Pilot IMS Birmingham - Case Studies - Engineering: Sheet Metalworking

Sheet Metalworking

Besides requiring specialist knowledge for operating individual items of machinery, the skilled mechanic needs to have a keen general alertness for health and safety hazards throughout the workshop. The correct use of protective equipment is essential for the individual operator, with care required for handling and temporary storage of cut and shaped materials. The rapid introduction of new technology also imposes pressures on machinists to learn new procedures but also to keep up the traditional skills, possibly originally learnt as a traditional engineering apprentice many years previously. Whilst increasingly relying on computer generated operational programmes, the modern engineer is still required to have a keen understanding of the materials and processes being used. The NVQ courses are set to cover the wide breadth of operational activities that could be undertaken within the workshop.

Companies in this sector we have worked with include:

HVC Ltd.

Rojac Engineering Ltd.

Example of Programme undertaken

Programme Details
Pilot was invited by the client company to run the City and Guilds course, Performing Manufacturing Operations, to confirm that all the engineers were working to the organisation's and nationally approved standards.

Preparation
The Company operates from a single site, with an office block attached to the main factory, with an adjoining warehouse. An overhead crane is operated throughout the production area. The Company employs a full range of engineering machinery, from a hand press through to a laser cutter, which is operated on a 2 shift basis. The bulk of production work is of a batch nature. All the engineers were skilled operators who set up their machines from drawings provided with their work instructions and are given a high degree of autonomy to complete their allotted tasks.

Course Delivery
The course was established within the Company in agreement with the Company's Managing Director. As a result, the organisation of the course programme was fully supported by management throughout the Company. Pilot's Assessor was provided with full information on Company organisation and work procedures.

Access to the engineers was straightforward. Observations could be undertaken at any time. Discussions, questioning and work on Course Portfolio had to be undertaken whenever suitable breaks arose in the progress of work. This caused delay as pressure of work was continuous and particularly important with sequential operations for any one job. To cater for this pressure on the engineers and recognising their capacity to work under their own initiative, Pilot's Assessor arranged to visit on a weekly basis. This enabled the engineers to find some time during the week in which to progress the written component of their course. Despite the ongoing time pressures for production, the weekly arrangement worked well.

Outcomes
All the engineers completed their course, some in a very short time and many with clever and useful suggestions for practical improvements within their work area, which were all referred to management, either directly or through the assessor.

One engineer was so empowered by his course that, in his own time, he used scrap material to construct new, well-located trays for his machine tools. Even those who were initially reluctant to take the course were delighted and even proud to have successfully completed it, resulting in improved timekeeping and attention to procedures and health and safety.

The course proved that all the engineers not only performed to company and national standards but also took a great pride in their work, for both quality and timing. Participation on the course helped to foster improved communications between the sections and health and safety practices within the workshop.

The Company invited PILOT to follow the course with health and safety training throughout the organisation.

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