ETCAL Level 4 NVQ Extended Diploma in

Engineering Manufacture (QCF)

Qualification No 601/1863/5 Credit Value 107 GLH 461 TQT 1070

Qualification Structure

The Learner must complete the common mandatory unit plus the Performing

Engineering Operations unit requirements from either Engineering Practices or

Technical Support plus 11 optional units from Engineering Manufacture, which

must include a minimum of 3 units from Group C and one unit from either

Group D or E

Unit Number

Unit Title Unit Credit Value/GLH

QCF Unit Number

Mandatory Unit (must be completed by all Learners) MAN2.01 Complying with Statutory Regulations and

Organisational Safety Requirements 5/35 A/601/5013

Performing Engineering Operations - Engineering Practices Optional Units: Candidates must complete three more units from the following: Barred unit combinations: Note: Only one unit from 4, 32 and 61 may be included in the candidate’s choice of three. If unit 65 is selected units 5, 6, 8, 11, 12, 15, 16, 17 cannot be included in the learner’s choice of three units. If unit 66 is selected units 10, 22, 23, 25, 26, 27, 28, 29, 30, 34 cannot be included in the learner’s choice of three units. If unit 67 is selected units 33, 35, 36, 40 cannot be included in the learner’s choice of three units. If unit 68 is selected units 19, 21, 37, 38, 39, 40, 58, 59 cannot be included in the learner’s choice of three units.

Group A

PEO2.04 Producing Mechanical Engineering Drawings using a CAD System

11/61 F/504/6348

PEO2.05 Producing Components using Hand Fitting Techniques

14/64 J/504/6349

PEO2.06 Producing Mechanical Assemblies

15/68 F/504/6351

PEO2.07 Forming and Assembling Pipework Systems

14/64 L/504/6353

PEO2.08 Carrying Out Aircraft Detail Fitting Activities

14/64 R/504/6354

PEO2.09 Installing Aircraft Mechanical Fasteners

11/61 L/504/6367

PEO2.10 Producing Aircraft Detail Assemblies

14/64 L/504/6370

PEO2.11 Preparing and Using Lathes for Turning Operations

15/68 Y/504/6372

PEO2.12 Preparing and Using Milling Machines

15/68 K/504/6375

PEO2.13 Preparing and Using Grinding Machines

15/68 T/504/6377

PEO2.14 Preparing and Proving CNC Machine Tool Programs

14/64 F/504/6379

PEO2.15 Preparing and Using CNC Turning Machines

14/64 F/504/6382

PEO2.16 Preparing and Using CNC Milling Machines

14/64 L/504/6384

PEO2.17 Preparing and Using CNC Machining Centres

14/64 D/504/6387

PEO2.18 Preparing and Using Industrial Robots

14/64 D/504/6390

PEO2.19 Maintaining Mechanical Devices and Equipment

14/64 T/504/6394

PEO2.20 Assembling and Testing Fluid Power Systems

14/64 J/504/6397

PEO2.21 Maintaining Fluid Power Equipment

14/64 F/504/6401

PEO2.22 Producing Sheet Metal Components and Assemblies

14/64 J/504/6402

PEO2.23 Producing Platework Components and Assemblies

14/64 L/504/6403

PEO2.24 Cutting and Shaping Materials using Thermal Cutting Equipment

14/64 R/504/6404

PEO2.25 Preparing and Proving CNC Fabrication Machine Tool Programs

14/64 Y/504/6405

PEO2.26 Preparing and Using CNC Fabrication Machinery

14/64 D/504/6406

PEO2.27 Preparing and Using Manual Metal Arc Welding Equipment

15/68 K/504/6408

PEO2.28 Preparing and Using Manual TIG or Plasma-arc Welding Equipment

15/68 M/504/6409

PEO2.29 Preparing and Using Manual MIG, MAG and Other Continuous Wire Welding Equipment

15/68 H/504/6410

PEO2.30 Preparing and Using Manual Gas Welding Equipment

14/64 Y/504/6419

PEO2.31 Preparing and Using Manual Flame Brazing and Bronze Welding Equipment

11/61 L/504/6420

PEO2.32 Producing Electrical or Electronic Engineering Drawings using a CAD System

