| 1 | 1a. Making spring wire forms using hand forming methods | 1.1 | Work safely at all times, complying with health and safety and other relevant regulations and guidelines |
| 1.2 | Ensure that the tools and equipment to be used are appropriate to the application and are in a safe and usable condition, by carrying out all of the following checks: • obtain and interpret correctly the documentation for the type of wire form being made (such as job instructions, spring drawings and quality documentation) • adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work • check that the tools and spring wire forming equipment to be used are in a safe and usable condition • carry out the hand wire forming activities, following good practice/approved procedures • return all tools and equipment to the correct location on completion of the spring making activities • leave the work area in a clean and safe condition on completion of the activities |
| 1.3 | Follow the correct component drawing and any other related specifications for the component to be produced |
| 1.4 | Determine what has to be done and how this will be achieved |
| 1.5 | Use the appropriate tools and equipment for the pressure shaping operations and check that they are in a safe and usable condition |
| 1.6 | Use all of the following types of spring wire forming equipment: • wire forming machine (hand or power operated) • wire forming mandrels • hand tools • spring measuring/checking equipment • fly press |
| 1.7 | Shape the materials to the required specification using appropriate methods and techniques |
| 1.8 | Produce spring wire forms from two different materials from the following: • carbon steel • stainless steel • alloy steel • copper based alloy • nickel based alloys • titanium and other special material |
| 2 | 1b. Making spring wire forms using hand forming methods (continued) | 2.1 | Form three of the following types of spring wire form: • spring pins/clips • key rings • plain wire rings • retaining rings • other specific spring wire forms |
| 2.2 | Produce spring wire forms, to include carrying out all of the following: • selecting the correct type and size of wire • ensuring that any required wire pre-treatment activities have been carried out (where appropriate) • selecting the correct type and size of forming mandrel • using the appropriate techniques to form the spring wire forms to the required specification • checking spring-back after forming and adjusting, as required (where appropriate) • carrying out post forming operations (such as forming bends or loops in ends/legs) • preparing the spring wire forms for heat treatment (such as stress relieving, hardening and tempering) |
| 2.3 | Check that all the required shaping operations have been completed to the required standard |
| 2.4 | Carry out checks of the spring wire forms, to include all of the following: • size and shape of wire used • type of material used • dimensional accuracy of the spring wire form • shape/geometry of the wire form • spring wire form tension/torsion meets specification requirements • completed spring wire forms are free from tooling marks and deformation |
| 2.5 | Use four of the following whilst checking the quality of the spring wire forms produced: • Vernier callipers • micrometers • spring testing machines • Vernier protractors • squares • electronic measuring equipment • gauges • jigs |
| 2.6 | Produce spring wire forms which comply with one of the following: • BS, ISO or BSEN standards and procedures • customer standards and job requirements • company standards and procedures |
| 2.7 | Complete all relevant documentation on conclusion of the spring wire form making activities, to include one of the following: • job cards • quality control documentation • computer records • test documents • company-specific documentation |
| 2.8 | Deal promptly and effectively with problems within their control and report those that cannot be solved |
| 3 | 2a. Know how to making spring wire forms using hand forming methods | 3.1 | Describe the specific safety precautions to be taken when working with spring cold wire hand forming equipment and materials in a spring making environment (such as general workshop safety, appropriate personal protective equipment, accident procedure; statutory regulations, risk assessment procedures and COSHH regulations) |
| 3.2 | Describe the personal protective clothing and equipment to be worn when carrying out the spring wire form making activities |
| 3.3 | Describe the hazards associated with carrying out spring wire form hand forming operations (such as handling spring wire, using hand coiling machines and equipment, using dangerous or badly maintained tools and equipment), and how to minimise them and reduce any risks |
| 3.4 | Describe the terminology used in the manufacture of the spring wire forms |
| 3.5 | Describe the principles of operation of spring wire forms being made |
| 3.6 | Explain how to obtain the necessary drawings, specifications and work instructions |
| 3.7 | Explain how to extract and use information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS, ISO or BSEN standards) in relation to work undertaken |
| 3.8 | Explain how to interpret first and third angle drawings, imperial and metric systems of measurement, work reference points and system of tolerancing |
| 3.9 | Describe the hand tools used in the spring wire forming activities, and how to check that they are in a safe and usable condition |
| 3.10 | Describe the various hand and power operated coiling machines that can be used to produce a range of spring wire forms |
| 3.11 | Describe the various types of spring wire forming tools that are used, and how they are selected, prepared and mounted to the machine |
| 3.12 | Explain how to set up the hand wire forming machine and tooling to produce the required forms |
| 3.13 | Describe the techniques used to feed the wire into the hand wire forming machine in order to produce the wire form to the required specification |
| 4 | 2b. Know how to making spring wire forms using hand forming methods (continued) | 4.1 | Describe the ways of avoiding and correcting inaccuracies in the wire forming activities |
| 4.2 | Explain how the spring wire materials are to be prepared for the forming operations, and why some materials may require a heating process prior to forming |
| 4.3 | Describe the characteristics of the various materials used with regard to the forming process |
| 4.4 | Describe the variations in manufacturing methods and spring characteristics that will occur with different ferrous and non-ferrous metals |
| 4.5 | Describe the use of fly presses and tooling for forming bends and loops in the wire forms |
| 4.6 | Explain how to check that the tools and equipment used are in a safe and serviceable condition, and their care and maintenance procedures |
| 4.7 | Describe the organisational quality control procedures, and recognition of wire forming defects |
| 4.8 | Describe the dimensional and forming inspection checks to be carried out, and the tools and equipment to be used for this |
| 4.9 | Describe the limitations of the various wire forming processes, and the accuracy that may realistically be achieved |
| 4.10 | Describe the importance of completing all relevant documentation on conclusion of the spring wire forming activities |
| 4.11 | Describe the extent of their own responsibility and to whom they should report if they have problems that they cannot resolve |
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