When you have demonstrated that you can perform a skill to the required standard and that you understand what you are doing, you are 'signed off'. Assessment takes place when you are ready and there may be a number of people who can assess you.
Introduction for Trainers
1 Working safely in an engineering
Exercise checklist
Statutory
Duties and obligations
General duties of employers to their employees
Providing information, instructions, training and supervision to ensure the health and safety of all employees. There is also a requirement for every employer to draw up a written health and safety policy for their employees.
General duties of employees at work
Sources of information
Complying with statutory regulations
The above list is far from complete as there are many more laws related to health and safety that are not listed here.
Warning signs and labels of the groups of dangerous substances
Follow accident and emergency procedures
Note: If the current cannot be interrupted, remove the casualty from the electrical source with insulating gloves or with some dry, non-conductive material (eg a wooden stick or a wooden chair). Do not move the casualty unless he is in a position that exposes him to additional danger.
Artificial respiration procedure
Reporting of Injuries, Diseases and Dangerous Occurrences Regulations
State the procedure to follow in the event of an accident to another person at your workplace. The student has answered questions about the meaning of hazardous and dangerous malfunctions and knows why these must be reported even if no harm has occurred.
Procedures for emergency situations and evacuation of premises
The systems below reduce the spread of fire and allow the fire to be extinguished before it gets out of control. There may also be maps showing the location of collection points and how to get to them.
Use of basic fire fighting equipment
Sound the fire alarm to alert others to the danger
For each of them, find an example in your work area and write its location in the space provided. In the space, draw a map of the route you should follow if you hear an emergency alarm in your work area.
Dressing prepared for work activities
Never use these gloves unless you are sure they will protect you against the chemicals you are exposed to. Never use this device unless you are sure it will provide protection against the particular chemicals to which you are exposed.
Personal hygiene procedures
There are other pieces of specialized protective clothing for those who work in hazardous environments. The items of protective equipment described above are the most common, but if you are concerned about working in an environment, always ask your supervisor or another person responsible for protective clothing.
Behaviour in the working environment
Give three reasons why it is always necessary to act responsibly in a technical workshop to comply with the Health and Safety at Work Act 1974. State where your organisation's health and safety policy is kept and who is responsible for reviewing it and update it.
Manual handling techniques
Once you know how to lift safely, it's important to get into the habit of doing it to prevent injury. Remember that it is good practice to clean the area where you will place the load before it is picked up.
Transporting loads with manual trolleys and hand carts
If the spine is stressed while lifting or carrying, the ligaments can be damaged or the discs can be displaced. When lifting heavy or awkward loads, you should therefore bend your knees and keep your head up instead of bending your back.
Housekeeping in the work area
Storage of tools, equipment and materials
All tools and equipment must be stored in such a way that they do not present a risk of injury to persons, e.g. Tools and equipment should be stored in their designated place specifically to enable easy retrieval.
Disposal of waste materials
Control of hazards in the
Hazard spotting
Hazard control measures
Risk
Risk assessment
In the above two cases, there is a greater risk caused by the brick on the pier than the slippery floor, so the risk associated with the brick should be treated as a priority issue. Who should be informed about the actions to be taken to deal with workplace hazards that you are unable to deal with.
Safety rules, signs and warnings
Control measures to minimise risks
In the spaces below, write two situations where you took action to ensure that the work environment was made safer.
Accident-reporting procedure
Construction Creamery Transport Oil platform Hospital Time during. which accidents can occur Total number of non-injury accidents. It is essential that you show the stages in your work for the following calculations. a) Calculate the total area to be painted grey.
2 Developing yourself and
This chapter is also closely related to the two units of key skills: personal skills - working with others and personal skills - improving one's own learning and performance. So keep an eye out for the key symbols and make sure you fill out the key skills evidence as you go along.
You and your organisation
The following exercises should help you to help yourself and work with other people, and in doing so, you will develop personal skills that will help you throughout your working life. The first section examines some of the issues you should think about.
