding (TIG), submerged arc, oxy/fuel gas and plasma welding, electron beam, resistance welding, laser and friction welding and other relevant fusion welding processes)
- materials and their behaviour during welding (such as structure and property of metals; heat treatment requirements; types of steel and cracking phenomena, cast iron, copper, nickel, stainless steel, aluminium and their alloys; joining dissimilar materials)
- construction and design of welded joints (such as design principles of welded construction, joint design, behaviour of welded structures under static and dynamic loading)
- general principles of welding components and structures (such as use of jigs, fixtures and manipulating devices; residual stresses and distortion; types of defect and their avoidance; quality control during production)
- types and features of welded joints in plate, tube and sections (including fillet and butt welds, single and multi-run welds, welding positions, weld quality)
- how to obtain information on the production welding requirements, and the types of information available (such as customer requirements and instructions, quality control requirements, product specification, manufacturing methods, equipment manuals/specifications)
- how to obtain and interpret drawings, charts, specifications, manufacturers' manuals, history/maintenance reports and other documents needed in the problem solving process
- how to use and extract information from engineering drawings and related specifications (to include symbols and conventions to appropriate British, European or relevant International standards in relation to work undertaken)
- the principles of effective problem solving; the main problem solving methods and techniques in use, and how to apply them
- the importance of collecting as much relevant information as possible, and of collating such information in a way that facilitates decision making, and the methods to achieve this
- action planning (to include risk analysis, testing decisions, determining timescales and protecting the user/customer)
- the importance of analysing problems from a variety of perspectives
- how to define and verify the root cause of a problem
- the importance of involving a range of relevant people in generating possible solutions
- the importance of developing a range of possible options in solving problems
- the factors to be taken into account when solving problems and determining suitable solutions, especially those covering working conditions and safety
- how to present possible solutions in a way that helps relevant people to reach an informed and realistic judgement
- how to determine and select permanent corrective actions (to include decision making, assessing the criteria and determining the risks, costs and generating alternatives)
- how to prevent recurrence of the problems (to include proposed changes to management systems, operating systems and procedures, and the identification of opportunities for improvements)
- the importance of maintaining records of the problem solving activities; what needs to be recorded, and where records are kept
- the different ways in which the solutions can be reported back
- who should be informed of actions taken, and by what means
- the extent of your own responsibility, and to whom you should report if you have problems that you cannot resolve
- the sources of technical expertise if you have problems that you cannot solve
Scope/range
Scope Performance
Carry out all of the following during the problem solving activity:
- discuss/consult with the relevant people on the nature and extent of the problem and its impact on the welding activity
- gather information from appropriate sources to help identify and define the problem
- Identify and evaluate possible solutions, considering temporary, short term and long term solutions
- select the most appropriate solution to rectify the problem
- communicate the proposed solution to the relevant people, obtaining feedback where appropriate
- prepare a plan of action for implementation of the agreed solution
- ensure that the agreed solution is implemented in an effective and timely manner
- ensure that the agreed solution complies with appropriate regulations and guidelines
- implement preventive measures (where applicable) to ensure that the problem does not reoccur
Resolve two welding production problems from each of the following groups:
Before welding:
- parent materials
- welding consumables
- welding and associated equipment
- preparation for welding
- fit-up of joint
- welding procedure
- welder qualifications
During welding:
8. welding equipment performance
9. weld profile
10. low output
11. welder performance
12. defects
13. health and safety
14. quality control
15. distortion
After welding
16. dimensions
17. defects
18. weld properties
Gather and use all relevant information on welding production problems from six of the following:
- fabrication drawings
- heat treatment records
- material certificates
- welding equipment procedures and operation
- consumables certificates
- comments from the welder (written or verbal)
- welding records
- applicable codes, specifications and procedures
- inspection or NDT reports
- welding procedure qualification and welder approval certificate
- mechanical test reports
* *
Evaluate possible solutions to the problems, by considering all of the following:
- operational effectiveness
- environmental impact
- ease of implementation
- staffing implications
- timescale for implementation
- conformity with company policy
- financial impact
- health and safety implications
- functionality of the system
- other specific area
* *
Implement the solution for two of the following timescales, taking into account the urgency of the problem:
- temporary (interim solution – will require further action)
- medium term (may require further action)
- long term (permanent solution)
* *
Ensure that the solution complies with relevant regulations, directives, standards and guidelines, from all of the following, as appropriate:
- statutory bodies
- manufacturer specific
- company policy and procedures
- national
- industry specific
- international
- client requirements
* *
Update the quality assurance system, as appropriate, and communicate the solution of the problem to the relevant people, using the following methods:
- verbal report
Plus one more from the following:
2. specific company documentation
3. written or typed report
4. electronic mail
5. computer based presentation/media
Scope Knowledge
Values
Behaviours
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