Operating CNC fabrication machines
Overview
This standard identifies the competences you need to operate computer numerical controlled (CNC) fabrication machines, such as shearing machines, water, gas, laser or plasma cutting, punching, bending and forming machines, for the manufacture of marine steelwork components, in accordance with approved procedures.
Setting up of the machine, its tooling and associated workholding devices are the subjects of other standards.
You will be expected to take charge of the prepared machine and check that it is ready for the machining operations to be performed. This will involve checking that all the required materials and consumables are present and that the machine has been approved for production. In operating the machine, you will be expected to follow the correct procedures for calling up the operating program, dealing with any error messages and executing the program activities safely and correctly.
You will be required to continuously monitor the cutting or forming operations, making any necessary adjustments to machine parameters, in line with your permitted authority. Meeting production targets will be an important issue, and your production records must show consistent and satisfactory performance.
Your responsibilities will require you to comply with organisational policy and procedures for the CNC machining activities undertaken and to report any problems with the equipment, tooling, program, materials or activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work to instructions, with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you produce.
Your underpinning knowledge will be sufficient to provide a sound basis for your work and will provide an informed approach to applying CNC fabrication machining procedures. You will have an understanding of the CNC fabrication machining process used and its application and will know about the machine, tooling, materials, machining activities and consumables, in adequate depth to provide a sound background to machine operation and for carrying out the activities to the required specification.
You will understand the safety precautions required when working with the machine, its associated tools and equipment. 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
- confirm that the equipment is set up and ready for operation
- follow the defined procedures for starting and running the operating system
- operate the equipment to produce fabricated components
deal promptly and effectively with error messages or equipment faults that are within your control and report those that cannot be solved
produce components which meet the required accuracy requirements
monitor the computer process and ensure that the production output is to the required specification
- shut down the equipment to a safe condition on conclusion of the activities
Knowledge and Understanding
You need to know and understand:
- the specific safety precautions to be taken when working with CNC fabrication machines and equipment
- the safety mechanisms on the machine and the procedures for checking that they are operating correctly
- the hazards associated with working on CNC cutting and forming machines (such as moving machinery, automatic machine operation, handling cutting tools, lifting and handling workholding devices, handling sheet materials, hot materials, fumes, pressures)
- the correct methods of moving or lifting plate materials and components
- how to start and stop the machine, in both normal and emergency situations
- the importance of wearing the appropriate personal protective clothing and equipment (PPE) and of keeping the work area clean and tidy
- the application of the CNC machine and the range of operations it can perform
- how to obtain and interpret information from job instructions, drawings and machining specifications, in relation to the work undertaken
- how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing
- how to interpret the visual display and understand the various messages displayed
- the function of error messages and what to do when an error message is displayed
- how to find the correct restart point in the program when the machine has been stopped before completion of the program
- the operation of the various hand and automatic modes of machine control (such as program operating and control buttons)
- how to operate the machine using single block run, full program run and feed/speed override controls
- how to make adjustments to the program operating parameters
- how to set and secure the workpiece to the machine, the effects of clamping the workpiece and how material removal can cause warping/distortion of the finished workpiece
- the problems that can occur with the cutting and forming activities and how these can be overcome
- care of equipment and operating programs, including safe storage of electronic materials away from possible contamination and corruption
- 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 quality control procedures used, inspection checks to be carried out, and the equipment that is used for this
- the extent of your own responsibility and whom you should report to if you have problems that you cannot resolve
Scope/range
Scope Performance
Ensure that the machine is ready for operation, by carrying out all of the following:
- checking that the correct operating program is loaded and is at the correct start point
- ensuring that machine guards are in place and correctly adjusted
- positioning and securing material/components without distortion
- checking that cutting tools/tooling are in a suitable condition
- setting plate/section datums and positioning the machine
- updating program tool data, as applicable
- ensuring that the correct start-up procedures are observed
- ensuring that machine settings are adjusted as required to maintain accuracy
Operate one of the following CNC fabrication machines:
- shearing machine
- forming machine
- plasma cutting
- gas cutting
- punching machine
- bending machine
- laser cutting
- water jet cutting
Position and secure the workpiece, using two of the following holding methods/devices:
- jigs and fixtures
- pneumatic clamps
- clamps and stops
- other workholding devices
Produce components which combine several different operations and which cover five of the following:
- straight cuts
- holes radially pitched
- multi-bend platework
- square/rectangular profiles
- louvres
- curved plates
- curved profiles
- swages
- internal profiles
- bends at 90°
- holes linearly pitched
- bends of various angles
- other specific operations
Produce components for four of the following:
- deck plates
- transverses/longitudinal girders
- bulkheads
- beam knees/brackets
- shell plates
- frames/longitudinals/stiffeners
- web/cantilevers
- intercostals/wash plates
Produce components using one of the following types of material:
- ferrous
- non-ferrous
- stainless
- special alloys
- other specific material
Carry out the necessary checks during production, for accuracy of four of the following:
- linear dimensions
- accuracy of profiles
- flatness/freedom from excessive distortion
- position of features
- accuracy of louvres and swages
Produce components which meet all of the following quality and accuracy requirements:
- dimensional accuracy is within the specification tolerances
- the plate conforms to best practice and or specification, without deformation or cracking
- the component conforms to the required shape/geometry (to the template profile)
- components to be free from deformity, burrs and sharp edges
Scope Knowledge
Values
Behaviours
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