Developing training plans
Knowing about your training
If you are concerned that you do not understand something or need help, what steps should you take? Finally, it is important that you keep copies of your training plans, signed by you and your supervisor.
Dress,
The fact that you do this and complete the exercises in this book shows that you understand the nature of your qualification and what is required of you.
Appropriate dress
If you are in a shopping area and you see a truck reversing, what will you hear? If you are in an area where safety clothing is required, who is responsible for making sure you wear the appropriate clothing?
Tools and equipment
An employer may argue that if someone is often late, the effect is the same as stealing because the person is paid to be present. A learner must notice these signs and be aware that if they are concerned about the safety of any equipment, they must report it to the supervisor.
Tools
Equipment
Materials
Reporting deficiencies in tools, equipment and materials
Working with other people
Respecting the views of others
Be willing to help, and if you want help, make sure the person you ask has time to help you and that you ask in a polite way. Also think about how you could help each other; show some initiative but be careful not to do anything you shouldn't.
Respecting others’ property
Respecting the property and views of others
Teamwork, cooperation and integration
Showing that you can work with other people
Working in an organisation
Organisation chart
Reporting difficulties in working relationships
The Equality Commission investigates breaches of employment law where people believe they are being discriminated against, for example people in wheelchairs now have the right to demand access to workplaces and they cannot be discriminated against because of their disability. Cases of discrimination do not go to the police; they are dealt with under civil law.
Taking part in discussions
Taking part in a discussion
Making comments like “where do we go from here?” or “what is the next step or what should we do?” This affects you as it means you are the one who has to do most of the prep.
Effective
One way you can be helpful is to make sure you know how your organization works. By doing this, you will make life easier for your supervisor because you will be seen as someone who can be trusted.
Identifying the types of communication methods present at work
Thinking about effective communication
You as a communicator
Showing that you can communicate effectively with those who are helping to train you
Accident reporting
Use the information from the above report (which was provided to the Health and Safety Officer site by the injured person in hospital) to complete the accident report form which can be found as Appendix XV at the back of the book. Carry out a risk assessment using the form provided at the end of the book in Appendix XIV and make recommendations on the procedure to be followed.
Look at the two pictures below and note four points each for good and bad communication
Mr Pid was treated by paramedics at the scene before being taken to Grangemeouth General Hospital for treatment for a broken right ankle, concussion and cuts to his left leg and face. Mr. Pid told me that he had been worried about the storm damage, and being quite concerned about the unstable condition of the bricks, had decided to start the job himself instead of waiting for his workmate.
Talking to Visitors
Providing evidence of good communication to visitors
Jay is 19 years old, passed his driving test on the first try and has been driving the family car for a year with no convictions or accidents. Refer to the following information about safe stopping distances and calculate the ratio of the thinking time to the total stopping distance for each speed: (Round to the nearest whole number). a) At 20 mph, the ratio of thinking distance to total stopping distance is
3 Communicating using engineering
Types of drawing
Types of line on drawings
Orthographic projection
Third angle projection (sometimes referred to as American projection) is an alternative method of laying out the individual views on the drawing page. The drawings are shown in either first or third angle projection, and some are drawn.
Dimensioning engineering
Holes for fasteners or for locating devices must be dimensioned according to one of the alternative methods shown for each type of hole. If a specific surface texture is required, the RA (roughness average) value is written on top of the machining symbol as shown.
Limits of size
The machining symbol shown below is used to indicate whether a surface should be machined or not. The finished component must have a diameter between 9.5mm and 10.5mm to be acceptable.
Types of fit
BS 4500 is long and complex, but it is important to be aware of its existence. Remember that the drawing is in 2:1 scale (ie the final component will be twice the size shown).
BS 308 drawing conventions
On the cast iron bracket drawing opposite, measure the drawing and add all dimensions and center lines in accordance with BS 308. Indicate on your drawing that the bore on the large hole must be within +0.10 and -0.05mm of the nominal size.
