www.abcawards.co.

uk

LEVEL 4 DIPLOMA
IN

SUPERVISORY MANAGEMENT
IN
FABRICATION AND WELDING
STUDIES

7/41/D5503-04 0609 ssue 3

Qualification No: 100/5764/X
Customer Service Statement
ABC Awards strives to provide a prompt, high quality service to enable its centres, in
turn, to meet the needs of its customers. A full copy of ABC Awards Customer
Service policy can be seen on the web site. Any comments or suggestions are
welcome.

Enquiries
Any enquiries relating to the qualification contained within this specification should be
directed to:

ABC Awards
Robins Wood House
Robins Wood Road
Aspley
Nottingham
NG8 3NH

Tel: 0115 854 1616

Fax: 0115 854 1617
E-mail: enquiries@abcawards.co.uk

www.abcawards.co.uk

Those without Internet access may also wish to contact this office.

All information contained in this specification is correct at the time of going to press.
All material is also copyright.

ABC Issue 3 June 09

 Contents

Background Page No:

About ABC Awards, its Portfolio and Qualifications 1
Centre Recognition 2
Qualification Approval 2
Health and Safety 2
Staffing 2
Evaluation and Review 3
Internal Moderation 3
External Moderation 3
Accreditation of Prior Learning 3
Unit Design 4
Diversity 4

Level 4 Diploma for Supervisory Management in Fabrication

and Welding Studies
Introduction 5
Working Party 5
Aims 6
Outcomes 6
Target Group 6
Entry Requirements 7
Progression Opportunities 7
Qualification Structure 7
Qualification Delivery 8
Resources 9
Assessment 9
Certification 10
Qualification Content 11

Appendices
1 Authenticity Statement 26
2 Sample Examination Questions 27
3 National Occupational Standards Mapping 29
4 Key Skills Signposting 30
5 Wider Curriculum Signposting 32
6 Glossary and Acronyms 33
7 Useful Information 36
Background
ABC Awards, its Portfolio and Qualifications
ABC Awards (ABC) is approved by the Qualifications and Curriculum Authority
(QCA) to offer qualifications throughout the United Kingdom. QCA is the regulatory
body for public examinations and publicly funded qualifications and also has the
authority to monitor awarding bodies through quality audits. ABC has offices in
Chorley, Nottingham and Taunton. ABCs current portfolio contains qualifications
accredited onto the National Qualifications Framework (NQF) ranging from Entry
Level to Level 6. NQF qualifications are eligible for funding under the Learning and
Skills Act 2000. More information on funding can be obtained from the Learning and
Skills Council (LSC) www.lsc.gov.uk

ABC specialise in developing Vocationally Related Qualifications (VRQs). These are

designed to underpin much of the knowledge for the National Occupational
Standards (NOS) and assist in the development of practical skills. In turn, NOS form
the basis of National Vocational Qualifications (NVQs). Therefore, although VRQs
have links with NVQs, they are not designed to deliver occupational competence and
as such do not require delivery and assessment in the workplace. All ABC VRQs are
mapped to the NOS for purposes of future accreditation of prior learning (APL)
should candidates opt to achieve the NVQ at a later date.

Centres offering ABC qualifications may be colleges, private training providers,

community groups, adult education centres, schools, prisons and businesses.

ABC works closely with the relevant Sector Skills Council (SSC) when developing a
qualification for the NQF. A network of SSCs exists to lead the skills and productivity
drive in industry recognised by employers. They bring together employers, trade
unions and professional bodies working with the government to develop the skills that
UK business needs. The Sector Skills Development Agency (SSDA) has been
established to underpin the SSC network and promote effective working between
sectors www.ssda.org.uk

ABC has the support of SEMTA for this particular qualification

www.semta.org.uk
ABC VRQs are signposted for Key Skills or Basic Skills wherever possible. Whilst
Key Skills are not a part of ABC VRQs, it is recognised that they are transferable
skills that play an important role in developing personal effectiveness in adult and
working life. Signposting illustrates which Key Skills may be realistically achieved
through completion of this qualification; candidates may apply to other Key Skills
awarding bodies for certification once they have achieved and been assessed in the
relevant units.

ABC VRQs also provide opportunities for developing an understanding of the wider
curriculum (spiritual, moral, ethical, social and cultural issues and an awareness of
environmental issues, health and safety considerations and European
developments). Each component of the wider curriculum is signposted as
appropriate.

Finally, ABC qualifications are generally available throughout the UK, unless
otherwise stated. Please note however that different regulations exist in Scotland.

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ABC provides all printed materials in English, however can provide materials in
Welsh and/or Irish (Gaeilge) where requested and where appropriate.

Further information, policies, procedures and forms can be obtained from

www.abcawards.co.uk

Centre Recognition
Centres wishing to offer an ABC qualification require approval as a centre with the
ABC in advance of submitting an application for qualification approval. Full details of
registration policy and procedures are given in the Examination Officers Guide, which
is issued to the examinations office of all ABC approved centres, and on the web site.

Qualification Approval
Centres should apply for approval prior to enrolling candidates in order to guarantee
certification. Initially centres are given approval to offer a qualification on the basis of
a written submission. Each submission may be forwarded to an external moderator
for a paper review. If necessary the Moderator will make an approval visit to verify
the accuracy of that submission. At this stage the External Moderator may request
further documentation and advise the Centre of its next course of action.

Health and Safety

Centres are required to ensure that health and safety regulations are adhered to at
all times with regard to the health and well being of all staff and candidates. Centres
health and safety policies should be sent to the Awarding Body, together with details
of training available for staff and candidates. In the assessment of a centre, the
Moderator will give particular attention to health and safety practices / issues.

Staffing
It is expected that staff involved with the delivery of the course will be appropriately
qualified to assess candidates against the standards. The ABC approval process
requires prospective centres to provide names of the staff involved in delivery and
assessment including their qualifications and relevant training/employment
experience, plus staff development arrangements. Whilst these details are passed on
to the External Moderator appointed by the Awarding Body, it is the Centres
responsibility to ensure tutors qualifications are both bona fide and appropriate to the
level of the qualification.

2
Evaluation and Review
There should be ongoing evaluation by the staff and candidates and this should take
place in the following ways:
Candidate self-evaluation
Regular review of learning outcomes against agreed criteria
Validation by suitably qualified and experienced internal assessor and internal
moderator

Internal Moderation
ABC requires centres to implement a programme of internal moderation to ensure
that:
Candidates gain access to fair and reliable assessment opportunities
Everyone assesses to the same standards
Assessment decisions of assessors are sampled and monitored to ensure
consistency
Assessors are supported with advice and guidance
All work carried out is within agreed systems and procedures

Internal moderators must not, under any circumstances, check their own assessment
decisions.

Further guidance on internal moderation can be seen on the web site.

External Moderation
ABC will appoint, train and allocate external moderators to:
Visit each centre on ABCs behalf, usually once per academic year
Monitor and sample candidates work to ensure that assessment decisions are
fair, reliable, valid and consistent with required standards
Liaise between centres and ABC to establish standardisation
Establish goodwill and assist with any problems arising from the delivery of an
ABC qualification

Further guidance on external moderation can be seen on the web site.

Accreditation of Prior Learning (APL)

ABC encourages its centres to recognise the previous achievements of candidates
through APL. Prior achievements may have resulted from past or present
employment, previous study or voluntary activities. Once the assessor is satisfied
that the evidence is authentic and current, s/he should assess the evidence against
the requirements of the ABC unit(s) in the normal manner. Any queries should be
referred to the internal moderator.

