Producing replacement components for marine maintenance activities
Overview
This standard identifies the competences you need to produce replacement components for marine maintenance activities, in accordance with approved procedures. You will produce these components using manual machining techniques, such as milling, turning, grinding, shaping/slotting, drilling/boring, combined with a range of hand fitting techniques. You will be expected to produce components that require you to use a range of different machines and this will involve setting up the workholding arrangements, workpiece and machine tooling. You will also be expected to use a range of hand tools, portable power tools, shaping and fitting techniques, appropriate to the type of material and operations being performed. These activities will include such processes as hand sawing, machine sawing, filing, drilling, chiselling, threading, and offhand grinding. The components produced will typically be such items as shafts, bushes, sleeves, distance pieces/spacers, packings, plates, studs, slides, pulleys, gear blanks, handles, levers or linkages.
Your responsibilities will require you to comply with organisational policy and procedures for the manufacturing activities undertaken and to report any problems with the machines, tooling, materials or activities that you cannot personally resolve, or are outside your personal responsibilities, to the relevant people. You will be expected to work with minimal 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 manufacturing procedures and instructions for the production of replacement marine components. You will understand the machining and fitting processes used and their application and will know about the machine, tooling, ancillary equipment, materials and consumables in adequate depth to provide a sound basis for carrying out the activities, correcting faults and producing the components to the required specification.
You will understand the safety precautions required when working with the machines and their 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, whether in workshops, dry dock or dockside areas.
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 instructions and any relevant specifications to produce the component
- produce the required components using appropriate manufacturing methods and techniques
- check that the finished component meets the requirements and make any necessary adjustments
- deal promptly and effectively with problems within your control and report those that cannot be solved
- complete relevant documentation in line with organisational procedures
Knowledge and Understanding
You need to know and understand:
- the safe working practices and procedures to be followed whilst carrying out the machining and fitting activities
- the safety mechanisms on the machine and the procedure for checking that they are operating correctly
- how to operate all the machine controls in both hand and power modes and how to stop the machine in case of an emergency
the importance of wearing appropriate protective clothing and equipment (PPE) and of keeping the work area clean and tidy
how to obtain and interpret drawings, specifications, manufacturers' manuals and other documents needed in the manufacturing process
- where no drawings are available, how to take measurements and produce working sketches of parts to be made
how to use filing, scraping and lapping to achieve the required surface finish (including using various types of files/scrapers, checking that file/scraper handles are in good condition, selecting and using lapping mediums)
how to cut external threads using hand dies and the method of fixing and adjusting the dies to give the correct thread fit
- how to determine the drill size for tapped holes and the importance of using the taps in the correct sequence
- how to produce a sliding or mating fit
- how to select saw blades for different materials and different operations
- the use of vice jaw plates to protect the workpiece from damage
- how to use hand power tools and specialist equipment (such as electrical, pneumatic, lifting equipment) correctly
- how to check that portable power tools and extension cables are free from damage and in a safe, tested and usable condition
- the operating requirements and any specific statutory regulations, for the machine tools and accessories being used (such as guards, workholding devices, taper turning attachments, steadies, dividing heads, abrasive wheels regulations)
- the various shapes and types of tooling that can be used (such as solid, high-speed tooling, brazed-tip tooling, interchangeable-tipped tooling)
- how to handle and store tools and equipment, safely and correctly
- factors which affect the selection of cutting feeds and speeds and the depth of cut that can be taken (such as workpiece rigidity, machine condition, type of tooling being used, material type, finish and tolerance required)
- the application of cutting fluids with regard to a range of different materials and processes
- the clamping of a workpiece in a chuck/workholding device (including safely secured for the process, not causing distortion in the finished components)
- how to recognise machining faults and how to identify when tools need re-sharpening/dressing
- types and applications of grinding wheels, methods of mounting and why some wheels require balancing (abrasive wheels regulations)
- the methods that can be used to position the workpiece in relation to the cutting tools
- the effects of backlash in the machine slides and how this can be overcome
- the procedure for the safe disposal of waste materials
- the problems that can occur with the machining and fitting activities and how these can be overcome
- the extent of your own responsibility and whom you should report to if you have problems that you cannot resolve
Scope/range
Scope Performance
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Carry out all of the following during the manufacturing activities:
- obtain and use the correct drawing, sketch or sample/damaged component to be replaced
- check that the machines used are in a safe and usable condition
- check that cutting tools and equipment are in a serviceable condition
- ensure that workpieces are held securely, without distortion
- apply safe and appropriate manufacturing techniques at all times
- use correctly adjusted machine guards and safety devices
Produce replacement components using a range of methods, to include five from the following:
- hand sawing
- band/power sawing
- filing
- drilling
- chiselling
- threading external
- offhand grinding
- scraping
- threading internal
- lapping
- bending and forming
Produce replacement marine components using two of the following processes:
- turning
- milling
- grinding
- shaping or slotting
- drilling
- spark/wire erosion
- welding
- cutting/shearing
Produce replacement marine components which cover five of the following features:
- external diameters
- faces that are square to each other
- drilled holes
- internal diameters
- angular/tapered surfaces
- bored holes
- flat faces
- threads
- reamed holes
- parallel faces
- circular/curved/radial profiles
- concave or convex form
- steps/shoulders
- slots/recesses
- special forms
Produce components which comply with all of the following standards:
- dimensional tolerances are to specification/replacement component requirements
- the surface finish complies to replacement component requirements
- components are free from false tool cuts, burrs and sharp edges
- components are fit for purpose
Produce replacement marine components from two different types of material from the following:
- low carbon steel
- brass
- high carbon steel
- bronze
- stainless steel
- plastic/synthetic
- cast iron
- composite
- aluminium
- special steels or alloys
Complete the relevant documentation in line with organisational procedures, to include one from the following and pass it to the appropriate people:
- build records
- log cards
job cards
quality documentation
- other specific recording methods
Scope Knowledge
Values
Behaviours
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