Tool process design engineer Apprenticeship Standard

Interested in a simple Skills Scan and Learning Progress Tracker tool for the Tool process design engineer standard?

Knowledge

K1: Strategic tool design including the principles and practices of toolmaking machine capability and the limitations of new press tools
K2: How to design a new tooling process for volume production without inhibiting existing production demand using leadership and management techniques
K3: Planning and forecasting outcomes of new tooling processes including those where there is limited definition tooling processes
K4: Applies business improvement processes and techniques, innovative ways of working and failure proofing techniques (for example Poke Yoke) to deliver a feasible and economically viable process
K5: Collaborative working including relationship management with clients, stakeholders and the supply chain by utilising negotiation, influencing and mutual problem solving techniques.
K6: The scientific, technical, engineering and mathematical principals involved in creating the optimal manufacturing process design, including geometric dimensioning and tolerances allowing conceptualisation and refinement of the design and theoretical fixture behaviour
K7: Advanced lean manufacturing techniques including programme management, failure mode analysis, problem solving, advanced quality planning and single minute exchange of dies (SMED)
K8: Properties of materials including the metallurgical properties of various metals, for example, mild steel stainless steel and predicting the effect on the material during the tooling process
K9: Business planning including project management, planning, forecasting, risk analysis, financial planning, commercial impact and contractual obligations, together with supply chain management, logistics and resource constraints
K10: Team formation and leadership including motivation, coaching and human resource development, preventing dysfunctional working using techniques such as emotional intelligence, conflict resolution and change management
K11: High volume sheet metal forming and cutting techniques in a continuous production environment taking into consideration industry requirements and regulations.

Skills

S1: Design and trial volume press tooling processes including blanking, piercing, forming, draw forming, press tool components selection, ganged setup, progression tooling, transfer tooling, clamping, material selection and heat treatment
S2: Create new tooling solutions using specialist software programmes to produce 3 dimensional (3D) models
S3: Critically analyse, interpret and evaluate complex information and ideas to create the new tooling solution, using bespoke software programmes to create 3D models such as car seat chassis assemblies
S4: Design and develop gap gauges, acceptance gauges including co-ordinate measuring machine (CMM) dimensional checking and 3D laser scanning for analysis and problem resolution
S5: Undertake advanced forming simulation using computer aided equipment (CAE)
S6: Confirm feasibility and estimate the cost of volume component production including, gross material cost, labour costs, machine cost overheads, machine utilisation capacity (Takt time) capital expenditure and consumables and contribute to overall budget management.
S7: Design tooling solution to meet customer requirements including external specifications set by clients and original equipment manufacturers (OEMs) while fulfilling ethical and sustainability requirements.
S8: Lead and manage a team to implement new tool process projects from their inception into full production, for example by using planning, organising team control and motivational techniques. Build on the ideas of others to improve outcomes.
S9: Communication and influencing techniques by choosing appropriate communication methods for the audience, ensuring understanding and delivering effective presentations and reports
S10: Provide timely succinct written reports that explains complex technical issues and potential consequences using language and phrases appropriate to the audience’s knowledge and understanding.

Behaviours

B1: Strong work ethic with a positive attitude, motivated by engineering and business values for example: motivated by externally set challenges, accountable and persistent in completing tasks.
B2: Professionalism - dependable, ethical, responsible and reliable while consistently setting demanding personal targets
B3: Team player, works effectively within a team and supports others when required. In doing so, applies these behaviours in a respectful and professional manner
B4: Self-analytical, overcomes problems through a process of reflection and review and by undertaking continuous professional development (CPD) in order to use new technological advances in the sector
B5: Commits to the beliefs, goals and standards of their own employer and to the wider industry and its professional standards
B6: Problem solving identifies issues quickly, enjoys solving complex problems at the root cause and applying appropriate solutions
B7: Quality focus that promotes continuous improvement and consistently applies logic to the design process
B8: Resourceful and adjusts to different conditions and technologies through market research quickly while continuing to meet the tool process design criteria
B9: Demonstrates a safety mind-set and promotes Health and Safety leadership to others at all times. This occupation sits within an industry with extensive and rigorous Power Press Regulation (PUWER) requiring a disciplined and responsible approach to manage, mitigate and avoid risk

Duty 1

DUTY: Design new unique tooling in line with a developing process route. Using computer aided engineering technology to ensure the full potential of the manufacturing equipment is best utilised against a background of competing existing production demands also applying and promoting Environmental, Health and Safety (EHS) requirements to the process.

Duty 2

DUTY: Undertake complex forming simulation trials where the new component is "formed" from a series of process steps

Duty 3

DUTY: Use bespoke computer aided design (CAD) equipment to create the design of the unique press tools associated equipment necessary to produce the component.

Duty 4

DUTY: Interpret customer data in order to develop a tool process route that meets the quality & quantity of parts needed by the client

Duty 5

DUTY: Consider manufacturing feasibility issues and offer counter proposals back to the customer offering safety performance to the component including component handling issues (sharp edges and component lifting weight)

Duty 6

DUTY: Develop the tool design brief to meet customer requirements in relation to cost quality and delivery including health and safety (H&S) considerations such as tool handling features.

Duty 7

DUTY: Design and developing the process brief, while being an implementer of best practice in safety management.

Duty 8

DUTY: Applies the companies’ quality standards to create a tool pathway design as specified by the customer in line with internal H&S standards and the customer's needs.

Duty 9

DUTY: Interact with the design office, factory floor, suppliers and customers to confirm design parameter

Duty 10

DUTY: Use appropriate planning techniques necessary to meet design, technical and budgetary requirements

Duty 11

DUTY: Provide technical updates and progress reports to the Managing or Production Director and client using Advanced Product Quality Planning (APQP) Technique reporting

Duty 12

DUTY: Controls expenditure and works within specified budgetary constraints, liaise with the finance team and ensure the appropriate level of financial impact on the company

Tool process design engineer

Interested in a simple Skills Scan and Learning Progress Tracker tool for the Tool process design engineer standard?

Knowledge

Skills

Behaviours

Duty 1

Duty 2

Duty 3

Duty 4

Duty 5

Duty 6

Duty 7

Duty 8

Duty 9

Duty 10

Duty 11

Duty 12

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Interested in a simple Skills Scan and Learning Progress Tracker tool for the Tool process design engineer standard?