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Unit Design
Each unit contains:

Learning Outcomes: defines what the candidate needs to do.

Knowledge Requirements: defines what the candidate needs to know. The

minimum requirements are outlined.

Assessment Guidance: explains how the assessment may be carried out, depth of
coverage expected, what should be included and what could be included.

Diversity
ABC will endeavour to ensure that through its policies, procedures and actions all
candidates entered for assessment are treated fairly and on an equal basis. All
centres will be expected to have a clear commitment in support of this objective.

Access to ABC qualifications is open to all candidates irrespective of gender, ethnic

origin, creed, employment status, nationality, sexual orientation, marital status or
special assessment arrangements. Centres must ensure that no candidate is
subjected to unfair discrimination on any of these grounds in relation to access to
assessment and to the fairness of the assessment.

A copy of ABCs full policy can be seen on the web site.

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Level 4 Diploma for Supervisory Management in Fabrication
and Welding Studies

QCA Accreditation No 100/5764/X

Accreditation Start Date: 01/11/2005

Accreditation End Date: 31/12/2010

Certification End Date: 31/12/2013

Introduction
The Level 4 Diploma for Supervisory Management in Fabrication and Welding
Studies has been developed following recommendations from our National Advisory
Committee, from Local and National employers who required an additional
qualification for their employees, enquiries from tutors at centres delivering the ABC
welding and fabrication programme and by a desire from ABC to provide a full suite
of qualifications from foundation up to and including supervisory management level.

The development of the qualification has also considered the report from the
Government titled, The Engineer of the 21st Century Inquiry: Change Challenges for
Sustainability published in February 2003. Particular emphasis has been put on
quality assurance and cost-effectiveness within the qualification to support and
complement the report.

An approach was also made to ABC by Chesterfield College during the early part of
2003 to offer the centre as a pilot for the newly developed qualification. This pilot
commenced in September 2003 and the first group of candidates successfully
completed the course in June 2004. The pilot has continued during 2004/5.

This qualification offers a full career progression path and extends the skills base
within the engineering industry to meet the needs of companies, both small and
large, wishing to maintain effective productivity levels in a modern and cost-effective
way.

The main emphasis of this qualification is to provide a candidate with an awareness

of the fabrication and welding environment at the supervisory management level.

Working Party
ABC has developed this qualification in association with a variety of colleges, for
example; Lowestoft, Colchester, Chesterfield, and participating companies, examples
include; G W Sissons, W H Clarke, Collis Engineering, William Twigg (Matlock),
Penney Hydraulics, G H Prestons, G Bopp, Hi-Tec Welding, who all have a vested
interest and commitment to maintaining the standards of welding and fabrication
skills.

The five members of the team who developed the detail of this qualification were Mr
Malcolm Briggs, Mr Harry Culshaw, Mr Michael Gray, Mr Ray Peet and Mr John
Watson.

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Aims
To introduce the candidate to a range of supervisory management styles and
techniques
To provide learners with opportunities to explore supervisory management
skills in an applied fabrication welding learning environment
To provide a supervisory management development route
To provide access to further management programmes
To provide foundation for in-house company programmes
To facilitate progression to further, higher level and professional qualifications
To enable learners to engage with current industry practice
To enable the candidate to understand the applications of metallic and non-
metallic materials within the fabrication engineering industry
To enable the candidate to evaluate welding processes and provide the
necessary skills to select appropriate processes for particular applications
To raise candidates awareness of European / International Standards and their
impact on production and control of welded fabrications

Outcomes
On completion of this qualification the candidate will be able to demonstrate an
understanding of:
The application of both metallic and non-metallic materials within the fabrication
engineering industry
Effective supervisory management skills in relation to team working and
delegation
Fabrication processes and associated site and workshop procedures
Operating principles and applications for welding processes
Quality management systems
The production of working sketches, templates and patterns (both the use of
micro computers and by hand) for use in the structural and fabrication industry
Applying skills and knowledge gained within industry-relevant context
Current industry practice at the supervisory management level
Progression routes within the industry

Target Group
This qualification is designed for those candidates:
Wishing to acquire supervisory skills in a fabrication and welding context to
enhance future employment prospects
Wishing to progress to more advanced study

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 Already in employment looking for professional development
Seeking single units as a specialism
Seeking a supervisory / management role within the industry
Aspiring to supervisory / management
Who, for a number of reasons have not been able to previously access
appropriate provision and accreditation across the sector, to facilitate
progression to further education/training and/or promotion.

It is appropriate for the 19+ age group.

Entry Requirements
Candidates entering Level 4 should have passed ABC Level 3 Certificate in Welding
and Fabrication or have reached an equivalent standard, perhaps through relevant
experience in the fabrication and welding industry, possibly including supervisory
management or engineering studies.

Each centre is required to notify the awarding body of its policies on access and
equality of opportunity. Within the parameters of these policies, a centre is expected
to recruit with integrity on the basis of a candidates ability to contribute to and
successfully complete the qualification.

Progression Opportunities
The acquisition of knowledge and development of skills as a result of successfully
completing this qualification will directly benefit the individual not only in their
employment but also as a progression to further education and training opportunities.
Possible progression routes include:
HNC / HND
Middle management
Supports university entrance
Access to professional qualifications
Enhanced employment opportunities

Qualification Structure
For successful completion of the ABC Level 4 Diploma for Supervisory Management
in Fabrication and Welding, candidates must complete 4 units, ONE Mandatory and
THREE units from the Option Units listed below:

Mandatory
Unit 1 Supervisory Management in the Fabrication and Welding
Industry (D/103/5302)*

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Optional
Unit 2 Applied Fabrication and Welding Science (H/103/5303)*
Unit 3 Advanced Fabrication Processes (K/103/5304)*
Unit 4 Principles and Applications of Advanced Welding Process
Technologies (M/103/5305)*
Unit 5 Managing Quality Assurance in the Fabrication and Welding Industry
(T103/5306)*
Unit 6 Advanced Pattern Development of Plate Work and Steel Structures
(A/103/5307)*
*Numbers in brackets indicate QCA Unit Numbers

All units have equal weighting.

A Certificate of Unit Credit is to be awarded if less than the 4 units are achieved.

The qualification has been allocated 240 guided learning hours for completion, with
each unit being allocated 60 guided learning hours.

The LSC definition of guided learning hours is all times when a member of staff is
present to give specific guidance towards the learning aim being studied on a
programme. This includes lectures, tutorials, and supervised study in, for example,
open learning centres and learning workshops. It also includes time spent by staff
assessing learners achievements. It does not include time spent by staff in the day-
to-day marking of assignments or homework where the learner is not present. It does
not include hours where supervision or assistance is of a general nature and is not
specific to the study of the learners

Centres should bear this in mind when planning qualification delivery.

Qualification Delivery
Centres should adopt a delivery approach that supports both the vocational nature of
the Fabrication and Welding Diploma and the particular group of candidates. Units in
the Diploma contain both practical learning outcomes and theoretical knowledge
requirements, so delivery should ensure appropriate association between theory and
practice. The aims, aspirations and experience of the candidates will also be
considered.

Delivery may be enhanced by:

Liaising with employers with reference to delivery, work experience and/or
resources
Visits to relevant companies within the Fabrication and Welding industry
The provision of information and guidance to candidates on the availability and
type of employment the qualification may lead to and on the progression routes
available for further education and training

The unit structure of the qualification will enable candidates to achieve accreditation
for units successfully completed, if for some reason they are unable, or do not wish to
achieve a full Diploma.