11/61 R/504/6421

PEO2.33 Wiring and Testing Electrical Equipment and Circuits

14/64 Y/504/6422

PEO2.34 Forming and Assembling Electrical Cable Enclosure and Support Systems

13/65 D/504/6423

PEO2.35 Assembling, Wiring and Testing Electrical Panels/Components Mounted in Enclosures

14/64 H/504/6424

PEO2.36 Assembling and Testing Electronic Circuits

14/64 K/504/6425

PEO2.37 Maintaining Electrical Equipment/Systems

15/68 M/504/6426

PEO2.38 Maintaining Electronic Equipment/Systems

15/68 T/504/6427

PEO2.39 Maintaining and Testing Process Instrumentation and Control Devices

15/68 A/504/6428

PEO2.40 Wiring and Testing Programmable Controller Based Systems

15/68 F/504/6429

PEO2.41 Using Wood for Pattern, Modelmaking and Other Engineering Applications

15/68 T/504/6430

PEO2.42 Assembling Pattern, Model and Engineering Woodwork Components

14/64 A/504/6431

PEO2.43 Producing Composite Mouldings using Wet Lay-up Techniques

14/64 F/504/6432

PEO2.44 Producing Composite Mouldings using Pre-Preg Laminating Techniques

14/64 L/504/6434

PEO2.45 Producing Composite Mouldings using Resin Infusion Techniques

14/64 R/504/6435

PEO2.46 Producing Composite Assemblies 14/64 Y/504/6436

PEO2.47 Producing Components by Rapid Prototyping Techniques

11/61 D/504/6437

PEO2.48 Producing and Preparing Sand Moulds and Cores for Casting

14/64 H/504/6438

PEO2.49 Producing and Preparing Molten Materials for Casting

14/64 K/504/6439

PEO2.50 Producing Cast Components by Manual Means

13/65 D/504/6440

PEO2.51 Fettling, Finishing and Checking Cast Components

11/61 H/504/6441

PEO2.52 Finishing Surfaces by Applying Coatings or Coverings

9/41 M/504/6443

PEO2.53 Finishing Surfaces by Applying Treatments

9/41 T/504/6444

PEO2.54 Carrying Out Heat Treatment of Engineering Materials

9/41 A/504/6445

PEO2.55 Carrying Out Hand Forging of Engineering Materials

9/41 F/504/6446

PEO2.56 Stripping and Rebuilding Motorsport Vehicles (Pre-Competition)

14/64 J/504/6447

PEO2.57 Inspecting a Motorsport Vehicle During a Competition

14/64 L/504/6448

PEO2.58 Diagnosing and Rectifying Faults on Motorsport Vehicle Systems (During Competition)

15/68 R/504/6449

PEO2.59 Carrying out Maintenance Activities on Motorsport Vehicle Electrical Equipment

15/68 J/504/6450

PEO2.60 Stripping and Rebuilding Motorsport Engines (Pre-Competition)

14/64 L/504/6451

PEO2.61 Producing CAD Models (Drawings) using a CAD System

11/61 R/504/6452

PEO2.65 General Machining, Fitting and Assembly Applications

12/55 K/504/6456

PEO2.66 General Fabrication and Welding Applications

12/55 M/504/6457

PEO2.67 General Electrical and Electronic Engineering Applications

12/55 T/504/6458

PEO2.68 General Maintenance Engineering Applications

12/55 A/504/6459

PEO2.69 Joining Public Service Vehicle Components by Mechanical Processes

11/61 L/503/4056

PEO2.70 Assembling Structural Sub-Assemblies to Produce a Public Service Vehicle

14/64 R/503/4057

PEO2.71 Fitting Sub-Assemblies and Components to Public Service Vehicles

14/64 Y/503/4058

PEO2.72 Preparing and Manoeuvring Fighting Vehicles AFVs for Maintenance and Transportation

