Apprenticeship training course

Tool process design engineer (level 6)

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Information about Tool process design engineer (level 6)

The design of a unique tooling process pathway that enables components to be mass produced in the most economically viable way.

• Knowledge, skills and behaviours:
  View knowledge, skills and behaviours

  Knowledge

  • Strategic tool design including the principles and practices of toolmaking machine capability and the limitations of new press tools
  • How to design a new tooling process for volume production without inhibiting existing production demand using leadership and management techniques
  • Planning and forecasting outcomes of new tooling processes including those where there is limited definition tooling processes
  • 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
  • Collaborative working including relationship management with clients, stakeholders and the supply chain by utilising negotiation, influencing and mutual problem solving techniques.
  • 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
  • Advanced lean manufacturing techniques including programme management, failure mode analysis, problem solving, advanced quality planning and single minute exchange of dies (SMED)
  • 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
  • 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
  • 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
  • High volume sheet metal forming and cutting techniques in a continuous production environment taking into consideration industry requirements and regulations.

  Skills

  • 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
  • Create new tooling solutions using specialist software programmes to produce 3 dimensional (3D) models
  • 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
  • Design and develop gap gauges, acceptance gauges including co-ordinate measuring machine (CMM) dimensional checking and 3D laser scanning for analysis and problem resolution
  • Undertake advanced forming simulation using computer aided equipment (CAE)
  • 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.
  • Design tooling solution to meet customer requirements including external specifications set by clients and original equipment manufacturers (OEMs) while fulfilling ethical and sustainability requirements.
  • 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.
  • Communication and influencing techniques by choosing appropriate communication methods for the audience, ensuring understanding and delivering effective presentations and reports
  • 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

  • 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.
  • Professionalism - dependable, ethical, responsible and reliable while consistently setting demanding personal targets
  • Team player, works effectively within a team and supports others when required. In doing so, applies these behaviours in a respectful and professional manner
  • 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
  • Commits to the beliefs, goals and standards of their own employer and to the wider industry and its professional standards
  • Problem solving identifies issues quickly, enjoys solving complex problems at the root cause and applying appropriate solutions
  • Quality focus that promotes continuous improvement and consistently applies logic to the design process
  • Resourceful and adjusts to different conditions and technologies through market research quickly while continuing to meet the tool process design criteria
  • 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
• Apprenticeship category (sector): Engineering and manufacturing
• Qualification level: 6; Equal to degree
• Course duration: 48 months
• Maximum funding: £22,000 ; Maximum government funding for ; apprenticeship training and assessment costs.
• Job titles include:
  • Tool process design engineer
  • Tooling process specialist
  • Process design engineer
  • Senior process specialist
  • Press tool designer

View more information about Tool process design engineer (level 6) from the Institute for Apprenticeships and Technical Education.