Centres must ensure that adequate arrangements are in place for supporting
candidates. This could be either through separate tutorial/assessment sessions or
through the use of time within structured study sessions.

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Resources
There are no special resources required, but candidates must posses a FULL
understanding of the operating principles, applications, advantages and / or
limitations of the processes.

Assessment
Candidates must be successful in the following assessment components to achieve
the ABC Level 4 Diploma for Supervisory Management in Fabrication and Welding
Studies:

Units 3, 4, and 6 are assessed through externally set and externally marked
written examination papers
Units 1, 2 and 5 are assessed through externally set and internally marked
assignments.

Each unit is graded: Pass: 40-59%

Credit: 60-79%
Distinction: 80-100%

Externally set and marked examinations

For units 3, 4 and 6, ABC will provide 21/2 hour duration long-answer question papers,
which will be externally marked. Each paper is designed to test the application of
skills across the unit and contains questions that require a detailed response. The
pass mark is 40%. ABC exams policies will apply to the paper; centres will be given
set periods during the year in which they may sit the paper. Alternative papers will
be available for re-sits. This assessment serves to reinforce the knowledge acquired
during delivery of each unit.

Externally set and internally marked assessment

ABC will provide the externally set assignments for units 1, 2 and 5 which will be
internally marked and externally moderated. Each assignment is designed to test the
application of skills across the unit and contain both short and long answer questions.

ABCs examination policy will apply to the papers. This assessment serves to
reinforce the knowledge acquired during delivery of each unit.

N.B. The assignments are not conducted under examination conditions, with the date
determined by the course tutor. However, the date of completion for the assignments
must be prior to the external moderator visit. Centres will be provided with the
marking criteria for the assessments.

Recording Assessment

Assessment mark sheets are provided by ABC for the internal and external
moderators to complete where they have assessed sampled candidates work.

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Certification
Awarding is at Level 4

Candidates must achieve the learning outcomes and knowledge requirements for
each unit in order to pass them.

For the award of the Level 4 Diploma for Supervisory Management in Fabrication
and Welding Studies, candidates must complete successfully the Mandatory Unit 1
and any other three units.

The Units completed will be shown on the relevant Diploma.

Additional Units will be added as endorsements to the full Diploma.

ABC will award a Certificate of Unit Credit on request for individual units, which could
later be converted into a full Diploma.

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 Qualification Content

Unit 1 SUPERVISORY MANAGEMENT IN THE FABRICATION AND WELDING

INDUSTRY

(60 Guided Learning Hours)

Unit Summary
This is a Mandatory Unit. The candidate is required to develop an understanding of methods used
by management personnel to communicate information between themselves and their workforce.
This will include for example:
An introduction to the management styles as outlined by McGregor's Theory X/Y and
Ouchie's Theory Z.
An understanding of Maslow's Hierarchy of Needs relative to the fabrication industry and
how these may affect human relations.
An understanding of the types of authority and how this may be delegated.
The candidate is also required to develop an understanding of Work Study and how this may be
applied within the fabrication workshop
Learning Outcomes
1.1 Responsibilities and duties of a supervisor
Candidates will be expected to be able to
1. Explain the duties and responsibilities of a supervisor
2. Compare and contrast an authoritarian style of management and a participative one
1.2 Human Relations
Candidates will be expected to be able to:
1. Explain and justify the importance of encouraging good human relations within the primary
working group
2. Identify 2 benefits and 2 disadvantages of formal/informal working groups
3. Evaluate the consequences of permitting unofficial groups and leaders to influence working
morale
4. Produce a management tree structure for at least 3 levels and describe different ways in
which each will interact with the other levels
5. Analyse how motivational theories may influence relationships within a working group
1.3 Delegating Authority
Candidates will be expected to be able to:
1. Explain the term Formal Authority and discuss the benefits of authority having been gained
by respect
2. Explain the meaning of the term delegation and discuss the benefits gained from its
effective implementation within a company or organisation
3. Explain and justify TWO circumstances where the delegation of authority cannot be given
1.4 Planning of Work
Candidates will be expected to be able to:
1. Demonstrate an understanding of process planning by discussing the types of planning
methods used for named production methods(See Knowledge Requirements)and justifying
how each acts to aid the manufacturing process
2. State and compare the production methods used in the named production methods
1.5 Work Study
Candidates will be expected to be able to:
1. Define Work Study, Method Study, and Work Measurement
2. Explain how work study techniques can be used in the workplace
3. Describe the different stages required for Method Study and Work Measurement
4. Use a variety of process charts with appropriate symbols, explaining the sequence of events
within them

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Knowledge Requirements
1.1 Responsibilities and Duties of a Supervisor
Candidates should understand:
The role of a supervisor and their different responsibilities
- operational (how methods and personnel are chosen for a particular function),
- technical (The supervisors influence on technical aspects of the production methods)
- personnel (How the supervisors management style affects relationships with the workforce)
What is meant by an authoritarian style and participative style of management
1.2 Human Relations
Candidates should understand:
The importance of good human relations within the primary working group
The difference between formal and informal working groups
The difference between official and unofficial group leaders
Management tree structures
Motivational theories e.g. McGregors Theory of X/Y and/or Maslows Hierarchy of Needs
1.3 Delegating Authority
Candidates should understand:
The terms formal authority and delegation and their benefits
Circumstances where delegation cannot be given
1.4 Planning Work
Candidates should understand:
Planning methods used for production of
- one off job,
- batch production,
- flow system
- mass production and the production methods used in each
The principles of process planning and how it acts as an aid to the manufacturing process
1.5 Work Study
Candidates should understand:
The terms work study, method study and work measurement
The different stages required for method study e.g. Selection of tasks to study, recording
facts, examining facts, developing a new method, installing/implementing/maintaining it
The different stages required for work measurement e.g. Selecting the task to study,
recording the facts, analysing them, calculating the basic and standard times for the task,
agreeing the method and its related time
Operation process charts, flow process charts ( single and multiple column), multiple activity
charts(man and machine), workplaces charts(left and right hand), simultaneous motion
cycle charts(SIMO charts) and the types of symbols used in conjunction with these

Assessment Guidance

This unit is assessed through two externally set, internally marked and externally moderated
assignments.

Each assignment is designed to test the application of skills across the unit and contains long or
short answer questions as required. This assessment serves to reinforce the knowledge acquired
during delivery of each unit.

NB The assignments are not conducted under examination conditions with the date of completion
being determined by the course tutor. However, the date of completion of the assignments
must be prior to the External Moderators visit. Centres will be provided with the marking criteria
for the assignments selected.

