Tool process design engineer
Engineering and manufacturing
Level 6 -
The design of a unique tooling process pathway that enables components to be mass produced in the most economically viable way.
Reference: OCC0641
Status:
SOC 2020 sub unit groups:
- 2125/03 Industrial and production engineers
- 2122/03 Mechanical design engineers
- 5222/02 Tool makers
Technical Education Products
Employers involved in creating the standard:
Confederation of British Metalforming, Stadco, Milton Keynes Pressings Ltd, Gestamp, Regent Engineering, Kiyokuni Europe, Impression Technologies, HT Brigham, Denso Marston, Aisin Europe, Hadley Group
Summary
This occupation is found in the advanced manufacturing sheet metal/presswork supply chain of automotive and aerospace. The broad purpose of the occupation includes the design of a unique tooling process pathway that enables components to be mass produced in the most economically viable way. The process pathway often includes a sequential series of steps using uniquely designed press tooling procedures such as blanking, drawing, piercing and forming in order to make the completed component.
The tool process design engineer has to determine from the volume of required components whether to design manually operated or automatic (progression) press tooling. In some designs the components being produced could also be part of an assembly created from different additional sheet metal pressings that have to be welded together.
Examples of a tool process design is the manufacture of complex automotive and aerospace sub-assemblies such as aeroplane and car seat chassis, vehicle doors and bumper beam assemblies that undergo several process steps. Working with clients on unique components that create commercial advantage to the original equipment manufacturer (OEM), and through a process of critical analysis, interpretation and evaluation of complex information a unique innovated tool process pathway is created.
In their daily work, an employee in this occupation interacts with managing directors, technical/production directors, senior managers in finance and purchasing, management/technical specialists from customers together with technical specialists from suppliers, the production team and operatives on the shop floor. A tool process design engineer will typically spend their time working between the design office, board room and the factory floor.
An employee in this occupation will be responsible for designing a unique economically viable high-volume process tooling pathway, capable of mass production while meeting customer specification and achieving consistently high tolerances and quality standards. A tool process design engineer will work both autonomously or as part of a team, depending on the project, company size, and will exercise considerable judgement on projects with a high-level personal decision making and influence.
Depending on the size of the organisation a tool process design engineer would typically report to the production or managing director of the company and will have significant leadership and project management responsibility together with budget accountability.
Employers involved in creating the standard:
Confederation of British Metalforming, Stadco, Milton Keynes Pressings Ltd, Gestamp, Regent Engineering, Kiyokuni Europe, Impression Technologies, HT Brigham, Denso Marston, Aisin Europe, Hadley Group
Typical job titles include:
Keywords:
Knowledge, skills and behaviours (KSBs)
Duties
Duty D1
Design new unique tooling in line with a developing process route. Using computer aided engineering technology to ensure the full potential of the manufacturing equipment is best utilised against a background of competing existing production demands also applying and promoting Environmental, Health and Safety (EHS) requirements to the process.
Duty D2
Undertake complex forming simulation trials where the new component is "formed" from a series of process steps
Duty D3
Use bespoke computer aided design (CAD) equipment to create the design of the unique press tools associated equipment necessary to produce the component.
Duty D4
Interpret customer data in order to develop a tool process route that meets the quality & quantity of parts needed by the client
Duty D5
Consider manufacturing feasibility issues and offer counter proposals back to the customer offering safety performance to the component including component handling issues (sharp edges and component lifting weight)
Duty D6
Develop the tool design brief to meet customer requirements in relation to cost quality and delivery including health and safety (H&S) considerations such as tool handling features.
Duty D7
Design and developing the process brief, while being an implementer of best practice in safety management.
Duty D8
Applies the companies’ quality standards to create a tool pathway design as specified by the customer in line with internal H&S standards and the customer's needs.
Duty D9
Interact with the design office, factory floor, suppliers and customers to confirm design parameter
Duty D10
Use appropriate planning techniques necessary to meet design, technical and budgetary requirements
Duty D11
Provide technical updates and progress reports to the Managing or Production Director and client using Advanced Product Quality Planning (APQP) Technique reporting
Duty D12
Controls expenditure and works within specified budgetary constraints, liaise with the finance team and ensure the appropriate level of financial impact on the company
Occupational Progression
This occupational progression map shows technical occupations that have transferable knowledge and skills.
In this map, the focused occupation is highlighted in yellow. The arrows indicate where transferable knowledge and skills exist between two occupations. This map shows some of the strongest progression links between the focused occupation and other occupations.
It is anticipated that individuals would be required to undertake further learning or training to progress to and from occupations. To find out more about an occupation featured in the progression map, including the learning options available, click the occupation.
Progression decisions have been reached by comparing the knowledge and skills statements between occupational standards, combined with individualised learner movement data.
Engineering and manufacturing