Produce Cold Formed Tube And Pipe Training

Objectives:
• Understand the scope and outcomes of the unit standard 119052
• Identify key terminology and definitions used in tube and pipe manufacturing
• Recognize the importance of workplace safety and quality standards
• Describe the basic principles of cold forming processes

Topics:
• Overview of unit standard 119052 and course structure
• Industry applications of cold formed tube and pipe
• Basic metallurgy for cold forming
• Safety regulations and personal protective equipment (PPE)
• Introduction to cold forming vs hot forming

Objectives:
• Identify common materials used in cold forming (steel, aluminium, copper)
• Explain material properties affecting formability
• Demonstrate correct material handling and storage procedures
• Interpret material specifications and certifications

Topics:
• Types of metals and alloys for tube/pipe production
• Mechanical properties: yield strength, ductility, hardness
• Material receiving, inspection, and storage
• Handling equipment: cranes, forklifts, and slings
• Material traceability and documentation

Objectives:
• Describe the main cold forming methods: roll forming, bending, swaging
• Differentiate between tube and pipe manufacturing steps
• Explain the role of lubrication in cold forming
• Identify typical defects in cold formed products

Topics:
• Roll forming process and applications
• Tube bending techniques (mandrel, rotary draw)
• Swaging and expanding operations
• Lubricants: types and application methods
• Common defects: wrinkling, cracking, springback

Objectives:
• Identify major equipment used in tube and pipe production
• Explain the function of each machine component
• Perform pre-operation checks on forming equipment
• Understand basic maintenance requirements

Topics:
• Tube mill components: uncoiler, accumulator, forming section
• Welding stations and seam guides
• Sizing and straightening machines
• Cutting equipment: saws, shears
• Preventative maintenance schedules

Objectives:
• Describe the design and function of roll tooling
• Explain the roll setup procedure for different profiles
• Adjust roll gaps and alignment
• Identify wear patterns and tooling maintenance

Topics:
• Roll tool materials and coatings
• Roll profile design basics
• Setup procedures: shimming, alignment, gap adjustment
• Tooling inspection and replacement criteria
• Troubleshooting misalignment issues

Objectives:
• Identify key forming parameters (speed, pressure, temperature)
• Explain the effect of parameters on product quality
• Monitor and adjust parameters during production
• Record process data for quality control

Topics:
• Forming speed and its impact
• Roll pressure and material thinning
• Temperature considerations in cold forming
• Process control charts and data logging
• Parameter adjustment for material variations

Objectives:
• Describe quality standards for tube and pipe (dimensions, wall thickness, ovality)
• Use measuring instruments: callipers, micrometers, gauges
• Conduct visual and dimensional inspections
• Identify non-conformances and corrective actions

Topics:
• Quality specifications per industry standards (ASTM, EN)
• Measurement tools and techniques
• Visual inspection criteria: surface defects, scratches
• Dimensional checks: OD, ID, wall thickness
• Non-conformance reporting and corrective actions

Objectives:
• Explain the principles of high-frequency induction welding
• Describe the welding process in tube mills
• Identify weld defects and their causes
• Perform weld quality checks

Topics:
• High-frequency welding: induction and contact
• Weld setup: coil positioning, impedance
• Weld bead formation and control
• Common weld defects: cold welds, burn-through
• Weld testing: visual, ultrasonic, hydrostatic

Objectives:
• Describe post-forming processes: straightening, cutting, end finishing
• Operate straightening and cutting equipment safely
• Perform end finishing (deburring, chamfering)
• Inspect finished product for quality

Topics:
• Straightening methods: roller, press
• Cutting to length: sawing, shearing, laser
• End finishing: deburring, bevelling
• Surface treatment: cleaning, oiling
• Final inspection and packaging

Objectives:
• Explain the importance of efficient changeovers
• Plan and execute tooling changeovers
• Apply SMED principles to reduce downtime
• Document setup procedures

