Performing Engineering

Operations
Level: 2
PEO2/005
Producing components using hand fitting
techniques

Candidate Name:      

 EAL Assessment Route Summary
This EAL assessment route covers a broad range of basic hand fitting competencies.

You will be required to undertake a range of activities commencing with making sure you plan the
hand fitting activities before starting them and concludes with leaving the work area in a safe and tidy
condition on completion of the hand fitting activities. In producing the components, you will be

Complete assessment plan and evidence record

expected to use appropriate tools and equipment to mark out the material for a range of features to
be produced and then to use hand tools, portable power tools, shaping and fitting techniques that are
appropriate to the type of material and operations being performed.

During and on completion of the fitting operations you will be expected to check the quality of the
workpiece and ensure that the finished workpiece is within the drawing requirements.

Your responsibilities will require you to comply with health and safety requirements and organisational
policy and procedures for the activities undertaken, and to take account of any potential difficulties or
problems that may arise and seek appropriate help and advice in determining and implementing a
suitable solution. You will work under a high level of supervision whilst taking responsibility for your
own actions and the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide an understanding of your work, and its application, to
provide a sound basis for carrying out the activities to the required specification.

You will understand the safety precautions required when using hand fitting techniques, demonstrate
safe working practices throughout and understand the responsibility you owe to yourself and others in
the workplace.

Specific assessment requirements:

In order to prove your ability to combine different hand fitting operations, at least one of the
components produced must be of a significant nature and have a minimum of five of the features
listed in the expanded assessment requirment ‘specification’.

© 2006 EMTA Awards Limited

Page 2 of 10
PEO2-005 Issue 1
 Producing components using hand fitting
techniques
Performance to be assessed and evidenced:

Complete assessment plan and evidence record

1. Work safely at all times, complying with health and safety legislation, regulations
and other relevant guidelines
Assess all by work performed:
 adhere to procedures or systems in place for risk assessment, COSHH, personal
protective equipment and other relevant safety regulations      
 ensure all power tool cables, extension leads or air supply hoses are in a
serviceable condition      
 return all tools and equipment to the correct location on completion of the fitting
activities      
 check all measuring equipment is within calibration date      

2. Plan the fitting activities before you start them

3. Obtain the appropriate tools and equipment for the hand fitting operations and check
they are in a safe and usable condition

4.Mark out the components/materials for the required operations using

appropriate tools, methods and techniques

mark out: Assess all by work performed:

 datum/centre lines        circles      
 linear hole positions        radial profiles      
 square/rectangular profiles      

Plus
Assess one more by work performed:
 angles/angular profiles        allowances for bending      
 simple pattern development        radial hole positions      

components/materials: Assess two by work performed:

 square/rectangular (such as bar stock, sheet material, machined components)      
 circular/cylindrical (such as bar stock, tubes, turned components, flat disks)      
 sections (such as angles, channel, tee section, joists, extrusions)      
 irregular shapes (such as castings, forgings, odd shaped components)      

tools: Assess all by work performed:

 rules/tapes        scribers        protractor      
 punches        squares      
 scribing blocks        dividers/trammels      
 vernier instruments      

Continued

Page 3 of 10
PEO2-005 Issue 1
 Producing components using hand fitting
techniques
Performance to be assessed and evidenced:

Complete assessment plan and evidence record

methods and techniques: Assess by work performed:
 direct marking using instruments      

Plus

Assess one more by work performed:

 use of templates        tracing/transfer methods      

materials to the required specification using appropriate

5. Cut and shape the
tools and techniques
materials: Assess two by work performed:
 low carbon/mild steel        stainless steel      
 plastic/nylon/synthetic        high carbon steel      
 aluminium/aluminium alloys        composite      
 cast iron        brass/brass alloys      
 other specific material: State here            

specification: Assess all by work performed:

 flat datum faces        drilled holes through      
 internal threads        reamed holes      
 external threads        curved profiles      
 faces which are square to each other      

Plus

Assess three more by work performed:

 chamfers and radii        faces angled to each other      
 drilled holes to a depth        sliding or mating parts      
 faces which are parallel to each other      
 counterbore, countersink, or spot face      

Note - Specific assessment requirements: In order to prove your ability to combine different
hand fitting operations, at least one of the components produced must be of a significant nature
and have a minimum of five of the features listed in the expanded assessment requirment
‘specification’ as above.

tools and techniques: Assess all by work performed:

 filing        drilling        hand sawing      
 threads internal        threads external      

Plus

Assess one more by work performed:

 power sawing        scraping        lapping      

Page 4 of 10
PEO2-005 Issue 1
 off hand grinding        chiselling      

Continued

Complete assessment plan and evidence record

Page 5 of 10
PEO2-005 Issue 1
 Producing components using hand fitting
techniques
Performance to be assessed and evidenced:

Complete assessment plan and evidence record

dimensional and geometrical aspects of the
6. Measure and check all
component are to the specification

dimensional and geometrical aspects - features: Assess all by work performed:

 hole position        flatness        hole size/fit      
 squareness        depths        angles      
 profiles        surface finish      
 linear dimensions        thread size and fit      

dimensional and geometrical aspects - measuring equipment: Assess all by work

performed:
 external micrometers        vernier calliper      
 surface finish equipment (such as comparison plates, machines)      

