| 1 | 1a. Cut Materials using Saws and Abrasive Discs | 1.1 | Work safely at all times, complying with health and safety and other relevant regulations and guidelines |
| 1.2 | Use two of the following types of cutting equipment: • machine saw • band saw • hand held portable abrasive disc • radiac abrasive disc |
| 1.3 | Ensure that the equipment is fit for purpose and used safely by carrying out all of the following: • selecting the appropriate equipment/machine for the operation being performed • checking that machine guards and safety devices are in position and function correctly • checking that cutting discs/blades are in a serviceable condition (sharp, and free from damage or chips) • isolating the equipment from its power supply whilst changing blades or discs • using the equipment safely and correctly and only for its intended purpose |
| 1.4 | Confirm that the machine is set up and ready for the machining activities to be carried out |
| 1.5 | Manipulate the machine tool controls safely and correctly in line with operational procedures |
| 1.6 | Carry out all of the following cutting and shaping activities: • straight sawing • abrasive disc cutting • contour shaping using saws |
| 1.7 | Cut and shape components which contain all of the following features: • straight parallel cuts • square cuts • curved contours • angled/mitred cuts |
| 2 | 1b. Cut Materials using Saws and Abrasive Discs (continued) | 2.1 | Cut and shape three of the following forms of material: • flat plate • solid bar (square, round, hexagonal etc) • rolled sections (angle, channel, RSJ ) • pipe/tube • rail section • non-ferrous material |
| 2.2 | Produce components to the required quality and within the specified dimensional accuracy |
| 2.3 | Produce components that comply with all of the following quality and accuracy standards: • material dimensional accuracy is within specification tolerances • cuts are square, clean and free from excessive burrs • angled cuts are within specification requirements |
| 2.4 | Carry out quality sampling checks at suitable intervals |
| 2.5 | Deal promptly and effectively with problems within their control and report those that cannot be solved |
| 2.6 | Shut down the equipment to a safe condition on conclusion of the machining activities |
| 3 | 2a. Know how to Cut Materials using Saws and Abrasive Discs | 3.1 | Explain the specific safety precautions to be taken when working in a fabrication environment and when working with power operated saws and abrasive disc cutting machines (statutory requirements, risk assessment procedures and relevant requirements of HASAWA, COSHH and Work Equipment Regulations; safe disposal of waste materials) |
| 3.2 | Describe the personal protective clothing and equipment to be worn when carrying out the fabrication activities (leather gloves, eye protection, safety helmets, etc) |
| 3.3 | Explain the safe working practices and procedures to be observed when working with the machines (including emergency shutdown procedures) |
| 3.4 | Explain the correct methods of moving or lifting heavy plate or rolled sections |
| 3.5 | Describe the hazards associated with fabrication work and cutting operations (such using dangerous or badly maintained tools and equipment; airborne particles; hot metal; burrs and sharp edges), and explain how they can be minimised |
| 3.6 | Explain how to obtain the necessary drawings, specifications and work instructions |
| 3.7 | Explain how to extract information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS or ISO standards in relation to work undertaken) |
| 3.8 | Explain how to interpret marking out conventions (cutting lines, centre lines, etc) |
| 3.9 | Describe the range of machine saws available (such as power hacksaws, circular saws and bandsaws) |
| 3.10 | Describe the abrasive cutting equipment available (to include hand held portable machines and bench type radiac cutting machines) |
| 3.11 | Explain the selection and fitting of abrasive cutting discs; cutting disc identification markings, and how to identify the correct type of disc for the type of material being cut |
| 4 | 2b. Know how to Cut Materials using Saws and Abrasive Discs (continued) | 4.1 | Explain the statutory regulations regarding the fitting and use of abrasive discs |
| 4.2 | Explain the material cutting characteristics and process considerations to be taken into account when cutting materials |
| 4.3 | Describe the use and care of tools and equipment (such as checking that trailing leads, plugs and sockets are in a safe and usable condition) |
| 4.4 | Explain the use of safety screens to protect other uses from flying sparks whilst using abrasive cutting discs |
| 4.5 | Explain the importance of ensuring that machine guards are correctly fitted and positioned before using the equipment |
| 4.6 | Explain how to set and adjust power saws for the various operations being performed |
| 4.7 | Explain the importance of using tools or equipment only for the purpose intended; the care that is required when using the tools or equipment; the proper way of preserving tools or equipment between operations |
| 4.8 | Describe the things that can go wrong when cutting materials using saws or abrasive discs, and explain how these can be avoided |
| 4.9 | Describe the inspection techniques that can be applied to check that shape and dimensional accuracy is to specification and within acceptable limits |
| 4.10 | Describe the extent of their own authority and explain whom they should report to if they have problems that they cannot resolve |
| 4.11 | Explain the reporting lines and procedures, line supervision and technical experts |
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