| 1 | 1a. Set shaping, planing or slotting machines for production | 1.1 | Work safely at all times, complying with health and safety and other relevant regulations and guidelines |
| 1.2 | Carry out all of the following activities during setting up: • obtain and use the appropriate documentation (such as job instructions, drawings, quality control 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 • follow safe practice/approved setting up procedures at all times • ensure that correctly adjusted machine guards are in place • check that cutting tools are in a suitable condition • hold components securely without distortion • leave the work area and machine in a safe and appropriate condition on completion of the activities |
| 1.3 | Follow the correct specifications for the component to be produced |
| 1.4 | Set the machine to produce components within all of the following quality and accuracy standards as applicable to the operations performed: • components to be free from false tool cuts, burrs and sharp edges • dimensional tolerance equivalent to BS 4500 or BS 1916 Grade 7 • flatness and squareness within |
| 1.5 | ” per inch or |
| 1.6 | mm per 25mm • surface finish 63 µin or |
| 1.7 | µm • angles within +/- |
| 1.8 | degree |
| 1.9 | Determine what has to be done and how the machine will be set to achieve this |
| 1.10 | Mount and set the required workholding devices, workpiece and cutting tools |
| 1.11 | Select, mount and secure the workpiece using three of the following workholding devices: • clamping direct to machine table • pneumatic or magnetic table • machine vice (such as plain, swivel, universal) • angle plate • vee block and clamps • jigs/fixtures • chucks (such as 3 or 4 jaw) • indexing head/device • rotary table |
| 1.12 | Select and mount tools to include three of the following types appropriate to the machine: • flat facing • vertical facing • forming/profiling • recessing • keyway slotting • spline slotting • serrating • special slotting |
| 2 | 1b. Set shaping, planing or slotting machines for production (continued) | 2.1 | Set the machine tool operating parameters to achieve the component specification |
| 2.2 | Set up one of the following types of machine: • shaping • planing • slotting • milling machine with slotting attachment |
| 2.3 | Set up the machine in accordance with instructions and specifications, to include all of the following: • position of workpiece • position of tools in relationship to workpiece • stroke position and length mechanisms • stroke speed • linear feed rate • depth of cut for roughing and finishing • cutting fluid flow rate • machine guards/safety mechanisms |
| 2.4 | Set up machine to produce internal and external profiles that includes six of the following: • flat faces • parallel faces • faces square to each other • steps/shoulders • angular faces • slots/grooves • key ways • splines • flat sided holes (eg. square, hexagonal) • serrations • other specific forms |
| 2.5 | Machine components made from one of the following types of material: • ferrous • non-metallic • non-ferrous |
| 2.6 | Check that all safety mechanisms are in place and that the equipment is set correctly for the required operations |
| 2.7 | Deal promptly and effectively with problems within their control and report those that cannot be solved |
| 3 | 2a. Know how to set shaping, planing or slotting machines for production | 3.1 | Describe the specific safety precautions to be taken when setting up workholding devices and accessories, workpiece and shaping/slotting tools |
| 3.2 | Describe the hazards associated with setting shaping, planing and slotting machines (such as moving parts of machinery, handling cutting tools, handling cutting fluids, tool breakage, insecure components), and how to minimise them and reduce any risks |
| 3.3 | Explain how to start and stop the machine in normal and emergency situations |
| 3.4 | Describe the importance of ensuring that the machine is isolated from the power supply before mounting tools and workholding devices |
| 3.5 | Describe the importance of wearing the appropriate protective clothing and equipment, and of keeping the work area clean and tidy |
| 3.6 | Describe the basic principles of operation of the shaping, planing or slotting machine and its accessories, and typical operations that they can perform |
| 3.7 | Explain how to handle and store shaping, planing and slotting tools safely and correctly |
| 3.8 | 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 |
| 3.9 | Explain how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing |
| 3.10 | Describe the terminology used in shaping, planing or slotting in relation to the activities undertaken |
| 4 | 2b. Know how to set shaping, planing or slotting machines for production (continued) | 4.1 | Describe the range of work holding methods and devices that are used on shaping, planing and slotting machines (such as plain, swivel and universal machine vice, three and four jaw chucks, jigs and fixtures, direct clamping to machine table, rotary and indexing devices) |
| 4.2 | Describe the methods of mounting and setting the workpiece in/on the workholding devices, and the tools and equipment that can be used |
| 4.3 | Describe the different types of shaping, planing and slotting tools that are used, and how they are selected, prepared and mounted to the machine tool holding devices (such as clapper box, slotting or planning head) |
| 4.4 | Describe the factors which determine stroke speeds and feeds to be used (such as material, type of tooling, depth of cut, workpiece rigidity, machine condition, tolerance and finish required) |
| 4.5 | Explain how the various types of materials used will affect the feeds and speeds that can be used |
| 4.6 | Describe the types of cutting fluid that are used, and precautions to be taken when handling and using them |
| 4.7 | Explain how to set up the shaping, planing or slotting machine, and its accessories, for the particular operations being performed (such as setting stroke length, stroke position, angle of tool head) |
| 4.8 | Describe the need to conduct trial runs, and to check that the machine is set up and producing the components correctly |
| 4.9 | Describe the problems that can occur with setting up the workholding devices, tooling and machine operating parameters, and what to do if problems occur |
| 4.10 | 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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