| 1 | 1a. Set automatic spring making machines for the production of clock, power, scroll and volute springs | 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 during the setting up of the automatic spring making machine: • obtain and interpret correctly the documentation for the type of spring 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 machine and spring forming equipment to be used is in a safe and usable condition • carry out the setting-up activities, following good practice/approved procedures • ensure that first-off springs are correctly heat treated for inspection/verification • ensure that correctly adjusted machine guards are in place • leave the machine and work area in a safe and clean condition on completion of the setting-up 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 the machine will be set to achieve this |
| 1.5 | Mount and set the correct forming tools and devices for the component being produced |
| 1.6 | Select and set up four of the following types of spring making tooling: • bending tools • forming tools • looping tools • straightening tools • cut-off/cropping tools • other special-purpose tooling |
| 1.7 | Set the machine operating parameters to achieve the required pressure shaping requirements and component specification |
| 1.8 | Produce clock/power springs from two different types of material from the following: • carbon steel • stainless steel • alloy steel • copper based alloy • nickel based alloys • titanium and other special material |
| 1.9 | Set up automatic spring making machines for the production of three of the following types of spring: • clock • power • scroll/spiral • constant force • variable force • volute • other wire forms |
| 2 | 1b. Set automatic spring making machines for the production of clock, power, scroll and volute springs (continued) | 2.1 | Set up the operating control systems for an automatic spring making machine, to include four of the following devices: • material guide/wire feed mechanisms (such as feed rollers, pneumatic, magazine) • cams and mechanical actuators • pneumatic/hydraulic actuators • electro-mechanical actuators • de-reeler • pitch spacers • feed fingers • straighteners |
| 2.2 | Set up the machine in accordance with instructions and specifications, to include all of the following, as appropriate: • strip feed/speed rollers • strip stop mechanisms • selecting and setting appropriate cams/gears • correct helix • correct pitch • number of coils required • spring arm/leg length • finished spring dimensions • trip dogs and limit switches • position and operation of forming tools • position and operation of cropping tool • guards/safety mechanisms |
| 2.3 | Check that all safety mechanisms are in place and that the equipment is set correctly for the required operations |
| 2.4 | Carry out checks of the springs, to include all of the following: • size of strip and material specification • dimensional accuracy of the finished spring • the number of coils is as specified • the spring is wound with the correct hand helix • spring ends are finished correctly • spring tension/load meets specification requirements • completed springs are free from tooling marks and deformation |
| 2.5 | Use four of the following whilst checking the quality of the springs produced: • Vernier callipers • micrometers • spring testing machines • Vernier protractors • squares • electronic measuring equipment • gauges • jigs |
| 2.6 | Set up automatic spring making machines to produce springs to 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 completion of the spring making activities, to include one of the following: • job cards • quality control documentation • company-specific documentation • computer records • test documents |
| 2.8 | Deal promptly and effectively with problems within their control and report those that cannot be solved |
| 3 | 2a. Know how to set automatic spring making machines for the production of clock, power, scroll and volute springs | 3.1 | Describe the specific safety precautions to be taken when setting up automatic spring making machines (such as general workshop safety, appropriate personal protective equipment, accident procedure; statutory regulations, risk assessment procedures and COSHH regulations) |
| 3.2 | Describe the hazards associated with working on automatic spring making machines (such as handling coils of spring material, moving parts of machinery, tool malfunction, automatic operations, using dangerous or badly maintained tools and equipment), and how to minimise them and reduce any risks |
| 3.3 | Describe the safety mechanisms on the machine, and the procedure for checking that they function correctly |
| 3.4 | Explain how to start and stop the machine in normal and emergency situations |
| 3.5 | Describe the importance of ensuring that the machine is isolated from the power supply before setting up the various cams and operating systems |
| 3.6 | Describe the importance of wearing the appropriate protective clothing and equipment, and of keeping the work area clean and tidy |
| 3.7 | Describe the basic principles of operation of the automatic spring making machine used and its accessories, and typical operations that it can perform |
| 3.8 | Explain how to handle and store spring forming tools and equipment, safely and correctly |
| 3.9 | 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 |
| 3.10 | Explain how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing |
| 3.11 | Describe the terminology used in relationship to the automatic spring making machine used, the activities undertaken and types of springs produced |
| 3.12 | Explain how to check that the tools and equipment used are in a safe and serviceable condition, and their care and maintenance procedures |
| 3.13 | Describe the range of forming tools and devices that are used on the machine (such as for forming, bending, straightening, cropping) |
| 4 | 2b. Know how to set automatic spring making machines for the production of clock, power, scroll and volute springs (continued) | 4.1 | Describe the selection of cams, and how they are set up and timed in order to produce the components to the required specification |
| 4.2 | Describe the factors which determine the coiling/forming speed and material feed to be used, and how they are set (such as type of material, type of tooling, operations performed, simultaneous multiple operations, tolerance required) |
| 4.3 | Explain how the spring strip materials are to be prepared for the coiling operations, and why some materials may require a heating process prior to forming |
| 4.4 | Describe the characteristics of the various materials used with regard to the coiling and forming process |
| 4.5 | Describe the variations in manufacturing methods and spring characteristics that will occur with different ferrous and non-ferrous metals |
| 4.6 | Explain how the various types of materials will affect the feeds and speeds that can be used |
| 4.7 | Explain how to set up the automatic spring making machine and its accessories for the particular operations being performed |
| 4.8 | Explain the need to conduct trial runs, and to check that the machine is set up and producing the components correctly |
| 4.9 | Describe the organisational quality control procedures, and the recognition of coil forming defects |
| 4.10 | Describe the various checks to be carried out on the springs (such as dimensional checks, coil forming checks and tension/load checks), and the tools and equipment to be used |
| 4.11 | Describe the importance of completing all relevant documentation on conclusion of the spring making activities |
| 4.12 | Describe the problems that can occur with setting up the tooling and machine operating parameters, and what to do if they occur |
| 4.13 | 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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