This standard may be applied in a tool room situation which involves a great deal of autonomy based on a sound knowledge of the operation of production tooling.

The tooling being maintained may include any of the following: press tools, plastic moulds, forging dies, die casting, or jigs and fixtures, gauges etc. requiring precision repair.

A normal range of tool room equipment would be used which may include lathes, mills, grinders, hand and power tools used for precision work.

For simple maintenance not requiring precision repair, see Unit MEM18006C (Repair fit engineering components).

Band: A

Unit Weight: 4

Path 1

MEM06007B

Perform basic incidental heat/quenching, tempering and annealing

MEM07005C

Perform general machining

MEM07006C

Perform lathe operations

MEM07007C

Perform milling operations

MEM07008D

Perform grinding operations

MEM09002B

Interpret technical drawing

MEM12003B

Perform precision mechanical measurement

MEM12023A

Perform engineering measurements

MEM18001C

Use hand tools

MEM18002B

Use power tools/hand held operations

MEM18003C

Use tools for precision work

MEM18006C

Repair and fit engineering components

MEM18055B

Dismantle, replace and assemble engineering components

ELEMENT

PERFORMANCE CRITERIA

1. Identify and analyse defects in tooling

1.1. Defects are determined from any of: production components produced, production reports or tool inspections.

1.2. Sequence of maintenance operations is planned.

2. Disassemble and assess tooling components

2.1. Tooling is disassembled, and condition of components against prints, drawings, manufacturers' drawings etc. is assessed.

2.2. Worn/damaged parts are replaced/reconditioned.

3. Obtain and prepare replacement materials

3.1. Materials are obtained to meet tooling requirements.

4. Manufacture/repair tooling components

4.1. Appropriate hand and hand held power tools are selected and used.

4.2. Appropriate machining process is chosen from a range of standard tool room machines.

4.3. Machining parameters are set to produce components to specification.

4.4. Where appropriate, heat treatment is initiated according to specification.

5. Assemble tooling components

5.1. Using acceptable tool making techniques and procedures, tooling components are checked and assembled correctly in conformance with specifications.

6. Measure production components

6.1. Production components are checked with precision instruments to ensure conformance to specifications as required.

7. Identify potential production/maintenance problems

7.1. Conditions leading to tooling failure are identified and recorded.

7.2. Recurrent faults are identified and solutions are initiated.

Required skills

Look for evidence that confirms skills in:

obtaining all relevant information with respect to defective tooling

examining the defective tooling for breakage, wear, etc.

preparing a sequential plan for the repair/maintenance of the defective tooling and documenting the plan

disassembling the defective tooling in accordance with acceptable tool making techniques and procedures

obtaining all relevant drawings, specifications and sample products/components

marking worn/damaged components for repair or replacement

testing tooling components for hardness

obtaining the appropriate materials for manufacture of replacement tooling components

using the appropriate hand and hand held power tools to fashion/manufacture tooling components to specification

utilise sample components or sections to test the tooling components being manufactured

shaping and producing the tooling components to specifications using appropriate machines and machining processes

assembling and fitting all tooling components to specification using acceptable tool making techniques and procedures

checking the first-off component/product using appropriate precision instruments for conformance to specification

recording the conditions that lead to the failure of the given set of tooling

initiating design modifications/alterations to rectify recurring faults or failure

Required knowledge

Look for evidence that confirms knowledge of:

common tooling defects from a range of sample products/components

the probable causes of tooling failure

the reasons for selecting the probable causes of tooling failure

the reasons for establishing a sequential plan for the repair/maintenance of defective tooling

the procedures for documented plans for the repair/ maintenance of defective tooling

the procedures for disassembling defective tooling

the specifications of all tooling components

the precision instruments to be used to check tooling components for conformance to specification

the reasons for selecting the chosen precision instruments

the procedures for identifying worn/damaged tooling

components for repair or replacement

the reasons for deciding to repair or replace worn/damaged components

the appropriate materials for each component of the tooling to be replaced

the required physical properties of the tooling to be replaced

the reasons for selecting the chosen materials in terms of: strength, durability, component finish, heat treatment requirement, and availability

the procedures for hardness testing materials

the procedures for obtaining tooling materials

the hand and hand held power tools to be used to fashion/manufacture the required tooling components

the reasons for selecting the chosen hand and hand held power tools

the appropriate machines and machining processes to shape/produce the required tooling components

the reasons for selecting the chosen machines and machining processes

the effect of machining parameters on the surface finish and tolerances achievable from machining processes

the machining parameters appropriate to given machining tasks and specifications

the reasons for selecting the chosen machining parameters

the reasons for heat treating the tool steel in accordance with heat treatment procedures and specifications

the heat treatment of tooling components initiated

the heat treatment requirements of a range of given tool steels to achieve specified hardness

the procedures for heat treating tool steels

the procedures for initiating the heat treatment of tool steels

the procedures for fitting/assembling the tooling components

the precautions to be taken when fitting/assembling tooling components

the appropriate precision instruments for checking the components produced

the specifications of the finished product

the common causes of tooling failure

the procedures for documenting tooling failures

the conditions leading to the failure of a given set of tooling

the reasons for selecting the chosen mode of failure

previous faults with the given set of tooling

any commonalities of causes of failures or trends/events associated with tooling failure

appropriate proposed solutions for a range of recurrent faults that may occur in tooling

the reasons for selecting the chosen solutions

the procedures for initiating modifications/alterations to tooling design

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment

A person who demonstrates competency in this unit must be able to maintain tool and dies. Competency in this unit cannot be claimed until all prerequisites have been satisfied.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Assessors must be satisfied that the candidate can competently and consistently perform all elements of the unit as specified by the criteria, including required knowledge, and be capable of applying the competency in new and different situations and contexts.

Context of and specific resources for assessment

This unit may be assessed on the job, off the job or a combination of both on and off the job. Where assessment occurs off the job, that is the candidate is not in productive work, then an appropriate simulation must be used where the range of conditions reflects realistic workplace situations. The competencies covered by this unit would be demonstrated by an individual working alone or as part of a team. The assessment environment should not disadvantage the candidate.

This unit could be assessed in conjunction with any other units addressing the safety, quality, communication, materials handling, recording and reporting associated with tool and die maintenance or other units requiring the exercise of the skills and knowledge covered by this unit.

Method of assessment

Assessors should gather a range of evidence that is valid, sufficient, current and authentic. Evidence can be gathered through a variety of ways including direct observation, supervisor's reports, project work, samples and questioning. Questioning should not require language, literacy and numeracy skills beyond those required in this unit. The candidate must have access to all tools, equipment, materials and documentation required. The candidate must be permitted to refer to any relevant workplace procedures, product and manufacturing specifications, codes, standards, manuals and reference materials.

Guidance information for assessment

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Unit sector

Maintenance and diagnostics

This unit contains employability skills.