Plus
Assess four more by work performed:
 rules        feeler gauges        squares      
 callipers        slip gauges        protractors      
 bore/hole gauges        radius/profile gauges      
 depth micrometers        depth verniers      
 thread gauges        dial test indicators (DTI)      

specification: Assess all by work performed as applicable to the process:

 angles within +/- 1 degree      
 surface finish 63µin or 1.6 µm      
 screw threads to BS Medium fit      
 reamed and bored holes within H8      
 general dimensional tolerance +/- 0.25mm or +/- 0.010”      
 flatness and squareness 0.05mm per 25mm or 0.002 per inch      
 components to be free from false tool cuts, burrs and sharp edges      
 there must be one or more specific dimensional tolerances within +/- 0.1mm or
+/- 0.004”      

7. Deal promptly and effectively with problems within your control and seek help and
guidance from the relevant people when you have problems you cannot resolve

8. Leave the work area in a safe and tidy condition on completion of the fitting activities

Page 6 of 10
PEO2-005 Issue 1
 Producing components using hand fitting
techniques
Knowledge to be assessed and evidenced:

Complete assessment plan and evidence record

1. What are the Health and Safety requirements, and safe working practices and
procedures required for the hand fitting activities undertaken?
     

2. Why is it important to wear appropriate protective clothing and equipment, and to

keep the work area safe and tidy?
     

3. What are the hazards associated with the hand fitting activities and how they can
be minimised?
Such as: use of power tools, trailing leads or hoses, damaged or badly maintained tools and
equipment, using files with damaged or poor fitting handles.
     

4. What is the procedure for obtaining the required drawings, job instructions and
other related specifications?
     

5. How do you use and extract information from engineering drawings and related
specifications?
To include: symbols and conventions to appropriate BS or ISO standards in relation to work
undertaken.
     

6. How do you interpret first and third angle drawings?

     

7. How do you interpret imperial and metric systems of measurement?

     

8. How do you interpret workpiece reference points?

     

9. How do you interpret the system of tolerancing?

     

10. How do you prepare the materials in readiness for the marking out activities, in
order to enhance clarity, accuracy and safety?
Such as: visually checking for defects, cleaning the materials, removing burrs and sharp
edges, applying a marking out medium.
     

Continued

Page 7 of 10
PEO2-005 Issue 1
 Producing components using hand fitting
techniques
Knowledge to be assessed and evidenced:

Complete assessment plan and evidence record

11. How do you select and establish a suitable datum?
     

12. Why is it important to make sure that marking out is undertaken from the selected
datum, and what are the possible effects of working from a different datum?
     

13. What are the methods of holding and supporting the workpiece during the marking
out activities?
     

14. What equipment can be used to hold and support the workpiece?
Such as: surface plates, angle plates, vee blocks and clamps parallel bars, screw jacks.
     

15. What marking out conventions do you use when marking out the workpiece?
To include: datum lines, cutting guidelines, square and rectangular profiles, circular and
radial profiles, angles, holes which are linearly positioned, boxed and on pitch circles.
     

16. What are the ways of laying out the marking out shapes or patterns to maximise
use of materials?
     

17. Why is clear and dimensional accuracy in marking out to specification and drawing
requirements important?
     

18. How do you set and adjust tools?

Such as: such as squares, protractors and verniers.
     

19. Why is it important to use tools only for the purpose intended?
     

20. What care is required when using the equipment and tools?
     

21. What is the proper way of storing tools and equipment between operations?
     

Continued
Page 8 of 10
PEO2-005 Issue 1
 Producing components using hand fitting
techniques
Knowledge to be assessed and evidenced:

Complete assessment plan and evidence record

22. What are the cutting and shaping methods that need to be used?
     

23. What is the sequence in which the operations will need to be carried out?
     

24. What various types of files are available?

     

25. What is the cut of files for different applications?

     

26. Why is it important to make sure file handles are secure and free from embedded
foreign bodies or splits?
     

27. How do you prepare the components for the filing operations?
Such as: cleaning, de-burring, marking out.
     

28. How do you use vice jaw plates to protect the workpiece from damage?
     

29. How do you file flat, square and curved surfaces and achieve a smooth surface
finish?
Such as: by draw filing, the use of abrasive cloth, lapping using abrasive pastes.
     

30. How do you select saw blades for different materials, and how are the saw blades
set for different operations?
Such as: cutting externally and internally.
     

31. How do you cut external threads using hand dies?

     

32. What is the method of fixing and adjusting the dies to give the correct thread fit?
     

Continued
Page 9 of 10
PEO2-005 Issue 1
 Producing components using hand fitting
techniques
Knowledge to be assessed and evidenced:

Complete assessment plan and evidence record

33. How do you determine the drill size for tapped holes?
     

34. Why is it important to use the taps in the correct sequence?

     

35. How do you prepare drilling machines for operations?

Such as: adjustment of table height and position, mounting and securing drills, reamers,
countersink and counterbore tools in chucks or Morse taper sockets, setting and adjusting
spindle speeds, setting and adjusting guards/safety devices.
     

36. How do you mount the workpiece?

Such as: in a machine vice, clamped to table, clamped to angle brackets, techniques of
positioning drills to marking out, use of centre drills and taking trial cuts and checking
accuracy, how to correct holes which are off centre.
     

37. How do you produce a sliding or mating fit using filing, scraping and lapping
techniques?
     

38. What problems can occur with the hand fitting activities, and how can these be
overcome?
Such as: defects caused by incorrectly ground drills, inappropriate speeds, damage by
workholding devices.
     

39. When should you act on your own initiative and when should you seek help and
advice from others?
Such as: removing and storing power leads, isolating machines, removing and returning
drills, cleaning the equipment and removing and disposing of waste.
     

40. Why is it important to leave the work area in a safe and clean condition on
completion of the fitting activities?
Such as: removing and storing power leads, isolating machines, removing and returning
drills, cleaning the equipment and removing and disposing of waste.
     

Page 10 of 10
PEO2-005 Issue 1