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 Unit 2 APPLIED FABRICATION AND WELDING SCIENCE

(60 Guided Learning Hours)

Unit Summary
In this Option Unit, the candidate is required to develop an understanding of both metallic and non-
metallic materials and their applications within the fabrication engineering industry: this includes
looking at problems such as corrosion, erosion and degradation of plastics. The use of rectification
and inverter technology, along with mathematical calculations and applications provide the
candidate with the appropriate knowledge to solve problems in the workshop.
Learning Outcomes
2.1 Materials (Metallic)
Candidates will be expected to be able to :
1. Compare the chemical, physical and mechanical properties of carbon manganese steel,
stainless/heat resisting steels, aluminium/aluminium rich alloys, copper/copper rich alloys,
titanium, clad materials and hard surfacing alloys
2. Explain the use of the Schaeffler Diagram
3. Give typical applications for the materials stated above
2.2 Materials ( Non-Metallic)
Ceramics and glass
Candidates will be expected to be able to :
1. Give examples and state the typical properties of engineering ceramics which are based on
oxides, nitrides, carbides, borides or silicides and their applications
2. Simply describe the reaction Bonding, Sintering and Hot pressing methods used to produce
ceramic
Thermoplastics
3. Explain the basic structure of polymers and state the typical properties of Thermoplastics
4. Explain addition polymerisation and the importance of the Dipole Effect
5. Describe van der Waals forces and explain how they react when heated
Thermosetting Plastics
6. Simply explain how condensation polymerisation is used to produce Thermosetting plastic
7. State the typical properties of Thermosetting plastic materials
Rubbers (Natural and Synthetic)
8. Describe the properties of natural rubber and explain how sulphur is used to change them
9. State the typical applications of natural rubber
10. Explain why synthetic rubbers are used in preference to natural rubber, give examples of
synthetic rubbers and state their applications
2.3 Chemistry
Corrosion
Candidates will be expected to be able to :
1. Define the coherent and non-coherent types of surface corrosion and describe how surface
corrosion of steel occurs
2. Describe the principles of Electrochemical Corrosion. Explain how zinc provides sacrificial
protection against corrosion on steel products
3. Explain how surface corrosion on aluminium may be detrimental to a welded product if it is
not removed either prior or during welding

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Fluxes
4. Explain the basic compositions and functions of fluxes used in a variety of welding
processes ( See Knowledge Requirements)
Changes of State
5. Describe how the changes of state in a material affect how the material is formed and
welded and state the types of defects that this may cause during welding and forming
2.4 Electricity
Half and full wave rectification
Candidates will be expected to be able to :
1. State the reasons why solid state diodes are used in rectifiers
2. Explain the principle of a half wave rectification for a single phase power supply
3. Produce 2 simple circuit diagrams, one to illustrate how the half wave rectifier works and
one to illustrate how the full wave rectifier works
4. List the advantages of a rectifier
Inverter Technology
5. Explain the principles of an inverter welding power source
6. Identify the main components of an inverter and state their function
7. List the advantages of using an inverter power source
2.5 Calculations
Candidates will be expected to be able to :
1. Calculate the bending allowances required when determining the developed lengths of the
circumference of a cylinder and angled bends using mean/neutral line for calculations
(bending allowances)
2. Determine the thickness allowance to be used when forming
3. Using practical examples, use simple transposition of formula to solve problems
4. Calculate the volume of weld metal required for butts of different joint preparations, fillet and
outside corner welds including an allowance to ensure the weld is not less than the required
size
5. Calculate the weights of sheet and plate materials in terms of kilograms per square metre
6. Using realistic prices, determine economical use of plate/sheet for given components
7. Use trigonometry to determine the length of a line, value of an angle and chord lengths

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Knowledge Requirements
2.1 Materials (Metallic)
Candidates should understand:
Carbon Manganese steel
The typical compositions, applications and weldability of carbon-manganese steels
The main problems associated with the welding of carbon-manganese steels and how to
avoid such problems
Stainless/heat resisting steels
The typical compositions and weldability of the following: Ferritic, Martensitic, Austenitic and
Duplex
The use of the Schaeffler Diagram
The main differences between stainless and heat resisting steels
Aluminium and Aluminium Rich Alloys
How to categorise these as cast/wrought and heat-treatable/non-heat treatable
The effects of adding the alloy elements Silicon, Magnesium, Manganese and Copper to
Aluminium (AlSi, AlMg, AlMn and AlCu.)
Copper and Copper Rich Alloys
The types of copper available to the engineering industry and their weldability
The different types of Copper/Zinc (Brass) alloys and show how each type may be
determined using the Copper/Zinc Thermal Equilibrium Diagram.
The different types of Copper/Tin (Bronze) alloys and show how each type may be
determined using the Copper/Tin Thermal Equilibrium Diagram.
Titanium
Describe properties of the metal
Identify typical applications for the use of the metal
Clad Materials
The types and purpose of clad materials in terms of corrosion resistance, mechanical
properties and economics
How dilution is kept to a minimum during welding
How dilution may affect the properties of clad materials
The extent of weld metal dilution
Hard surfacing Alloys
The purpose of hard surfacing
The types of hard surfacing materials available and why different types are necessary
2.2 Materials (Non-Metallic)
Candidates should understand:
Ceramics and Glass
The term ceramics
The typical properties of engineering ceramics based on oxides, nitrides, carbides, borides
or silicides and their applications
Reaction Bonding, Sintering and Hot Pressing methods used to produce ceramics
Thermoplastics
The basic structure of polymers
Addition polymerisation and the importance of the Dipole Effect.
Van der Waals forces and how they react when heated
Thermosetting Plastics
How condensation polymerisation is used to produce Thermosetting plastic and how the
long chain of molecules are bonded by crosslinking
The properties of thermosetting plastics
Rubbers (Natural and Synthetic)
The properties and typical applications of natural rubber and how sulphur is used to change
these properties
Why synthetic rubbers are used in preference to natural rubbers giving examples and their
typical properties

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2.3 Chemistry
Candidates should understand:
Corrosion
Coherent and non-coherent types of corrosion
How surface corrosion occurs
The principles of Electrochemical corrosion
How zinc provides sacrificial protection against corrosion on steel products
The detrimental effect of surface corrosion on aluminium to a welded product
Erosion
The use of hard surfacing to minimise erosion
Degradation of Plastics
The use of additives to ensure temperature stability and prevent colour degradation in
plastics
Fluxes
The compositions and functions of fluxes used in oxy-acetylene welding and brazing,
manual metal arc welding and submerged arc welding
Changes of State
How changes of state in a material affect how the material is formed and welded.
The defects the changes of state in materials may cause during forming and welding
2.4 Electricity
Half wave and Full Wave Rectification
The use of solid state diodes in rectifiers
The principle of a half wave rectification for single-phase power supply
How the half wave and the full wave rectifier works
The advantages of rectifiers
Inverter Technology
The principles of an inverter welding power source
The main components of an inverter and their functions
The advantages of using an inverter power source
2.5 Calculations
How to calculate bending allowances
How to determine thickness allowance when forming
Symbolic expression
How to use simple transposition of formula to solve problems, using practical examples
How to calculate the volume of weld metal required
How to calculate weights of sheet and plate materials
How to determine economical use of plate/sheet for components
The trigonometrical ratios of sine, cosine and tangent relative to the right-angled triangle
and how to use them to determine the length of a line, value of an angle and chord lengths

Assessment Guidance

This unit is assessed through two externally set, internally marked and externally moderated
assignments.

Each assignment is designed to test the application of skills across the unit and contains long or
short answer questions as required. This assessment serves to reinforce the knowledge acquired
during delivery of each unit.

NB The assignments are not conducted under examination conditions with the date of completion
being determined by the course tutor. However, the date of completion of the assignments
must be prior to the External Moderators visit. Centres will be provided with the marking criteria
for the assignments.

16
 Unit 3 ADVANCED FABRICATION PROCESSES

(60 Guided Learning Hours)

Unit Summary
The candidate is required to provide evidence of competence and an understanding of advanced
fabrication processes. The candidate will learn about site and workshop procedures that need to be
followed whilst planning, cutting, forming and assembling a range of fabricated components using
advanced processes.

