Carrying out finishing by phosphating methods
URN: SEMMPF242
Business Sectors (Suites): Materials Processing and Finishing Suite 2
Developed by: Enginuity
Approved on:
30 Mar 2020
Overview
| This standard identifies the competences you need to carry out material finishing operations by phosphating methods, in accordance with approved procedures. You will be expected to confirm with the authorised person, such as your immediate supervisor, that the equipment is ready for the phosphating operations to be performed and that all the required components/materials and consumables are available. You will be required to operate the phosphating equipment, in line with safe working practices and approved procedures, continuously monitoring the phosphating operations and where necessary, making minor adjustments or seeking help from the authorised person to make the required adjustments, in order to ensure that the work output is to the required quality. 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 phosphating activities undertaken and to report any problems with these 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 actions and for the quality of the work that you carry out. Your underpinning knowledge will be sufficient to provide a sound basis for your work and will enable you to adopt an informed approach to applying phosphating procedures. You will have an understanding of the phosphating process and its application and will know about the equipment, materials and consumables in adequate depth to provide a sound background for carrying out the activities, recognising and reporting phosphating defects and ensuring that completed components are to the required specification. You will understand the safety precautions required when working with phosphating equipment and solutions. You will be required to demonstrate safe working practices throughout. You will also understand your responsibilities for safety and the importance of taking the necessary safeguards to protect yourself and others in the workplace and towards the environment. |
Performance criteria
You must be able to:
| 1. work safely at all times, complying with health and safety, environmental and other relevant regulations, directives and guidelines 2. follow work instructions and specifications for finishing operations 3. ensure the material surfaces to be treated are prepared for the finishing operations check that the finishing equipment and treatment solutions are set up and maintained at satisfactory operating conditions and levels 4. carry out the treatment process following operating procedures and to meet the component specification 5. ensure that the treated workpiece achieves the required characteristics and meets the finishing specification 6. deal promptly and effectively with problems within your control and report those that cannot be solved 7. ensure that work records are completed, stored securely and available to others, as per organisational requirements 8. leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements |
Knowledge and Understanding
You need to know and understand:
| 1. the specific safety precautions to be taken whilst carrying out the activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials) 2. the health and safety requirements of the work area and the activities, and the responsibility these requirements place on you 3. the hazards associated with the activities, and how to minimise them and reduce risks 4. the personal protective equipment and clothing (PPE) to be worn during the activities 5. the importance of keeping the work area clean and tidy including the use of 5S or similar techniques 6. how to obtain and interpret the production documentation required during the phosphating activity 7. the basic principles of the operation of phosphating equipment 8. how to prepare and make additions to the process solutions 9. the visual checks to be made on components prior to phosphating 10. the pre-treatments to be carried out on components prior to phosphating 11. the methods used to hold/secure components during the phosphating process 12. the importance of monitoring the equipment settings and process solutions during the phosphating process 13. the types of adjustment that can be made to equipment settings to maintain component quality 14. how to identify phosphating processing faults (including missed coating, bridging, excessive coating and dull finish) 15. the basic quality checks to be carried out on phosphated components 16. how to pack and store finished components to avoid damage 17. the importance of completing the production documentation throughout the phosphating process 18. the extent of your own responsibility and whom you should report to if you have problems that you cannot resolve 19. how to access, use and maintain information to comply with organisational requirements and legislation |
Scope/range
Scope Performance
| 1. Apply phosphating to components, carrying out all of the following activities: 1. use the correct issue of process documentation (specifications, job cards, quality control documentation) 2. adhere to health and safety regulations, systems and procedures to realise a safe system of work 3. confirm with the authorised person that the plant is ready for carrying out the phosphating operations 4. maintain sufficient quantities of process materials and components during the production cycle 5. seek any necessary instructions/training on the operation of the phosphating equipment 6. follow the defined operating procedures ensure that the equipment settings and process solutions are adjusted (either by yourself or the authorised person) to maintain the correct customer specification 7. leave the work area in a safe and clean condition 2. Carry out phosphating processes on one of the following substrates: 1. ferrous 2. non-ferrous 3. Apply phosphating to components using one of the following processes: 1. zinc phosphating 2. iron phosphating 3. manganese phosphating 4. multiple ion phosphating 4. Carry out three of the following activities during the phosphating process: 1. segregate any defective components or batches (pre and post phosphating, rinsing) 2. prepare the phosphating solutions 3. carry out pre-treatments (such as cleaning, de-greasing, pickling, conditioning) 4. load components safely into plant 5. wiring/racking 6. monitor the process settings and solutions (time, temperature, deposition rate, levels) 7. safely make adjustments to solutions or process settings 8. carry out post phosphating operations (sealing, staining, oiling, wax coating) 5. Identify all of the following types of defects in phosphated components: 1. missed coating 2. poor colour (brown staining) 3. excessive build up 4. amorphous crystalline deposit (low temperature) 6. Carry out four of the following checks on phosphated components: 1. free from damage 2. free from contamination 3. surface quality/appearance 4. completeness of the phosphating operations 5. thickness of coating 7. Carry out three of the following completion activities: 1. place components in the specified container/area 2. store components in the correct quantities/weight 3. use the correct packaging so as to avoid damage 4. complete the production documentation 5. place all labels/production documentation in the specified location 6. safely dispose of process solutions 7. clean the tools and equipment (de-sludge phosphating tanks) 8. change and replenish post phosphating sealant 8. Check coatings applied to components by phosphating comply with one of the following quality standards: 1. military or aviation 2. current industry standards or codes of practice 3. international standards 4. company standards and requirements 5. customer standards and requirements |
Scope Knowledge
Values
Behaviours
Skills
Glossary
Links To Other NOS
External Links
Version Number
2
Indicative Review Date
31 Mar 2023
Validity
Current
Status
Original
Originating Organisation
Semta
Original URN
MPF2.42
Relevant Occupations
Engineering and Manufacturing Technologies, Manufacturing Technologies, Process Operatives, Process, Plant and Machine Operatives
SOC Code
8115
Keywords
Engineering; manufacturing; processing; phosphating; zinc; maganese; iron; parameters