BS 308 drawing abbreviations
Compare this with the view Section A–A, which will be seen if the cam flange is viewed on the cutting plane (all material to the left of the cutting plane is ignored). The area through which the cutting plane moves is hatched with fine lines drawn at 45◦ , usually about 4 mm apart.
Half section
Sectional assembly
Other methods used to illustrate how assemblies fit together
Pictorial projection
Isometric projection
Oblique projection
Production of an isometric sketch on isometric drawing paper
Production of an isometric sketch of a component
Sheet metal developments
Sketch the shape of the development that would be drawn for the following plate components:
4 Communicating technical
If what you were trying to listen to was the finale, you would have given up so easily. If the match was the final, explain why you might have made more of an effort to keep listening.
Communication within
Communicating technical
There will also be price guides with up-to-date information for people working in the service sector. Process information is usually stored in the area where the process is performed.
Sketches
What would you do to make sure that the drawing you were given was the right one to work from to make the necessary spare parts. The problem with this kind of information is that because it takes so much time to sort through the effort required to review it when changes are made to the process, it may not be put into the process information folder.
Other sources of information
Be sure to read these as they are there to protect you and the content. There may also be signs with instructions on work practices (eg turn off the mains before removing the cover).
Selecting appropriate
CD-ROMs, Computers and the Internet – Today, companies often issue catalogs in CD-ROM form, and it is also possible to access company websites for up-to-date information. Appendices – Appendices such as those at the end of this book may provide additional information.
Information deficiencies
Identify two people who are qualified to confirm that the information you discovered is valid and reliable. Describe an example where you found that the information was inadequate, but you had to check which alternative was the correct answer.
Communicating about yourself
Look carefully at the information in the list that follows and organize the information into 4 columns. Carrying out engineering operations including key skills at level 2. Work: I have worked for 'Designed for You' since leaving school and have enjoyed this work and particularly enjoyed my time in the CAD section.
Reading and summarising
Reading and summarising information assessment
You should also be able to identify by the tone of voice and the use of. Summary can be written or oral, but the language used must be suitable for the purpose of the summary.
Giving a short talk
You want your talk to be remembered, so create a word-processed handout, which should also include a copy of at least one of the images you've decided to use. Gather all your information, read through the section on 'Giving a short talk', practice giving the talk and make sure it is long enough (about 5 minutes).
Short task assessment
I have produced a word processing handout containing at least one image and have had someone proofread my use of spell check/or printed an uncorrected version. Stay on topic and help your listeners by giving pointers as you go along.
Key skills – communication level 2
So if you use technical words (jargon) that you have learned, then you need to explain what they mean. Speak in a place that suits you, for example in a workshop or a computer room, so that you can demonstrate using the software.
5 Identifying and selecting
Ferrous metals
Gray cast iron is widely used for the production of pre-machined parts, such as car engines and machine tool frames. High speed steel (HSS) is a special alloy steel developed for its hardness and toughness and used to make metal cutting tools such as twist drills and router bits.
Non-ferrous metals
It is also used to mark equipment such as multi-blocks and angle plates. They are usually specially developed for specific purposes, for example stainless steel is particularly resistant to corrosion and is consequently used in the food and chemical industries.
Plastics
Wood
Rubber
Stone
Ceramics
Synthetics
It can be used for car bodies and motorcycle skins and has the advantage of being corrosion resistant. Put in the boxes a typical material in each category and indicate what it is likely to be used for.
Physical
Ductility – The degree to which a material can be permanently stretched when subjected to a tensile force. Malleability – The degree to which a material can be formed by compressive stress, such as impact.
Changing the properties
The actual temperature of the steel being hardened can be judged by the color of the surface during heating. It is therefore important to know and identify the forms in which materials can be supplied.