Learning Outcomes
3.1 Layout and Plan Work
Candidates will be expected to:
1. Explain the suitability of the listed production methods used to produce sheet/plate
fabrications and structures (See Knowledge Requirements)
2. Compare marking out methods and state the advantages of using Direct Marking,
Templates and Calculations
3. Describe handling methods and equipment used when handling Sheet, Plate, Non-Ferrous,
Plastics and Section
4. Describe the planned disposition of joints on sheet/plate, stating processes and equipment
used
3.2 Procedures for Working On Site
Candidates will be expected to:
1. State the relevant sections of the Health and Safety at Work etc. Act 1974 and relevant
codes of practice
2. Describe factors to be considered when assembling fabrications on site
3. Describe the use of Erection Equipment, and Cranes on site
3.3 Methods of Cutting Sheet, Plate, Non-ferrous, Sections, Plastics and Clad Materials
Candidates will be expected to:
1. Describe the working principles of non-thermal cutting processes used to cut the stated
materials and compare advantages and limitations of the processes
2. Describe the working principles of thermal cutting processes and compare advantages and
limitations of the processes
3. Compare the relative merits of oxy-fuel gas, plasma, laser and abrasive water jet cutting
methods
4. Describe the application of CNC guillotines for cutting materials
3.4 Methods of forming Sheet, Plate, Non-ferrous, Sections, Plastics and Clad materials
Candidates will be expected to:
1. Describe the working principles of different forming machines used to form materials
2. Compare the use of hand and machine forming capacities taking into account Materials
Tensile Strength, Thickness and length of the material, Accuracy achieved, Speed of
operation, Quality required, Limitations and suitability of process
3. Compare the merits of machine selection for single or batch production of components.
4. Explain the effect of changing the die width on the load required for press brake forming and
the required quality of the fabrication
5. Describe the process of forming, folding, flanging and pressing to inside and outside
dimensions, and the necessary allowances required on the developed length
6. Compare rolling with folding, flanging and pressing of materials and state the need for pre-
setting prior to rolling. State the methods used to pre-set materials and the variation in
springback allowances necessary when forming different materials
3.5 Methods of assembling Sheet, Plate, Non-ferrous, Sections, Plastics and Clad materials
Candidates will be expected to:
1. Describe the sequence of assembly required and methods used to control distortion and
achieve alignment with dimensional accuracy of fabricated components.
2. Describe the use of jigs, positioners assembly and erection equipment

17
Knowledge Requirements
3.1 Layout and Plan Work
Candidates should understand:
Production methods and scale to include:
- Batch Flow Job - Mass
The following marking methods:
- Direct Templates - Calculations
Handling methods and equipment used for Sheet/Plate/Non-Ferrous/Plastics and Section,
to include: manual methods, protection of surfaces, clamps, Crosby clips, suction pad.
The following processes and equipment related to the planned disposition of joints on
Sheet/Plate:
- Economy of Material Labour - Simplicity of Fabrication - Joint Location - Distortion
Control - Use and Disposition of Templates - Folding/Cutting Allowances
3.2 Procedures for Working On Site
Candidates should understand:
The relevant sections of the Health and Safety at Work etc. Act 1974 and relevant codes of
practice to include:
- Risk Assessments, COSHH, PUWER, Work Permits, site related health and safety
regulations, legislation and safe working practices.
Issues relating to assembly fabrication on site to include:
- Type and size of fabrication - Size of lifting equipment - Maximum lift - Ground conditions -
Site restrictions - Juxtaposition of general public and site.
The use of erection equipment and cranes:
- Derricks - Mobile - Tower and Goliath cranes - Use of equipment for specific site conditions
3.3 Methods of cutting sheet, plate, non-ferrous, sections, plastics and clad materials
Candidates should understand:
The working principles of Non-Thermal Cutting Processes to include:
- Hand and power shears, Guillotines, Nibblers, Turret and power punches, Edge cutters,
Universal plateworker, Croppers, Punches, Power saws, Planing, Milling, Radial arm drills,
Water jet cutting.
The working principles of Thermal Cutting Processes to include:
- Oxy-fuel Gas - Plasma - Laser
The relative merits of Oxy-fuel Gas, Plasma, Laser and Abrasive Water Jet Cutting methods
in terms of:
- Equipment Costs - Operating costs - Cutting speed - Kerf width - Skill requirements -
Material type and thickness - Process versatility - Cut quality
The application of CNC guillotines for cutting materials considering:
- Health and safety requirements - Blade design - Programming operations for blade
clearance - Back gauge and blade rake angle - Ancillaries to aid production - Stroke counter
- Magnetic/non magnetic sheet supports - Holding down equipment for soft and polished
materials -Scrap dividers and Stacker units.
3.4 Describe methods of forming Sheet, Plate, Non-ferrous, Sections, Plastics and Clad
materials
Candidates should understand:
The working principles of the following machines forming machines: - Hand and powered
folders - CNC Press brake - Vertical stroke press - Manual and powered rolls - Wheeling
machine - Spinning machine Edging / Flanging machine - Rubber pad hydrostatic -
matched die and hot wire methods to form plastics.
Hand and machine forming capacities taking into account: - Materials Tensile Strength -
Thickness and length of the material - Accuracy achieved - Speed of operation - Quality
required - Limitations and suitability of process
The benefits of machine selection for single/batch production of components
Characteristics of the die width on the load required for press brake forming and the
required quality of the fabrication
The process of forming, folding, flanging and pressing to inside and outside dimensions, and
the necessary allowances required on the developed length
Rolling, folding, flanging and pressing of materials and state the need for pre-setting prior to
rolling. The methods used to pre-set materials and the variation in springback allowances
necessary when forming different materials

18
3.5 Methods of assembling Sheet, Plate, Non-ferrous, Sections, Plastics and Clad materials
Candidates should understand:
The sequence of assembly
Methods to control distortion and achieve accurate alignment with dimensional accuracy of
fabricated components
The use of jigs, positioners assembly and erection equipment in terms of: - Positioning of
components, use of datums - Joint alignment - Maintaining shape - Sub-assemblies - Trial
erections - Choice of lifting equipment - Mass production/repetitive work - Manipulation of
components - Surface protection - Economy of operation

Assessment Guidance

This unit is assessed through an externally set and externally marked written examination paper.

The paper is a 21/2 hour, long-answer question paper. Each paper is designed to test the application
of skills across the unit and contains questions that require a detailed response.

19
 Unit 4 PRINCIPLES AND APPLICATIONS OF ADVANCED WELDING PROCESS
TECHNOLOGIES

(60 Guided Learning Hours)

Unit Summary
The candidate is required to develop an understanding of the operating principles and applications
for advanced welding processes. The advantages and disadvantages of each process are evaluated
and this assists in providing the candidate with the necessary skills to select the appropriate process
for particular applications. The candidate will also be able to explain the consumable types, fluxes (if
any) and flux cored / metal cored wires (where applicable)for successfully welding a variety of
materials for these processes.
Learning Outcomes
4.1 Health and Safety Issues
Candidates will be expected to:
1. Explain general Health and Safety issues relating to a range of welding processes.
4.2 Inspection Requirements
Candidates will be expected to:
1. Describe in detail a minimum of 3 inspection requirements relating to a range of welding
processes
4.3 Operating Principles and Applications
Candidates will be expected to:
1. Describe in detail a range of operating principles and applications on a variety of materials
(where appropriate)
2. Identify 2 advantages and 2 disadvantages for each of the processes
4.4 Different Edge Preparations for Different Materials/Thickness and Processes
Candidates will be expected to:
1. Describe in detail the required edge preparations for different material types and thickness
for the processes listed in knowledge requirements 4.3 and 4.1.

