Block A – Common Occupational Skills

Context

Tool and die makers perform safety-related functions and use various tools and equipment to complete multiple tasks throughout their trade. They also use and maintain machine-tools and tooling in order to prolong service life and to ensure a safe environment. Tool and die makers also use organizational skills to perform their tasks in a safe, efficient and effective manner. The benchwork that tool and die makers perform is multi-functional; it takes in many various critical components of the trade from part layout to part fit-up to produce a finished component to exacting standards.

Trends

Safety standards are becoming more rigorous and require more thorough applications of practices. Safety officers and inspectors are becoming more common in the workplace.

The implementation of shop floor management systems (software) is becoming more common. That software facilitates the planning and scheduling process.

More and more workplaces are recycling paper products, oils, packaging materials and steels to reduce waste.

Related Components

All components apply.

Tools and Equipment

See Appendix A.

Task 1 Performs safety-related functions.

Required Knowledge

• K 1 types of personal protective equipment (PPE) such as respiratory, hearing, eye and body protection
• K 2 PPE and safety equipment operations
• K 3 Occupational Health and Safety (OH&S)
• K 4 location of PPE and safety equipment
• K 5 jurisdictional safety regulations
• K 6 types and operation of fire extinguishing equipment
• K 7 disposal and recycling procedures
• K 8 work hazards such as toxic chemicals and metals, and the improper operation of hand and power tools
• K 9 absorbent materials
• K10 lock-out and tag-out procedures
• K11 dangerous conditions and potential hazards
• K 12 required training and certification
• K 13 Workplace Hazardous Materials Information System (WHMIS) and Material Safety Data Sheets (MSDS)
• K 14 first aid
• K 15 company safety policy
• K 16 signage
• K 17 required ventilation

Sub-task - A-1.01 Maintains safe work environment.

Key Competencies

• A-1.01.01 comply with lock-out and tag-out procedures
• A-1.01.02 recognize worksite hazards such as slippery floors, tangled air lines and power cords, and hazardous fumes
• A-1.01.03 recognize machine hazards such as hot or irregular chip formation, insecurely mounted workpiece, defective equipment and contaminated coolant
• A-1.01.04 stack and store parts and materials in designated locations and formations
• A-1.01.05 follow specified safety procedures such as using safety glasses and safety shoes, and following evacuation procedures
• A-1.01.06 maintain a clean and tidy work area to avoid injuries to self and others
• A-1.01.07 identify hazardous tasks performed among workers to avoid injuries to self and others
• A-1.01.08 handle hazardous materials in accordance with WHMIS procedures such as disposal, labelling and use of PPE
• A-1.01.09 participate in safety meetings and discussions
• A-1.01.10 set up barricading devices and signage such as caution tape, fences and barriers to define work perimeters and contain contaminants or other hazards
• A-1.01.11 set up or identify location of safety zone containing components such as first aid kit, fire extinguishers, MSDS and eye wash stations
• A-1.01.12 document items such as faulty PPE and safety equipment, inspections, potential hazards, safety meetings, injuries and training according to jurisdictional regulations
• A-1.01.13 obtain required certification for regulated devices

Sub-task - A-1.02 Uses personal protective equipment (PPE) and safety equipment.

Key Competencies

• A-1.02.01 identify site hazards and regulations requiring the use of PPE and safety equipment
• A-1.02.02 maintain and store PPE and safety equipment
• A-1.02.03 identify and replace damaged PPE such as excessively worn boots and cracked safety glasses or face shields
• A-1.02.04 recognize Canadian Standards Association (CSA) approved PPE and applicable safety equipment such as fire extinguishers, breathing apparatus, hearing protection and safety shoes
• A-1.02.05 select and use PPE and safety equipment appropriate for individual tasks and situations
• A-1.02.06 ensure proper fit of PPE such as respirators, fall arrest harnesses and face shields

Task 2 Uses and maintains machine-tools and tooling.

Required Knowledge

• K 1 types of hand tools
• K 2 imperial and metric systems
• K 3 types of power tools such as electric, pneumatic and hydraulic
• K 4 operating procedures
• K 5 types of measuring devices such as micrometers, vernier calipers, protractors, sine bars and gauge blocks
• K 6 measuring device calibration
• K 7 types of layout tools and equipment such as height gauges, angle plates, scribers and surface tables
• K 8 types of hoisting and lifting equipment such as jacks, chain hoists and overhead cranes
• K 9 hoisting, lifting and rigging procedures
• K 10 jurisdictional requirements to operate forklifts and cranes
• K 11 cleaning equipment, techniques and their requirements
• K 12 machine lock-out and tag-out procedures
• K 13 types of lubricants and machine requirements
• K 14 maintenance schedule
• K 15 tool geometry such as rake angles, relief angles and chip breakers
• K 16 types of tool sharpening equipment
• K 17 types of cutting fluids such as oil and water soluble fluids
• K 18 machine operations and accessories
• K 19 types of alignment equipment
• K 20 equipment and procedures used in calibration of inspection equipment
• K 21 techniques and procedures for storing, handling and maintenance of equipment, materials and tooling

Sub-task - A-2.01 Uses hoisting and lifting equipment.

Key Competencies

• A-2.01.01 select and use forklifts and cranes in accordance with specified practices
• A-2.01.02 determine approximate weight of lift to stay within capacity of available equipment
• A-2.01.03 recognize shop and regulatory limitations and determine what rigging and hoisting operations need to be done by qualified personnel
• A-2.01.04 inspect hoisting, lifting and rigging equipment for defects according to specified schedule
• A-2.01.05 take out of service, mark and report defective equipment
• A-2.01.06 store equipment in clean and dry locations
• A-2.01.07 select and use slings, chains, wire ropes and other accessories

Sub-task - A-2.02 Maintains machine-tools and tooling.

