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BTEC Assignment Brief
Qualification Pearson BTEC Level 3 National Foundation Diploma in Engineering Unit number and title Unit 2: Delivery of Engineering Processes Safely as a Team Learning aim(s) (For NQF only) C: Carry out engineering processes safely to manufacture a product or to deliver a service effectively as a team. Assignment title Using engineering processes and working in teams Assessor Issue date Hand in deadline 21 /0 1 / Vocational Scenario or Context You are working as a final year apprentice in a medium- sized engineering company. Your manager is pleased with your work and has decided that you should be given some more responsibility. He wants you to become part of a small team that will manufacture a batch bevel gauges using a different approach to that normally employed by the company. Your manager wants you to work with colleagues to organise the team and set targets. He is also expecting you and your colleagues to interpret technical documentation and to safely and effectively manufacture a batch of bevel gauges by setting up engineering processes correctly and reviewing progress against team targets. All members of the team will be expected to take on the role of team leader at certain points, and your manager will be observing how well you can manage your own contributions, as the company are considering using a similar approach for other products and are mindful of possible training needs. Task 1 You are going to carry out engineering processes safely to manufacture a bevel gauge effectively as part of a team. To do this:
2 BTEC Assignment Brief v1. BTEC Internal Assessment QDAM January 2015 Your tutor will provide you and your team with a range of technical documentation (such as engineering drawings, production plans and specifications) that will detail the bevel gauge and the batch size. You then need to:
- Take an active role when meeting with other team members prior to the manufacture of a batch of bevel gauges to plan effectively and set team targets, and to record who is responsible and accountable for each aspect of the work required;
- Take an active role when meeting with other team members during the manufacture of a batch of bevel gauges to review team roles and responsibilities, targets and timings;
- Take on the role of team leader when requested to do so by your assessor;
- Complete independently a risk assessment for one of the engineering processes you will be using;
- Interpret the given technical documentation to effectively and independently set up at least one engineering process and to carry out engineering activities safely in order to manufacture a batch of bevel gauges as part of a team;
- Independently carry out quality checks and keep quality records that can be used to inform team progress;
- Make effective progress towards team targets and provide and respond to peer feedback as a team member and a team leader; and
- Demonstrate one or more of the following: forward thinking, adaptability or initiative throughout all of the above. Checklist of evidence required
4 BTEC Assignment Brief v1. BTEC Internal Assessment QDAM January 2015 Websites http://www.effectivemeetings.com/meetingbasics/minute ` s.asp http://www.kent.ac.uk/careers/sk/teamwork.htm gov.uk/risk/controlling-risks.htm ible.com/culture/five-keys-to-lead Other assessment materials attached to this Assignment Brief eg, work sheets, risk assessments, case study
Unit 2: Delivery of Engineering Processes Safely as a Team
Using engineering processes and working in teams
Part: Bevel Gauge
Evidence Section No. Instructor Initials Drawings 1 Planning 2 Risk Assessment 3 Observation Check List / Inspection Report/ Photographs 4 Learner Name: Peter Bodor Learner Signature: Assessor Signature: __________________________ Date: ______________
Section 2: Planning Job Description: Bevel Gauge Op No^ Sequence of operations 1 Carry out pre-use check before you start the manufacturing process. This includes checking the surrounding area for oil on floor or trip hazards, also check the hand tools for cracks. 2 Check the drawing provided and make sure to use the right material and make sure the measurements provided are correct. 3 Take two 120 mm of aluminium plates which are going to be the handles. Take one of the metal plates and engineers square and make sure that each corner is 90 degrees if their excess material just files it off repeat it for the other handle. 4 Apply the engineers blue on one side on both handles. 5 Centre punch one of the corners on both handles to help you identify which is to and which is bottom. 6 Set the height gauge to 12.5 then place the handle vertically against the angle plate with the centre punch on top than move the height gauge to inscribe the line onto the handle, gauge the then flip the handle upside down and repeat the same operation. After that flip the handle horizontally, then measure on 12.5 the height and create the line trough the centre of the handle. Repeat this operation for the 2nd^ handle. 7 Centre punch where the two lines intersect on both handles top and bottom. 8 Set the engineers divider to 12.5 and place one of the teeth in the centre punch and create a half circle on the bottom of the handle. Repeat this for the 2nd^ handle. 9 File of that half circle radius 12.5. File until the line. 10 Set the engineers protractor to 45 degree and place it on the top side of the handle to find the place for the other three holes, using a scribe create a mark to know where to centre punch, repeat this for the 2nd^ handle. 11 Centre punch the handle where you placed the mark. Repeat this for the 2nd^ handle. 12 Carry out the pre-use check on the pillar drill 13 Place one of the handles with the blue side the up into the bevel gauge jig and secure it with a toolmakers clamp and drill the holes which have a diameter of 3.2. After you drilled one hole just flip the handle and drill the other hole on top. 14 After you drilled the two holes move onto the other pillar drill which is set up for the other two holes which are 3.2 diameter. Repeat this for the other handle. 15 Set the machine up for the 6 - diameter hole on the top of the handle secure it with a toolmakers clamp. Repeat the same operation for the 2nd^ handle 16 Take a metal plate which has a length of 161mm. This is for the blade and the spacer. 17 Apply engineers blue on one side of the metal plate.