Knowledge Requirements
4.1 Health and Safety Issues
Candidates should understand:
Health and Safety issues specific to the following processes on a variety of materials identified
in Knowledge Requirement 4.3 Submerged-Arc, Resistance, to include Spot, Seam, Projection
Resistance, Butt and Flash Butt welding, MAGS, TAGS, SAW, Plasma, Electron-Beam,
Orbital, Robotics, Plastics, Rubbers, Ceramics. Pressure-welding to include Cold pressure
and Ultra-sonic welding, Pulsed, Carbon-arc, Atomic-hydrogen, Stud-welding to include arc
Capacitor discharge, Laser, Friction, Friction Stir and Explosive.
4.2 Inspection Requirements
Candidates should understand:
Inspection requirements for the above processes on a variety of materials identified in
Knowledge Requirement 4.3.
4.3 Operating Principles and Applications
Candidates should understand:
Operating principles and applications of the above processes on a variety of materials listed
below for the processes listed in 4.1, Materials to include: Carbon and Carbon Manganese
Steels, Aluminium, Aluminium Alloys, Ferritic, Martensitic, Austenitic and Duplex Stainless and
Heat Resisting Steels, Copper and Copper Alloys, Magnesium and Magnesium Alloys, Clad
Materials, Dissimilar Metals, Hard Surfacing Alloys, Titanium and Titanium Alloys, Plastics,
Rubbers, Ceramics.
Advantages and disadvantages of the processes listed in 4.1.
Assessment Guidance:

This unit is assessed by an externally set and externally marked, long answer, written examination
of 21/2 hours duration.

As unit 1.

20
 Unit 5 MANAGING QUALITY ASSURANCE IN THE FABRICATION AND
WELDING INDUSTRY

(60 Guided Learning Hours)

Unit Summary
The Quality Assurance unit is designed to develop the candidates understanding of Quality
Management systems and the specific recommendations set out in European Standards for welding
of metallic materials necessary in the fabrication industry.
This unit develops a candidates understanding of how quality management systems provide the
means for an organisation to demonstrate its ability to consistently provide a product that meets
customer and applicable regulatory requirements. In addition it also addresses how European
Standards provide the relevant guidelines for satisfactory production and control of welded
fabrications, including some of the possible detrimental phenomena that may occur, with advice on
methods by which they may be avoided.
Learning Outcomes
5.1 Quality Management System
Candidates will be expected to:
1. Describe the Process-Based Model and the methodology of the PDCA Approach
2. Identify the general requirements of the Quality Management System
3. Explain the responsibility of management
4. Identify how Quality Management Systems influence the product
5. Explain the importance of measurement, analysis and improvement
5.2 Quality Requirements for Welding-Fusion Welding of Metallic Materials
Candidates will be expected to:
1. Outline the manufacturers contractual requirements and responsibilities regarding Contract
Review, Design Review, Sub-contracting
2. Recognise the manufacturers need to have at his disposal competent personnel to carry
out planning, performing, supervising and examining welding production
3. Recognise the manufacturers need to identify and provide the relevant facilities and
equipment necessary to produce a quality related to fabrication and welding related
activities
4. Describe welding activities in terms of : Production Plans Weld procedure approval,
Welder approvals, and specifications Work Instructions and documentation
5. State the manufacturers responsibilities regarding : Storage of parent materials Batch
testing, storage and handling electrodes Post weld heat treatment
6. Explain the manufacturers responsibilities for inspection and testing before, during and after
welding
7. Describe the measures which should be implemented to deal with non-conformity and
corrective actions, calibration, identification and traceability, quality records

21
Knowledge Requirements:
5.1 Quality Management System
Candidates should understand:
That a Quality Management System can be used by internal and external parties, including
certificating bodies, to assess the organisations ability to meet customer, regulatory and the
organisations own requirements.
Quality Assurance models to include the Process-Based model and the PDCA Approach
(Plan, Do, Check, Act)
The general requirements of the Quality Management System in terms of : Quality policy -
Quality manuals - Control of documents - Control of records
Management responsibility in terms of : Management commitment - Customer focus -
Quality policy Planning Responsibility, authority and communications - Management
review
The necessity for management to provide: Provision of Resources - Relevant Human
Resources - Relevant Infrastructure and Working Environment
How Quality Management Systems influence the product via : Planning of product
realisation - Customer-related processes - Design and development Purchasing -
Production and service provision - Control of monitoring and measuring devices Case
histories of welding and fabrication disasters
The importance of measurement, analysis and improvement related to : Customer
satisfaction - Control of nonconforming product - Analysis of data Improvement
5.2 Quality Requirements for Welding-Fusion Welding of Metallic Materials
Candidates should understand:
How the application of comprehensive quality requirements provide manufacturers with the
capability to produce welded constructions fulfilling specified quality.
A manufacturers contractual requirements and responsibilities regarding contract review,
design review and subcontracting
The need to have competent staff to plan, perform ,supervise and examine welding
production in terms of : Welders - Welding Co-ordinators (with reference to the National
Welding Training Standard)- Non destructive testing personnel
The need to provide relevant facilities and equipment necessary to produce quality
fabrication and welding activities in terms of : Description and suitability of equipment -
Production and testing equipment - Maintenance of equipment
Welding activities in terms of Production Plans, Welding procedure approval and
specifications, Work instructions and documentation
Manufacturers responsibilities regarding Storage of parent materials, Batch testing, storage
and handling of electrodes, Post weld heat treatment
Manufacturers responsibilities for inspection and testing before, during and after welding
Measures which should be implemented to deal with : Non-conformity and corrective actions
Calibration - Identification and traceability - quality records

Assessment Guidance

This unit is assessed through an externally set and internally marked assignment. The assignment is
designed to test the application of skills across the unit and contains questions that require a
detailed response.

NB The assignment is not conducted under examination conditions, with the date of completion
being determined by the course tutor. However, the date of completion of the assignments
must be prior to the External Moderators visit. Centres will be provided with the marking criteria
for the assignment selected.

22
 Unit 6 ADVANCED PATTERN DEVELOPMENT OF PLATE WORK AND STEEL
STRUCTURES

(60 Guided Learning Hours)

Unit Summary
The candidate is required to provide evidence of competence in the ability to interpret and construct
workshop drawings, to produce working sketches, to develop templates and patterns as would be
used in the structural and fabrication industry.
Learning Outcomes
The candidate will be expected to:
1. Interpret drawings and use methods of construction to develop complex shape and
structural details
2. Determine lines of intersection to enable the development of complex shapes
3. Determine complex pattern shapes by the parallel line technique
4. Determine complex pattern shapes by the radial line technique.
5. Determine complex pattern shapes by the triangulation technique
6. Draw helical chutes, worm feed blades and spiral stairways.
7. Determine by calculation, sketch and dimension complex pattern shapes with the aid of
micro computers

Knowledge Requirements:
The candidate should understand:
How to construct auxiliary views in double projection to simplify development of right
cylindrical off-set branches and rectangular ducts.
How to determine true lengths and shapes of structural sections for inclined beams, hip
rakers, ties, struts, bevel, cleats and dihedral angle.
How to use the principle of a common central sphere applied to multiple junction pieces
involving right cones and cylinders
How to use cutting planes applied to :
- right cylindrical branches on transformer pieces
- oblique cone to oblique cone
- inclined right cylindrical branches on right cones on and off-centre
- various branch cross-sections on square / rectangular hoppers.
How to use the parallel line technique to develop pattern shapes for :
- swan-necked transition pieces
- rectangle to rectangle in angular plane
- cylindrical branches on to right segmental bends
- modified set-outs to accommodate material thickness.
How to use the radial line technique to develop pattern shapes for :
- right cones in multiple connections of right cones and right cylinders
- breeches and multi-way pieces involving oblique cones.
How to use the triangulation technique to :
- re-position triangles to aid surface contour and avoid kinks in the construction of transformer
pieces
- develop patterns of kink sided hoppers
- develop patterns of quadrilateral to round transformers between parallel planes
- develop patterns of square and rectangle to round transformers with openings at right angles
and different levels
How to construct the elevations pattern shapes of :
- worm feed screw blades showing inner and outer spirals
- spiral stairways and stringers
- helical chutes
How to use micro computers to determine, sketch and dimension :
- square and rectangular kink sided hoppers
- square to round transformers between parallel planes
- helical chutes and blades
- spiral stairway stringers
- frusta of right cones, including major and minor radii, pattern angle and chordal check length.

