| 1 | 1a. Produce Components by Vacuum Forming | 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 vacuum forming activities: • use the correct issue of drawings, specifications, material data sheets and planning documentation • use copies of relevant COSHH sheets, risk assessment and standards • obtain materials (colour, size, composition) • obtain tools to be used and check they are fit for purpose (part marked, cleared inspection, undamaged) • return all tools and equipment to the correct location • leave the work area in a safe condition on completion of the activities |
| 1.3 | Use three of the following types of equipment: • air circulating ovens • vacuum forming machines • tufnol tooling • metal tooling • wood tooling • trimming equipment • composite tooling |
| 1.4 | Confirm that the equipment is set up correctly and is ready for use |
| 1.5 | Manipulate the machine controls safely and correctly in line with operational procedures |
| 1.6 | Carry out four of the following operations: • bubble blowing to minimize webbing • positioning of robbers • tooling cleaning • temperature control • trimming techniques • drying of sheet • use of intensifiers • sheet cleaning |
| 2 | 1b. Produce Components by Vacuum Forming (continued) | 2.1 | Produce a range of components with three of the following features: • double curvatures • male shapes • female shapes • stiffened mouldings |
| 2.2 | Produce a range of components using all the following materials: • thermoplastic sheet (such as polycarbonate, polysulphone, acrylic, polyvinyl chloride, abs) • fibre reinforced thermoplastic sheet • structural foams (Polyvinyl Chloride (PVC), polymethate (Rohacell) etc) |
| 2.3 | Produce components to the required specification which comply with one of the following standards: • ISO 9000 series and procedures • customer standards and requirements • company standards and procedures |
| 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 Produce Components by Vacuum Forming | 3.1 | Explain the specific safety practices and procedures that they need to observe when working with vacuum forming equipment including any specific legislation, regulations/codes of practice for the activities, equipment or materials |
| 3.2 | Explain the health and safety requirements of the work area where they are carrying out the activities and the responsibility they place on them |
| 3.3 | Describe the protective equipment that they need to use for both personal protection and, where appropriate, protection of others |
| 3.4 | Describe the hazards associated with vacuum forming, and explain how they can be minimised |
| 3.5 | Explain the procedure for the correct separation and safe disposal of waste materials |
| 3.6 | Describe the layout of the area to give maximum throughput |
| 3.7 | Explain how to interpret the drawings, standards, quality control procedures and specifications used for the vacuum forming activity and the currency/issue checks of the documents they are working with |
| 3.8 | Explain the methods and techniques to be used during the tool preparation |
| 3.9 | Explain the reasons for the use of intensifiers, and the robber system |
| 3.10 | Explain the equipment checks, and the stores and kitting functions |
| 3.11 | Describe the methods of sheet trimming and sheet cleaning prior to forming |
| 3.12 | Explain the principles of deep drawing, concave/convex moulding, positive pressure moulding and stress relieving. |
| 3.13 | Describe the sheet profiling procedures and material trimming methods/procedures |
| 4 | 2b. Know how to Produce Components by Vacuum Forming (continued) | 4.1 | Explain the supply and storage of stock material (such as colour, thickness, sheet size, surface texture, material protection) |
| 4.2 | Describe the preparation methods and procedures applied to the moulding surface |
| 4.3 | Explain the merits of male/female moulding, de-moulding techniques and temperature control procedures |
| 4.4 | Explain the methods and techniques for carrying out the de-moulding procedures and first article inspection (such as test samples, non-destructive testing (NDT) requirements) |
| 4.5 | Describe the methods and techniques for lifting, handling and supporting the components, equipment and materials during the vacuum forming activities |
| 4.6 | Explain how to recognise vacuum forming defects (such as misalignment, distortion, foreign object damage, contamination and surface defects) |
| 4.7 | Describe the quality control procedures that need to followed during the vacuum forming operations |
| 4.8 | Explain the procedures for ensuring they have the correct type of tools and equipment |
| 4.9 | Describe the tools and equipment used in the vacuum forming activities and explain their calibration, care, preparation and control procedures |
| 4.10 | Explain why tool/equipment control is critical and what to do if a tool or piece of equipment is unaccounted for on completion of the activities |
| 4.11 | Describe the sort of problems that can occur with the vacuum forming operations and explain how these can be overcome |
| 4.12 | Explain the recording documentation that needs to be completed for the vacuum forming activities undertaken and, where appropriate, marking and identifying specific pieces of work in relation to the documentation |
| 4.13 | Describe the extent of their own responsibility and explain whom they should report to if they have problems that they cannot resolve |
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