Topics:
• Changeover planning and scheduling
• SMED (Single-Minute Exchange of Die) concepts
• Pre-set tooling and quick-change systems
• Step-by-step changeover procedure
• Setup documentation and standard work

Objectives:
• Identify common production problems (dimensional variation, surface defects)
• Apply systematic troubleshooting methods
• Use root cause analysis to resolve issues
• Implement corrective and preventive actions

Topics:
• Systematic troubleshooting: 5 Whys, fishbone diagram
• Dimensional problems: ovality, wall thickness variation
• Surface defects: scratches, die marks
• Equipment malfunctions: vibration, misalignment
• Corrective action plans and follow-up

Objectives:
• Apply safety procedures specific to tube and pipe production
• Identify hazards: pinch points, hot surfaces, noise
• Use lockout/tagout and confined space procedures
• Understand environmental regulations for waste disposal

Topics:
• Machine guarding and safety interlocks
• Lockout/tagout procedures
• Noise control and hearing protection
• Hazardous materials: coolants, lubricants
• Waste management and recycling

Objectives:
• Interpret production orders and specifications
• Plan material and tooling requirements
• Schedule production runs to meet deadlines
• Monitor production output and adjust plans

Topics:
• Reading production orders and job cards
• Material requirements planning (MRP)
• Tooling availability and setup times
• Production scheduling techniques
• Real-time monitoring and adjustments

Objectives:
• Record production data accurately (output, downtime, defects)
• Complete quality control documentation
• Interpret production reports for continuous improvement
• Communicate data to relevant stakeholders

Topics:
• Production logs and shift reports
• Quality control checklists
• Downtime tracking and analysis
• Defect reporting and trend analysis
• Shift handover communication

Objectives:
• Describe advanced forming methods: hydroforming, roll forming complex profiles
• Explain the benefits and limitations of each technique
• Identify applications for advanced techniques
• Understand process parameters for advanced methods

Topics:
• Hydroforming: process and applications
• Roll forming high-strength steels
• Pre-piercing and post-piercing operations
• Forming of tailored blanks
• Advanced lubrication and cooling methods

Objectives:
• Identify automation technologies used in tube mills
• Explain the role of sensors and PLCs in process control
• Understand data acquisition and analysis for optimization
• Describe Industry 4.0 concepts in manufacturing

Topics:
• Automated material handling and feeding
• Sensors for temperature, speed, dimensions
• PLC programming basics for forming lines
• Data collection and real-time monitoring
• Predictive maintenance using IoT

Objectives:
• Apply lean principles to tube and pipe production
• Identify waste (muda) in the process
• Participate in Kaizen events
• Implement 5S in the workplace

Topics:
• Lean principles: value, value stream, flow, pull, perfection
• Types of waste: overproduction, waiting, motion
• 5S methodology: sort, set in order, shine, standardize, sustain
• Kaizen: continuous improvement cycles
• Value stream mapping basics

Objectives:
• Communicate effectively with team members and supervisors
• Participate in shift handovers and team meetings
• Resolve conflicts constructively
• Contribute to a positive safety culture

Topics:
• Effective communication techniques
• Shift handover protocols
• Team roles and responsibilities
• Conflict resolution strategies
• Safety culture and near-miss reporting

Objectives:
• Review all theoretical and practical knowledge
• Practice key skills: setup, operation, inspection
• Prepare for final practical assessment
• Identify areas for improvement

Topics:
• Recap of cold forming processes and equipment
• Hands-on practice: tooling setup, parameter adjustment
• Quality inspection drills
• Troubleshooting scenarios
• Assessment criteria review

Objectives:
• Complete practical and theoretical assessments
• Demonstrate competence in producing cold formed tube/pipe
• Receive feedback on performance
• Plan for continued professional development

Topics:
• Final practical assessment: produce a tube/pipe to specification
• Written test on theory and safety
• One-on-one feedback session
• Course evaluation and certificates
• Career pathways and further training opportunities