| 1 | 1a. Polish and smooth lens or mirror surfaces | 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 polishing and smoothing of the lens or mirror surfaces: • obtain and interpret correctly the documentation for the lens or mirror to be polished (such as job instructions, component 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 • ensure that machine guards/safety mechanisms are in place and correctly adjusted at all times • use safe working practices and machine operating procedures at all times • clean down the polishing machines after each stage of polishing, to avoid contamination of differing grit sizes • check that all tools, templates and equipment to be used are within their calibration dates • return all tools and equipment to the correct location on completion of the activities • leave the ... |
| 1.3 | ... machine and work area in a safe and clean condition on completion of the polishing and smoothing activities |
| 1.4 | Follow the correct specifications for the component being produced |
| 1.5 | Determine what has to be done and how the machine will be set to achieve this |
| 1.6 | Perform polishing and smoothing for one of the following: • individual lens/mirror forming through grinding, polishing and smoothing • block forming of lenses/mirrors through grinding, polishing and smoothing |
| 1.7 | Prepare to carry out the polishing and smoothing activities, to include carrying out all of the following: • select the correct ‘right curve’ or test templates for the lens/mirror to be polished • prepare the series of abrasive grits ready for polishing, ensuring that each is handled correctly to avoid cross contamination • prepare the polishing and smoothing machinery, ensuring its correct and safe operation as well as cleanliness |
| 1.8 | Mount and set the required workholding devices, workpiece and polishing tools |
| 1.9 | Prepare and mount the lens/mirror for the polishing and smoothing activities, to include carrying out all of the following: • ensure that any steep radius surfaces have undergone correct machining prior to polishing and smoothing • perform any necessary rough shaping of the lens/mirror surface, if required • prepare the pitch mixture to the correct viscosity, according to the material type to be polished • application and forming of pitch to correct shape • application of a backing pitch and correct runner • cutting of grooves into pitch surface • careful heating of components (such as runner) to ensure correct mounting of the lens/mirror • mounting of lens/mirror into pitch, ensuring correct orientation and position |
| 2 | 1b. Polish and smooth lens or mirror surfaces (continued) | 2.1 | Set the machine tool operating parameters to achieve the component specification |
| 2.2 | Carry out polishing and smoothing of lenses/mirrors, to include all of the following: • correct mounting of lenses/mirrors onto the polishing machine in the correct orientation • checking that the polishing or smoothing machine is set up correctly to give the required profile • applying the appropriate grit and carrying out the polishing or smoothing process • carrying out appropriate checks to confirm that the profile is correct • adjusting polishing conditions based on the results of checks/tests • cleaning down of the polishing machine between each grit size • carrying out the polishing and smoothing activities with finer grades of grit until the final specification is achieved • preparing the lenses/mirrors for the cleaning process |
| 2.3 | Carry out polishing and smoothing of lens/mirror surfaces, in compliance with one of the following: • BS, ISO or BSEN standards and procedures • other accepted international standards • customer (contractual) standards and requirements • company standards and procedures |
| 2.4 | Complete the relevant paperwork, to include one from the following, and pass it to the appropriate people: • job cards • quality control documentation • computer records • company-specific documentation |
| 2.5 | Check that all safety mechanisms are in place and that the equipment is set correctly for the required operations |
| 2.6 | Perform three of the following inspection tests during the polishing process: • Foucault test • radius check • use of test plates to check for correct number of ‘rings’ as per specification • inspecting for surface defects • lens centre thickness • lens cap height • lens surface form error • prism angles |
| 2.7 | Deal promptly and effectively with problems within their control and report those that cannot be solved |
| 3 | 2a. Know how to polish and smooth lens or mirror surfaces | 3.1 | Describe the safe working practices and procedures to be followed while carrying out lens/mirror smoothing and polishing activities, and for the equipment and materials being used (such as safe use of polishing and smoothing equipment, handling of polishing compounds and pitches) |
| 3.2 | Describe the safety mechanisms on the equipment, and the procedure for checking that they function correctly |
| 3.3 | Describe the importance of wearing protective clothing and other appropriate safety equipment during the polishing and smoothing process; the type of equipment to be used, and where to obtain it |
| 3.4 | Describe the hazards associated with the lens/mirror polishing and smoothing surface forming process (such as handling pitch, polishing mixes, heating of pitch, making grooves in the pitch, handling test templates, applying and heating the runner), and how to minimise them and reduce any risks |
| 3.5 | Describe the importance of keeping the equipment and work area clean and tidy |
| 3.6 | 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 |
| 3.7 | Explain how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing |
| 3.8 | Explain how to prepare for the lens/mirror polishing and smoothing activities (such as obtaining the correct workholding jigs, selecting and preparing the various grades of grits, preparing the pitch to hold the lens/mirror) |
| 4 | 2b. Know how to polish and smooth lens or mirror surfaces (continued) | 4.1 | Explain how to mount the lens/mirror ready for the polishing activities (such as preparing the pitch, mounting of the lens/mirror in the correct position and orientation) |
| 4.2 | Explain how to set up the polishing and smoothing equipment to give the required lens/mirror profile |
| 4.3 | Describe the various quality checks that can be used, and how they are applied (such as Foucault test, ring counting) during the forming process |
| 4.4 | Describe the surface quality tests to be performed as part of the quality process (such as dig, scratches and sleeks) and to confirm that they are within the specification |
| 4.5 | Describe the problems that can occur with the lens/mirror polishing and smoothing activities, and how they can be overcome |
| 4.6 | Explain how to analyse and evaluate possible characteristics and causes of specific faults/problems |
| 4.7 | Explain how to prepare documentation after completing the surface forming tasks, ready for the next stage (such as cleaning process) |
| 4.8 | Describe the extent of their own responsibility and to whom they should report if they have problems that they cannot resolve |
Don't show this message again.