Producing replacement components for maintenance activities
Overview
This standard identifies the competences you need to produce replacement components resulting from maintenance activities, in accordance with approved procedures. You will produce these components using machining techniques, such as milling, turning, grinding, shaping/slotting, drilling/boring, combined with 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, the workpiece and the required machine tooling.
You will also be expected to use a range of hand tools, portable power tools, and shaping and fitting techniques that are appropriate to the type of material and operations being performed. These activities will include such processes as hand sawing, band sawing, filing, drilling, chiselling, threading and off-hand 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 machining activities undertaken, and to report any problems with the machines, tooling, materials or activities that you cannot personally resolve, or that are outside your personal responsibilities, to the relevant people. 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 provide a good understanding of your work, and will provide an informed approach to applying appropriate replacement component manufacturing procedures and instructions. 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 with 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.
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 processes
- check that the finished component meets the requirements and make any necessary adjustments
- complete the required component production documentation
- deal promptly and effectively with problems within your control and report those that cannot be solved
Knowledge and Understanding
You need to know and understand:
- how to work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- 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 (PPE) and equipment, 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
- how to take measurements and produce working sketches of parts to be made, where no drawings are available
- how to use filing, scraping and lapping to achieve the required surface finish
- 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
- the use of vice jaw plates to protect the workpiece from damage
- how to use hand power tools and specialist equipment correctly
- how to check that portable power tools, extension cables and air hoses are free from damage and are in a safe, tested and usable condition
- the operating requirements of the machine tools and accessories being used
- the various shapes and types of tooling that can be used
- 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
- the application of cutting fluids with regard to a range of different materials and processes
- the techniques and implications of clamping a workpiece in a chuck/workholding device
- how to recognise machining faults, and how to identify when tools need re-sharpening/dressing
- types and applications of grinding wheels, and methods of mounting, and why some wheels require balancing
- 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 problems that can occur with the machining and fitting activities, and how these can be overcome
- the extent of your own authority and to whom you should report if you have problems that you cannot resolve
Scope/range
Scope Performance
1. Carry out all of the following during the manufacturing activities:
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