Key Competencies

• A-2.02.01 clean machine-tools and tooling
• A-2.02.02 check oil levels and lubricate accordingly
• A-2.02.03 maintain level and quality of cutting fluids and coolants
• A-2.02.04 ensure compliance with maintenance schedule
• A-2.02.05 maintain quality and performance of machine-tools, spindles, holders, chucks, cutting tools and other accessories

Task 3 Organizes work.

Required Knowledge

• K 1 types of drawings and drawing notes
• K 2 first and third angle projection
• K 3 symbols such as surface finishes, scales and tolerances
• K 4 machine-tools and machining operations
• K 5 material characteristics such as composition, properties, application and machinability
• K 6 material non-destructive tests such as dye penetrant and x-ray tests
• K 7 material hardness tests such as Rockwell and Brinell
• K 8 time required to complete each operation
• K 9 types and grades of material such as metals and non-metallic materials
• K 10 heat treating procedures including torch, quenching, tempering, annealing, normalizing and carburizing
• K 11 heating mediums such as gas, electric and vacuum furnaces, and gas torches
• K 12 standards such as American National Standards Institute (ANSI), CSA and Society of Automotive Engineers (SAE)
• K 13 design and development of production tools and prototypes

Sub-task - A-3.01 Interprets drawings, specifications and applications.

Key Competencies

• A-3.01.01 determine information such as number of parts to make, engineered components and material to be used, and machines to be used
• A-3.01.02 check drawing for dimensioning, machining allowances and conflicting information
• A-3.01.03 visualize finished product by analyzing dimensions and drawings
• A-3.01.04 use process sheet to determine order of operations
• A-3.01.05 locate information in reference materials such as Machinery’s Handbook
• A-3.01.06 perform mathematical calculations to augment information provided by documentation
• A-3.01.07 refer to standards such as material certification, SAE, American Society of Mechanical Engineering (ASME) and military specifications (MILSPEC)

Sub-task - A-3.02 Plans project activities.

Key Competencies

• A-3.02.01 identify and confirm resources required such as components, machinery, materials and processes
• A-3.02.02 identify tasks to manufacture production tools and prototypes such as preparing materials, performing benchwork, sawing, turning, grinding, milling and assembling
• A-3.02.03 estimate timelines for each task
• A-3.02.04 prioritize operations into a logical sequence
• A-3.02.05 establish milestones by determining a schedule of operations
• A-3.02.06 verify feasibility of schedule by confirming availability of identified resources

Task 4 Performs benchwork.

Required Knowledge

• K 1 types and grades of material such as metals and non-metallic materials
• K 2 material characteristics such as composition, properties, application and machinability
• K 3 material identification markings such as ASME system, ANSI system, colour codes and number system
• K 4 raw material measurements
• K 5 layout procedures
• K 6 layout media such as dyes, paint, markers and coating
• K 7 marking procedures such as etching, engraving, colour coding and stamping
• K 8 types of material defects
• K 9 inspection procedures and techniques such as incoming, in-process and final
• K 10 types of layout and inspection equipment such as micrometers, dividers, height gauges, vernier calipers, protractors, and hardness testers
• K 11 dimensioning practices such as geometric dimensioning and tolerancing (GDT)
• K 12 sketching techniques
• K 13 types of projections such as first angle and third angle
• K 14 deburring techniques such as filing, stoning and scraping
• K 15 lapping and honing techniques
• K 16 polishing and blending techniques
• K 17 types of abrasives

Sub-task - A-4.01 Performs layout.

Key Competencies

• A-4.01.01 determine layout requirements by reading engineering drawings and specifications
• A-4.01.02 select and use layout tools and instruments such as surface plates, layout dye, scribers, height gauges and prick punches
• A-4.01.03 scribe workpiece to identify and locate part features according to drawing specifications
• A-4.01.04 verify layout by using measuring tools such as vernier calipers, dividers and steel rules

Sub-task - A-4.02 Marks material for identification.

Key Competencies

• A-4.02.01 follow coding system used in shop to maintain organization of inventory
• A-4.02.02 etch or stamp required information such as heat numbers, parts numbers and composition
• A-4.02.03 mark workpiece without compromising the integrity of the workpiece

Sub-task - A-4.03 Inspects workpiece.

Key Competencies

• A-4.03.01 perform inspection techniques using equipment such as vernier calipers, micrometers, dial indicators, optical comparators and coordinate measuring machines (CMM)
• A-4.03.02 perform basic non-destructive inspection (dye penetrant)
• A-4.03.03 perform visual inspection of workpiece for defects such as cracks, inadequate surface finish, distortions, surface deviation and damage

Sub-task - A-4.04 Finishes workpiece.

Key Competencies

• A-4.04.01 select finishing process such as grinding, CNC finish milling, lapping, honing, deburring, filing, and polishing according to job specifications
• A-4.04.02 select abrasives such as hones, stones and lapping compounds
• A-4.04.03 identify features to be deburred
• A-4.04.04 select required work holding devices such as vises, soft jaws, parallel clamps and C-clamps
• A-4.04.05 set up workpiece in work holding device to protect material and operator
• A-4.04.06 perform finishing technique to achieve required finish
• A-4.04.07 use comparators and measure workpiece throughout the process to make finish adjustments
• A-4.04.08 identify process problems such as scratching and rounded edges
• A-4.04.09 clean workpiece to remove debris
• A-4.04.10 verify workpiece meets specifications using inspection equipment such as precision squares, vernier calipers, surface finish comparators and micrometers
• A-4.04.11 protect finished workpiece using material such as rust inhibitor, paper and crating