14/64 R/503/7198

PEO2.73 Producing Composite Mouldings using Resin Film Infusion Techniques

14/64 J/504/3404

OR Performing Engineering Operations - Technical Support

Group B

Optional Units: Candidates must complete one of the following units:

PEO2.04 Producing Mechanical Engineering Drawings using a CAD System

11/61 F/504/6348

PEO2.32 Producing Electrical or Electronic Engineering Drawings using a CAD System

11/61 R/504/6421

PEO2.61 Producing CAD Models (Drawings) using a CAD System

11/61 R/504/6452

Plus two more of the following units:

PEO2.62 Producing Engineering Project Plans

8/37 Y/504/6453

PEO2.63 Using Computer Software Packages to Assist with Engineering Activities

8/37 D/504/6454

PEO2.64 Conducting Business Improvement Activities

8/41 H/504/6455

Plus two more units from the following:

PEO2.65 General Machining, Fitting and Assembly Applications

12/55 K/504/6456

PEO2.66 General Fabrication and Welding Applications

12/55 M/504/6457

PEO2.67 General Electrical and Electronic Engineering Applications

12/55 T/504/6458

PEO2.68 General Maintenance Engineering Applications

12/55 A/504/6459

Plus

Engineering Manufacture – Optional units 11units from Engineering Manufacture which must include a minimum of 3 units from Group C and 1 unit from either Group D or E Barred Combinations for Engineering Manufacture (L3, 4 and 5 units) Groups C, D and E: If unit 8 is selected unit 15 or 21 cannot be included in the learner’s choice of 11 units If unit 26 is selected unit 49 cannot be included in the learner’s choice of 11 units If unit 28 is selected unit 46 cannot be included in the learner’s choice of 11 units If unit 33 is selected unit 48 cannot be included in the learner’s choice of 11 units If unit 34 is selected unit 50 cannot be included in the learner’s choice of 11 units If unit 37 is selected units 95 to 113 cannot be included in the learner’s choice of 11 units If unit 54 is selected units 58 to 66 cannot be included in the learner’s choice of 11 units If unit 56 is selected unit 24 or 25 cannot be included in the learner’s choice of 11 units

Only one unit from 90 and 91 may be selected in the learners choice of 11 units

Group C (minimum of 3 units must be selected)

Research

EMan4.02 Identify and Define Areas of Engineering Research

16/56 J/505/0952

EMan4.03 Develop a Research Methodology for Engineering

16/56 L/505/0953

EMan4.04 Propose and Specify Engineering Research

16/56 R/505/0954

EMan4.05 Undertake Engineering Research

16/56 L/505/0936

EMan4.06 Evaluate the Results of Engineering Research

16/56 Y/505/0955

Design

EMan4.07 Identify Engineering Design Requirements of Clients

16/56 F/505/0934

EMan4.08 Establish an Engineering Design Brief

16/56 Y/505/0938

EMan4.09 Develop a Strategy for the Engineering Design Process

16/56 D/505/0956

EMan4.10 Create Engineering Designs

16/56 D/505/0939

EMan4.11 Evaluate Engineering Designs

16/56 R/505/0940

New Product Design and Introduction

EMan4.12 Contribute to a Team Feasibility Review of a New Product Design

16/56 Y/505/1006

EMan4.13 Control the New Product Design Change Process

16/56 H/505/1008

EMan4.14 Plan and Control New Product Design Benchmarking Activities

16/56 K/505/1009

EMan4.15 Establish New Product Development and Introduction Brief

16/56 H/505/1011

EMan4.16 Produce and Evaluate Conceptual Design Options for New Products

16/56 D/505/1010

EMan4.17 Verify New Product Designs using a Computer Model

16/56 K/505/1012

EMan4.18 Verify New Product Designs using a Physical Model

16/56 L/505/1018

EMan4.19 Produce New Product Designs for Manufacture and Assembly

16/56 T/505/1045

EMan4.20 Plan and Control New Product Manufacturing Process Benchmarking Activities

16/56 J/505/1048

EMan4.21 Establish Manufacturing Process Design Brief for New Product Introduction

