PERFORMING ENGINEERING

OPERATIONS LEVEL 2

SPEO2/066A- ASSESSMENT
Date: August 2020
Version: 1

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Charity Number: SC0 36198
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Evidence Ref No:

Candidate Name: Section:

Assessment No:

Qualification Title: Performing Engineering Operations

Evidence Route / Element :

With reference to the latest version of the drawing, the candidate has to list the planning
procedure for the component to be manufactured.

STEP No: PLANNING PROCEDURES

1 Assess the risks associated with carrying out fabrication operations

2 Gather tools / material required to complete the job

3 Gather engineering drawings to complete required tasks

4 Mark out sizes for end plates from drawings

5 Mark out body

6 Mark out lids

7 Mark out hinges

8 Mark out hasp

9 Cut and bend handles

10 Assemble

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Evidence Ref No:

Candidate Name:

Qualification Title: Performing Engineering Operations

Evidence Route / Element :

OPERATIONS SHEET

Health and Safety

This job was completed using all existing health and safety procedures, all
students were appropriately trained for all equipment and were competent with
the set tasks.

Body
The body of the toolbox was formed of 1mm galvanised steel plate, this was
sourced and checked for suitability in terms of size, smoothness and aesthetics.
Firstly, the centre line was marked for use as a datum using a scribe, steel rule
and engineers square. A line was then marked 100mm on either side of this
datum and then at 200mm. From the 200mm line on each side we marked
another line a further 10mm out. On each corner we then marked out 8mm X
20mm and this was
snipped out using either
right or left-handed snips
respectively. Each of
these folds was then bent
using the box ban folder
to 90 degrees.

End Plates

For the end plates we

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required two 177mm X 220mm plates, the centre line was then marked for use as
a datum.
The material was then marked with the material required to complete rolled
edges and the excess was then removed using the guillotine and snips. When the
flat profile of the end plate has been created fold lines marked at 4,8 & 12mm
along the top edges in order to create a rolled edge, this was created using the
techniques that have been practiced earlier on in the curriculum.
The lower flaps of the end plate were then bent to 90 degrees using the box pan
folder and joined to the folded body using 4mm rivets spaced evenly around the
ends of the body, the holes for these were drilled using a 4mm drill bit.

Hinges

For the 4 hinges we

required 8 strips of
material measuring
70mm X 50mm. We
then marked the
material as shown in
the drawing on the
left. And pre drilled the 4mm holes for the rivets
Using the techniques learnt earlier on in fabrication we created the rolled hinge
around a 4mm bar.
We then used files, snips, chisel and a hacksaw to remove the waste material.
And secured the halves together to make 4 complete hinges.

Lids

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For the lid we used two pieces of material, one sized 170mm x 410mm and the
other 150mm x 410mm. The production process was simple as the measurements
were the same for both sides with only 1 variation.

The corners were snipped with left or right-handed snips and the guillotine. The
sides were folded inwards using the box pan folder and flattened using the anvil
and nylon mallet. To achieve the specific angle for the lids we used a guide plate
that was held against the edge of the box pan folder to show how far to bend the
plates.

Hasp

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The first part of the hasp we made was the small hinge, this was rolled around a
4mm bar as was the case with the hinges for the lid. The difference being we
had to cut a slit in it to accommodate the other half of the hasp. This was
achieved by chain drilling with a 4mm drill bit and then using a chisel and files to
clean up the hole. On the other side of the hinge two rivet holes were drilled
10mm x 10mm in from the edge.
The other half of the hasp was created by folding a 80mm x 20mm strip of steel
in two and then using a hammer and a vice to create two small 15mm flaps
through which a 4mm hole was drilled on each side. We then used a 10mm drill
bit to make a hole through the folded section in order to make the toolbox
lockable. On corner of the folded material was filed down considerably in order
to all the hinge to pass smoothly over it.

Handles
For the toolbox handles we used 4mm steel rod, we cut two 325mm sections and
first marked the centre point. This was then lined up with the centre of the vice
and small hollow tube was used as a lever to bend the bar to 90 degrees.
We then marked 20mm from the bottom of each leg and bent that backwards by
90 degrees to create a bridge effect for a handle with clearance.
The Latches to hold the handle were made from a 20mm x 70mm strip with was
hammered around a former to create the specific shape for the 4mm bar. Two
4mm holes were them drilled in in each strip.

Assembly
After having attached the end plates to the main body earlier in the process it

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was now time to attach the lids to the body. Firstly, the hinges were attached to
the lower body 40mm in from each edge, the holes were marked using a pen and
drilled with a 4mm drill bit and then attached on with a 4mm rivet installed by a
pop rivet gun. Now the hinges are attached to the lower body we could attach
the lids, this was done by marking the hinge holes on the lid with a marker pen
and drilling through with the 4mm drill bit.
The hasp was attached by adding the hinge first and securing it with 4mm rivets,
this allowed us to find the correct position for the other half of the latch, this
was then secured with the 4mm rivets.
The handles were marked, drilled and attached by securing the small loops onto
the lids with the 4mm rivets.

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Evidence Ref No:

Candidate Name: Section

Company: Assessment No:

Qualification Title: Performing Engineering Operations

Evidence Route / Element :

Inspected Conforms to
Measuring Equipment
Drawing Dimension Size Specification
used
(Candidate) (Assessor)
Large steel rule 440mmx370mm (main body) YES / NO
Steel rule 220mmx177mm (end plates) YES / NO
Steel rule 70mmx50mm(hinges) YES / NO
Large steel rule 410mmx170mm (lids) YES / NO
Steel rule 80mmx20mm (hasp) YES / NO
Steel rule 50mmx30mm (hasp) YES / NO
Large steel rule 325mmx4mm (handles) YES / NO
YES / NO
YES / NO
YES / NO
YES / NO
YES / NO
YES / NO

YES / NO
YES / NO
YES / NO
YES / NO

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Accept
Does Component
Conform to drawing YES / NO Conformity report Reject
Specification
Re-assess

Report /
Feedback:

Describe any problems you encountered.

How did you overcome these and what would you do differently next time?

Candidate Signature: Date:

Assessor Signature: Date:

Assessor No:

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DRAWING/ CIRCUIT

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