18 Place the workpiece vertically against the angle plate and set the height gauge to 12.5 and move it across to create the engraving, then flip it horizontally and engrave a line across the middle of the workpiece. 18 At the bottom where the two lines intersect measure 128 mm from there and using a metal rule draw a straight line 19 Take an engineer’s protractor and set it to 45degrees and place it on the right flat side to mark out with a scribe where the blade. 20 Centre punch where the two lines intersect at the bottom of the blade. Then take an engineer’s divider and set it to 12.5mm and place one tooth into the centre punch and create a half circle. 21 After you marked everything out you are required to cut the blade and the spacer where you marked out the 45 degrees line. 22 File the 12.5mm radius half circle at the bottom of the blade 23 Carry out pre-use check on the milling machine 24 Than secure the workpiece into the chuck and close the guard and press the start button to start running the program 25 Drill out the 5 holes same as on the handles (same dimensions) 26 Enlarge the holes on the blade because the teachers could not get smaller rivets 27 Tap the 6mm-diameter hole on top of the handle. 28 Using a countersink hand drill, counter sink the 4 holes where the rivets go only on one handle it does not matter which one. You only require to counter sink 3 mm deep 29 Drill the 4 holes into the spacer. Each hole is 3.4 diameter but we enlarged it to 4 because of the new rivets 30 Assemble the two handles with the rivets in between them and the blade. Insert 4 rivets into the handles and spacer and attach the blade using a screw and nut. 31 Clamp the handle and spacer together to prevent them from falling apart. 32 Secure the bevel gauge into a bench vice than cut off half of the rivets and using a ball pin hammer use the curved side to make the rivets flat 33 After the rivets are flat enough use the hammers flat side to make the rivets flush with the workpiece and file of the excess. 34 Using sand paper clean the engineers blue of the handles and blade and inside the sot to give it a smother finish and a nicer look 35 Section 2: Planning Job Description: Bevel Gauge Op No^ Sequence of operations
Section 2: Planning Job Description: Bevel Gauge Op No^ Sequence of operations
Section 2: Planning Team Meetings – Prior To Manufacture Date: 02/12/ Time :13. Attendees: Peter, Anthony (TL), Ahmad Meeting Title: Introduction Planning Meeting This meeting: Risk Assessment Pre-use check on Pillar drill Today we signed off the Workshop Rules. Next week: Pre-use check on milling machine getting materials, cutting and filing Getting Materials: Peter Will get the materials from mike. Reading the drawing and measuring: Ahmad will read the drawing and give the measurements to Anthony and Peter. Marking out and scribing: Anthony will scribe the workpieces based on Ahmads measurements Filing: Peter will carry out the filing process. Cutting: Ahmad will carry out the cutting process. Final Check: Anthony will inspect the components for any mistakes. Date: 9/12/ Time: 11. Attendees: Anthony, Ahmad (TL), Peter Meeting title: carrying out operations This meeting: Pre-use check milling, getting materials, cutting and filing risk assessment Next week: drill the holes, filling a 45-degree angle, make the spacer. Drilling the holes : Ahmad will drill the holes today. Filling a 45-degreee angles: Anthony will file the 45-degree angle. Making the spacer: peter will make the spacer. Date: 13/01/ Time: 11: Attendees: Ahmad, Peter (TL), Anthony. Meeting title: carrying out operations This meeting: drill the holes, filling a 45-degree angle, make the spacer. Next week: assembly and slot operation on the milling machine. Assembly: Peter and Anthony will do the assembly for all the parts. Slot operation: Ahmad will do the closed slot operation on the milling machine. Date: 20 /01/ Time: 11: Attendees: Ahmad, Peter, Meeting title: Peter and Ahmad will assemble the bevel gauge and insert the rivets and clamp it together (Anthony was not present)
13/1/2022 Anthony (TL): while I was leader, I had a discussion with my piers about the steps to create the central section of the bevel gauge. We all took command of a section to complete this would involve applying the engineers blue to the work piece to allow us to get a clear mark on the work piece with a scribe while the others checked for imperfections with the measurements and file down the work to get the correct shape and size that is needed to complete the task. I was also in charge of health and safety while 2 out of the 3 where fine there was a minor accident that only needed some first aid 20/1/2022 Ahmad (TL): During manufacturing we helped each other by holding the others workpiece with the rivets while the other clamps it together to prevent them falling out while you are cutting them and hammering them. 27/01/2022 Peter (TL): During manufacturing of the bevel gauge we helped each other clamp up our workpieces because the bevel gauge jig broke and it made it harder to cut the rivets so it required help form our team members.
Role as a Leader During Manufacture 16/12/2021, Peter (TL): While I was the leader we had an idea to use two different pillar drills for different holes to increase efficiency and decrease time taken to manufacture. We take turn and while one drills the right hole for both pieces the other does the same thing on the other pillar drill but for the other hole then swap around.