Defects in materials
When the dye has soaked into the surface of the component, it is wiped dry, and a developer powder is dusted onto the component's surface. If the scale is embedded in the skin of the component, it cannot be easily removed.
En’ numbers and BS 970
Material colour codes and
Most of the following abbreviations are not material specific, but describe the material in loose or general terms. When you undertake any work, you will usually receive the materials to carry it out.
6 Checking
To ensure that appropriate readings are given, it is necessary to use high quality tools and to store and maintain them correctly. The most common measuring instruments, together with their typical applications and methods of using them, are described below.
Measuring
Spring Type Calipers – The legs of this type of caliper are opened or closed by adjusting nuts. Solid joint type calipers – The caliper legs on the solid joint rotate on a large screw that includes fiber washers.
Engineer’s squares
The try square
The cylinder square
Workshop protractor
I used squares and protractors to measure the following features of my workpieces and listed my actual measurements below:. Feature measured Size and limits Measured size. correctly select and use the above equipment to measure those characteristics listed by him/her within the tolerances required by this exercise.
Micrometer instruments
Setting and reading an external metric micrometer
Setting and reading an external imperial micrometer
Note If the accuracy of a micrometer is suspected to be inaccurate, it should be checked on a setting block and reset if necessary by a suitably qualified person. Look at the three metric and three imperial micrometer parameters below and enter the measurement shown in the space on the bottom line.
Other types of micrometers
Depth Micrometers - These tools are used for measuring the depth of holes, holes and so on. A vernier caliper is a useful tool as it has a long measuring range (150mm, or 6 is common) and a wide range of applications.
Setting and reading vernier calipers
The metric example above (0.05mm) reads like this: a) There are 16 whole millimeters before the zero line on the vernier scale. An example metric (0.02mm) shows the following:. a) There are 16 whole millimeters before the zero line on the vernier scale.
Comparative measuring
Feeler gauges
Limit gauges
To test a hole, the inspector tries each end of the gauge in the hole and makes sure the GO end goes in and the NOT GO end doesn't. The GO end goes into the hole and the NOT GO end does not go in.
Surface texture comparison plates
Select and correctly use surface finish comparison plates to check the surface finish of finished components to within 1.6µm (32µin).
Slip gauges
Clamping Slide Gauges To assemble a slide gauge assembly (a) Select the required gauges and close the box. Correctly select and use calipers to check linear dimensions and parallelism within the tolerances stated on the drawing.
Dial test indicator
Carefully lower the DTI further until the pointer does not go more than half a turn around the dial. Remove the calipers and insert the item under the DTI's stylus and record the reading on the disc.
7 Marking out for engineering
Preparation of data on the work piece is the initial stage of marking. Marking from all other lines can only proceed after the data has been carefully and accurately entered.
Marking out tools
When marking workpieces, the same datum pages, lines or dots as those on the drawing are usually used. The most commonly used markup tools are described in this chapter, along with methods of using them.
Pens and pencils
Always check your tools for condition and usability before use (for example, check the tip on a scriber before use).
Rules
- Remove all burrs and sharp edges from the component
- Gather all tools and check them over for safety, accuracy and suitability
- Mark out centre line on side of bar. Box square
- Mark out centre line on end of bar. Centre square
- Mark out centre of hole on end of bar. Centre square
The test square is described in 'Checking workpieces for accuracy'; the use of a center square and a square for marking is described here. Box squares are suitable for marking keyways and slots in round bars and tubes.
Radius gauges
Odd leg calipers
Adjusted with a rule, the odd-leg caliper can be used to accurately mark lines within ±0.5mm. Draw the center line of the radius from the surface B. f) The point where the center lines intersect is the center of the radius.
Dot punch and centre punch
Marking out the drill drift
- Dot and centre punch centre points of hole and radius
- Remove waste and surplus materials
- Ensure that the work area is left in a safe and tidy condition
Follow the pre-planned sequence of operations to mark the drilling movement shown below in drawing no.