23
Assessment Guidance

This unit is assessed through and externally set and externally marked written examination.

The paper is a 21/2 hour, long-answer question paper. Each paper is designed to test the application
of skills across the unit and contains questions that require a detailed response.

24
Appendices

1 Authenticity Statement

The authenticity statement should be copied and given to candidates to complete

and add to their evidence for units 1, 2 and 5.

2 Sample Assessment Questions

Sample questions have been included for units 3, 4 and 6

3 National Occupational Standards Signposting

For information purposes, this signposting shows the links to the national standards.
Candidates completing this qualification may be able to use some of their evidence
for APL against the associated NVQ; however this would be at the discretion of the
NVQ Awarding Body.

4 Key Skills Signposting

For information purposes, this signposting shows the links to the Key Skills.
Candidates completing this qualification may be able to use some of their evidence
for APL against the associated Key Skill; however this would be at the discretion of
the Key Skill Awarding Body.

5 Wider Curriculum Signposting

For information purposes, this signposting shows how the ABC Level 4 Diploma for
Supervisory Management in Welding and Fabrication Studies provides opportunities
for the candidate to develop an understanding of the wider curriculum (spiritual,
moral, ethical, social and cultural issues and an awareness of environmental issues,
health and safety considerations and European developments).

6 Glossary and Acronyms

An explanation of some of the terms, phrases and abbreviations commonly used
throughout ABC documentation.

7 Useful Information
British / European Standards reference and further reading for units are available
from ABCs Nottingham office.

25
ABC Awards Authenticity Statement

DECLARATION OF AUTHENTICITY

This declaration must be completed and signed by the candidate and countersigned
by the tutor/assessor.

Candidate Name:

Candidate Number:

Centre:

Candidate statement of authenticity

I confirm that the attached assignment / portfolio is all my own work* and does not
include any work completed by anyone other than myself. I have completed the
assignment / portfolio in accordance with the Awarding Body instructions and within
the time limits set by my Centre.

Signature: .. Date:

Centre confirmation of authenticity

On behalf of .(insert centre name), I confirm that the

above mentioned candidate, to the best of my knowledge, is the sole author of the
completed assignment / portfolio attached.

Signed: . Date:

Name: ..

Job Description:

*Unless otherwise stated e.g. for some entry level qualifications candidates can work
together but should show sections which are their own work.

26
Appendix 2 Sample examination questions

Unit 3:

Question 1

(a) Explain the process of planning for the production of fabricated

components. (4)

(b) Job and Batch are methods of producing fabrication components.

Compare the benefits and limitations of each as a means of producing:
i) structural steelwork
ii) pressure vessels (8)

(c) Briefly discuss the importance of fabrication shop layout in order to

facilitate the flow of work. (4)

(d) State the need to plan the flow of work from drawing office to erection on
site. (4)

(Total marks 20)

Unit 4:

Question 1

For the process known as resistance spot welding there are several
variables that have to be considered and set before successful welds
can be made on a component.

(a) Name FIVE of those variables. (5)

(b) For each of the five variables named in (a), explain ONE undesirable
effect on the resultant weld if the variable stated is set incorrectly? (10)

(c) By means of a sketch show how the process known as projection

welding is carried out.

Clearly indicate the following:

the fixed and moveable platens;
the direction of travel of the moveable platen,
a component clearly showing the projection/s positioned in the (5)
machine prior to welding.

(Total marks 20)

27
Unit 6:

Question 1

Two pitches of a worm feed screw are shown below.

(a) By construction, draw these two pitches and include a 12 drive shaft 170mm
long show hidden detail. (15)

(b) Using the formula of helix length = pitch + circumference, calculate, draw and
dimension the approximate circular form shape that may be used to form one
blade. (10)

Not to scale

28
Appendix 3 National Occupational Standards Mapping

The ABC Level 4 Diploma for Supervisory Management in Fabrication and Welding
Studies has been mapped to the following NOS, where this qualification supports
knowledge and understanding:

SEMTA Engineering Management Level 4 (July 2003). These appear with the prefix
EM

ECITB Welding Engineering Level 4 (2002). These appear with the prefix 2001.

ECITB Design and Draughting Level 3 (2002). These appear with the prefix DD

The Chartered Management Institute Management Standards (2004) N.B. at the time
of development, these standards had not been assigned levels. These appear with a
single letter prefix e.g. A

Guidelines for the International Institute of Welding, International welding

Technologist (IWT), approved June 2002. These appear with the prefix IWT.

ABC Level 4 Diploma for National Occupational Standards

Supervisory Management in As above
Fabrication and Welding Studies
Unit 1 Supervisory Management in EM4.01, EM4.15, EM4.16, EM4.18
the Fabrication and Welding 2001.13
Industry A1, B1, D1, D2
Unit 2 Applied Fabrication and EM4.15, EM4.22
Welding Science 2001.1
IWT Module 2
Unit 3 Advanced Fabrication EM4.01, EM4.15
Processes 2001.6
E5, E6
Unit 4 Principles and Applications of EM4.14, EM4.15, EM4.18
Advanced Welding Process 2001.6
Technologies E5, E6
IWT Module 4
Unit 5 Managing Quality Assurance EM4.29
in the Fabrication and 2001.7
Welding Industry F12
IWT Module 4
Unit 6 Advanced Pattern EM4.14
Development of Plate Work DD1, DD5
and Steel Structures

29
Appendix 4 Key Skills Signposting

The ABC Level 4 Diploma for Supervisory Management in Fabrication and Welding
Studies is mapped to the following Key Skills:

Level 4 Communication
Level 3 Application of Number
Level 4 Information Technology
Level 4 Working with Others
Level 4 Improving own Learning and Performance

Communication Level 4

Key Skill ABC Unit Signposting

C4.1Develop a strategy for using 1, 2 and 5 Evidence could be generated by
communication skills over an developing a strategy related to
extended period of time. the unit.
C4.2 Monitor progress and adapt 1, 2 and 5 Evidence could be generated by
your strategy, as necessary, to monitoring the planned strategy
achieve the quality of outcomes from C4.1
required in work involving at least:
One group discussion about a
complex subject
One document of 1,000 words or
more about a complex subject.
C4.3 Evaluate your overall strategy 1, 2 and 5 Evidence could be generated by
and present the outcomes from your reviewing the planned strategy
work, using at least one formal oral from C4.1 via a presentation.
presentation. Include a variety of
verbal, visual and other techniques
to illustrate your points.