20/01/2022. Peter (TL): While I was the leader we were require to help each other
because we encountered a problem the bevel gauge jig broke and we had to help each
other to cut of the rivets which was very hard but we done it after some struggle.
(Anthony Was on work experience)
Section 3: Risk Assessment
Hazards
- Slips, trips & falls 6. Tools Handling 11. Dust/Fumes
- Moving Parts 7. Harmful Substances 12. Noise/Vibration
- Falling/Flying objects 8. Unshielded Processes 13. Electricity
- Manual Handling 9. Other people 14. Heat/Fire/Explosion
- Materials Handling 10. Poor Lighting 15. Other
Risk Evaluation
Bevel Gauge F
Consequences 1 Trivial No first aid 2 Minor Minor first aid 3 Moderate Hospital visit 4 High Time off work 5 Catastrophic Possible fatality Likelihood 1 Rare <3% 1 Low 2 Low 3 Moderate 4 High 5 High 2 Unlikely 3% to 10% 2 Low 4 Low 6 Moderate 8 High 10 Extreme 3 Possible 10% to 50% 3 Low 6 Moderate 9 High 12 Extreme 15 Extreme 4 Likely 50% to 90% 4 Moderate 8 High 12 High 16 Extreme 20 Extreme 5 Almost certain
90% 5 High 10 High 15 Extreme 20 Extreme 25 Extreme Evaluation before control measures Evaluation after control measures Hazard No^ Likelihood x Severity Rating Hazard No^ Likelihood x Severity
Rating 1 1 X 3 3 1 1 X 2 2 2 2 X 3 6 2 1 X 2 2 3 2 X 3 6 3 2 X 1 2 4 3 X 2 6 4 1 X 2 2 5 2x 4 5 1x 2 6 3x 9 6 2x 4 7 2 x 2 7 1x 1 8 3x 6 8 2x 2 9 1x 5 9 1x 3 10 1x 2 10 1x 1 11 2x 6 11 2x 2 12 2x 6 12 2x 2 13 2x 8 13 1x 3
14 2x 6 14 1x 2 15 .machine malfunction 1x 5 5 1x 1
Hazards
- Slips, trips & falls 6. Tools Handling 11. Dust/Fumes
- Moving Parts 7. Harmful Substances 12. Noise/Vibration
- Falling/Flying objects 8. Unshielded Processes 13. Electricity
- Manual Handling 9. Other people 14. Heat/Fire/Explosion
- Materials Handling 10. Poor Lighting 15. Other Recommended Control Measures Hazard No 1 Measure Taken: Inspect the floor before you start operating machines, make sure to put yellow wet floor signs. Hazard No 2 Measure Taken: Moving parts mean on the machine such as the spindle and the tool on the pillar drill, you can prevent any injuries by making sure the machine guard is on and it functions as it should. Also Make sure the sleeves are above your elbow and hair is tied up to prevent it from getting caught Hazard No 3 Measure Taken: One of the control measures is that make sure the machine guard is closed and functions properly because if you did not tighten the workpiece properly it might come loose and start flying around. The second control measure is that your wear your safety boots because it protects your toes in case something falls from your hands or from the table. Hazard No 4 Measure Taken: One of the control measures are that you do not lift more than 20 kg and also if you lift a box or different objects you are using the right technique which prevents the box from slipping from your hand and it makes sure your back is positioned the right way so no injuries will occur. Hazard No 5 Measure Taken: The main control measure that must be taken is that when you are moving from one place to another use a pallet jack or a cart to transport it. The second control measure is that when you lift the material make sure to use the right technique and make sure the workpiece does not exceed 20 kg if it does use an electrical crane which is present in almost every engineering workshop. Hazard No 6 Measure Taken: Make sure the tool is in a static position (Press emergency button) if is mounted onto a machine to avoid cutting your fingers off. Also, when mounting a new cutting tool make sure to tighten it properly and do not touch the sharp edges to prevent cutting your finger. If the cutting tool is not mounted on a machine e.g. file or saw you must make sure to hold the wooden handle and keep your finger away from the sharp tip/edges. Hazard No 7 Measure Taken: The only harmful substance used is Engineers blue, we use a brush to apply it to the workpiece surface. You can prevent this hazard by washing your hands right after you used the substance. Hazard No 8 Measure Taken: One of the measures taken is pay attention to the cutting tool used also make sure to avoid touching the sharp parts. When carrying a cutting tool make sure to point it down to the ground to prevent stabbing somebody. Hazard No 9 Measure Taken: Make sure when somebody is using the pillar drill that other people are behind the metal bars and when carrying out unshielded operations with sharp cutting tools make sure to stay between the yellow line to avoid hurting somebody. Hazard No 10 Measure Taken: Poor lighting can cause mistakes and errors occurring which can cause accidents such as cutting your finger, Poor lightning can cause eye strain which can damage the retina This can be prevented by using LED light bulbs which give an even light also have natural light source which helps with concentration.