Application of Number Level 3

Key Skill ABC Unit Signposting

N3.1 Plan an activity and get Units 1 and Evidence could be generated
relevant information from relevant 6 when completing calculation
sources. tasks.
N3.2 Use this information to Units 1 and Evidence could be generated
carryout multi-stage calculations to 6 when completing calculation
do with: tasks.
a amounts or sizes
b scales or proportion
c handling statistics
d using formulae
N3.3 Interpret the results of your Units 1 and Evidence could be generated
calculations, present your findings 6 when completing calculation
and justify your methods. tasks.

30
 Information Technology Level 4

Key Skill ABC Unit Signposting

IT4.1 Develop a strategy for using
IT skills over an extended period of
time.
IT4.2 Monitor progress and adapt
your strategy, as necessary, to
achieve the quality of outcomes
required in work involving the use of
IT for two different purposes.
IT4.3 Evaluate your overall strategy
and present the outcomes from your
work using at least one
presentation, showing integration of
text, images and number.
1, 2 and 5 Evidence could be generated by
developing a strategy related to
the unit.
1, 2 and 5 Evidence could be generated by
monitoring the planned strategy
from C4.1.
1, 2 and 5 Evidence could be generated by
reviewing the planned strategy
from C4.1 via a presentation.

Working with Others Level 4

Key Skill ABC Unit Signposting

WO4.1 Develop a strategy for All units Evidence could be generated
working with others. except unit when drawing up a strategy of
6 how to work with others related
to the unit.
WO4.2 Monitor progress and adapt All units Evidence could be generated
your strategy to achieve agreed except unit when implementing the strategy
objectives. 6 to completed work related to the
unit.
WO4.3 Evaluate your strategy and All units Evidence could be generated
present the outcomes from work except unit when reviewing the strategy
with others. 6 used to carry out related to the
unit.

Improving Own Learning and Performance Level 4

Key Skill ABC Unit Signposting

LP4.1 Develop a strategy for
improving your own learning and
performance.
LP4.2 Monitor progress and adapt
your strategy to improve your
performance.
LP4.3 Evaluate your strategy and
present the outcomes of your
learning.
All units Evidence could be generated by
developing a learning plan,
either for an individual unit or
across units.
All units Evidence could be generated by
monitoring the plan drawn up in
LP4.1.
All units Evidence could be drawn up by
reflect on the ultimate success
or otherwise of the plan drafted
in LP4.1.

31
Appendix 5 Wider Curriculum Signposting

With regard to the enhancement of spiritual understanding, two definitions within the
Oxford English dictionary state of the human spirit or soul, not physical or worldly
and of the Church or religion. This qualification does not contribute to an
understanding of spiritual issues.

The word Moral can be defined as of or concerned with the goodness and badness
of human character or with the principles of what is right and wrong in conduct. In
the delivery of the qualification a tutor must undertake to instil in a student the
difference between good and bad practice, most significantly in those practices
relating directly to their employment. So in the context of the latter definition, an
understanding of moral issues may be gained from this award.

A definition of Ethical is given as morally correct, honourable, and can be attributed

to a fabricator or welder, as nearly every activity that they will undertake as part of
their working life will require their compliance with given procedures and processes.
To integrate into a working environment, an individual will always be required to
conform to accepted principles of conduct, professionally as well as personally, and
the lessons learnt during this programme of study should stand them in good stead.

A definition of Social is of the mutual relations of people or classes living in an

organised community. There may be minimal understanding of social issues gained
from working together as a team during delivery of the qualification.

Cultural can be defined as the customs and civilisation of a particular people or

group. Cultural awareness does not prevail in this qualification, nor do European
developments.

Health and Safety issues run throughout the entire award and its importance should
be emphasised at every opportunity. The importance of correct use of equipment,
manual handling, safety of self and others, PPE, etc should become second nature to
every student.

Environmental awareness runs throughout the award, in terms of safe disposal of

waste products. Discussions on the make-up of materials, resource availability and
the impact on the environment of materials used may also further contribute to an
understanding of environmental awareness.

32
Appendix 6 Glossary and Acronyms

ABC
ABC Awards.

Accreditation
The process through which the regulatory authorities (QCA) confirm that a
qualification and the associated specification conform to the regulatory criteria.

Accreditation of Prior Learning (APL)

The process of recognising a candidates previous achievements or learning.

Assessment
The process of making judgements about the extent to which a candidates work
meets the assessment criteria (requirements that must be met in order to achieve
success, or a given grade) for a qualification or unit, or part of a unit.

Awarding Body
An organisation or consortium that awards qualifications.

Basic Skills
Basic Skills refers to the ability to read, write and speak English/Welsh and use
mathematics at a level necessary to function and progress at work and in society in
general.

Centre
An organisation or consortium accountable to an awarding body for the assessment
arrangements leading to a qualification or units.

Centre Recognition
A process through which a centre wishing to offer ABCs qualifications is confirmed
as being able to maintain the required quality and consistency of assessment and
comply with other expectations of the awarding body.

External Assessment
A form of independent assessment where assessment tasks are set, and candidates
work assessed, by the awarding body.

External Moderator
An individual appointed by the awarding body to ensure accurate and consistent
standards of assessment, across centres and over time.

Independent Assessment
Assessment of candidates work that is carried out by assessors who do not have a
vested interest in the outcome.

Internal Assessment
Assessment where assessment tasks are set, and candidates work assessed,
wholly within the candidates centre, subject where appropriate to external
moderation.

Internal Moderator
An individual appointed by the centre to secure accurate and consistent standards of
assessment, both between assessors operating within a centre and between centres
offering the same award.

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Key Skills
General skills that apply across occupational and academic fields and assist in
improving learning and performance.

Knowledge Requirements
The part of the ABC qualification that the candidate needs to know.

Learning and Skills Council (LSC)

The body responsible for funding and planning education and training for over 16-
year-olds in England.

Learning Outcomes
The part of the ABC qualification that the candidate needs to do.

Level
The level at which a qualification is positioned in the National Qualifications
Framework.

Moderation
The process of checking that assessment standards have been applied correctly and
consistently between assessors, between centres and over time, and making
adjustments to results where required to compensate for any differences in standard
that are encountered.

National Occupational Standards (NOS)

Statements which describe the outcomes of competent work in an occupational field.

National Qualifications Framework (NQF)

The framework used by the regulatory authorities to position qualifications in
England, Wales and Northern Ireland.

National Vocational Qualification (NVQ)

NVQs are work-related, competence based qualifications that reflect the skills and
knowledge needed to do a job effectively throughout the country. They represent the
national standards recognised by employers.

Qualifications and Curriculum Authority (QCA)

Government-designed statutory organisation required to establish national standards
for qualifications in England and secure consistent compliance with them (the
regulatory authorities in Wales and Northern Ireland are ACCAC and CCEA
respectively).

Sector Skills Council (SSC)

A body recognised by the regulatory authorities as responsible for formulating and
reviewing standards of occupational competence for an employment sector.

Qualification Approval
A process through which a centre wishing to offer a particular qualification is
confirmed as being able to maintain the required quality and consistency of
assessment and has the correct resources, facilities and equipment specific to the
qualification.

Unit
The smallest part of a qualification that is (generally) capable of certification in its
own right.

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Vocationally Related Qualification (VRQ)
VRQs are linked to NVQs but are different. They are designed to underpin much of
the knowledge for the National Occupational Standards (NOS) and assist in the
development of practical skills and do not have to be delivered in the workplace.

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Appendix 7 Useful Information

British / European Standards reference and further reading for units are available
from ABCs Nottingham office. (Address at the front of the specification).

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