16/56 L/505/1049

EMan4.22 Develop a New Product Manufacturing Process Design Strategy

16/56

F/505/1050

EMan4.23 Develop a New Product Manufacturing Process Flow and Floor Plan Layout

16/56

J/505/1051

EMan4.24 Plan and Manage the Installation of the New Product Manufacturing Process

16/56

R/505/1053

EMan4.25 Commission a New Product Manufacturing Process

16/56

T/505/1059

Engineering and Manufacture

EMan4.26 Solve Engineering or Manufacturing Problems

16/56 A/505/0933

EMan4.27 Undertake Project Management Activities

16/56 T/505/0963

EMan4.28 Determine the Requirements for Engineering Activities

16/56 Y/505/0941

EMan4.29 Produce Engineering Specifications

16/56 J/505/0935

EMan4.30 Specify Methods and Procedures to Achieve Engineering Requirements

16/56 D/505/0942

EMan4.31 Schedule Engineering Activities

16/56 H/505/0943

EMan4.32 Obtain Resources for the Implementation of Engineering Activities

16/56 K/505/0944

EMan4.33 Implement Engineering Processes

16/56 M/505/0945

EMan4.34 Monitor and Evaluate Engineering Processes

16/56 T/505/0946

EMan4.35 Provide technical advice and guidance on engineering or manufacturing requirements

16/56 F/505/0951

EMan4.36 Implement Quality Assurance Methods and Procedures

16/56 J/505/0949

EMan4.37 Improve the Quality of Engineering Products or Processes

16/56 A/505/0950

EMan4.38 Specify Risk Reduction Methods and Procedures

16/56 F/505/0948

EMan4.39 Evaluate Engineering Risk Assessments

16/56 A/505/0947

EMan4.40 Investigate Incidents Relating to Engineering Activities

16/56 K/505/0961

EMan4.41 Configure Engineering Products, Processes or Facilities

16/56 H/505/0957

EMan4.42 Transfer Control of Engineering Products, Processes or Facilities

16/56 K/505/0958

EMan4.43 Propose Decommissioning of Engineering Products, Processes or Facilities

16/56 M/505/0959

EMan4.44 Plan and Decommission Engineering Equipment, Processes or Facilities

16/56 H/505/0960

EMan4.45 Commission Engineering Products, Processes or Facilities

16/56 M/505/0962

EMan4.46 Determine Welding and Related Technical Requirements to Achieve Objectives

16/56 D/505/0987

EMan4.47 Plan Welding Production Resources and Activities

16/56 H/505/0988

EMan4.48 Implement Welding Production Methods and Procedures

16/56 K/505/0989

EMan4.49 Solve Welding Problems in Production

16/56 D/505/0990

EMan4.50 Monitor Welding Activities in Production

16/56 H/505/0991

EMan4.51 Inspect Welded Components or Structures for Visual Quality and Dimensional Accuracy

16/56 K/505/0992

EMan4.52 Lead Welding and Fabrication Activities

16/56 L/505/0967

EMan4.53 Lead Rail Welding Activities

16/56 R/505/0968

EMan4.54 Lead Maintenance Activities

16/56 A/505/0964

EMan4.55 Lead Mechanical Manufacturing or Inspection Activities

16/56 F/505/0965

EMan4.56 Lead Installation or Commissioning Activities

16/56 J/505/0966

EMan4.57 Lead Electrical/Electronic Product Manufacturing or Testing Activities

16/56 Y/505/0969

EMan4.58 Carry Out the Testing and Calibration of Instrumentation Control Equipment and Circuits

16/56

L/505/0970

EMan4.59 Carry out Maintenance Activities on Mechanical Equipment

16/56 R/505/0971

EMan4.60 Carry out Maintenance Activities on Electrical Equipment

16/56 Y/505/0972

EMan4.61 Carry out Maintenance Activities on Fluid Power Equipment

16/56 D/505/0973

EMan4.62 Carry out Maintenance Activities on Instrumentation and Control Equipment

16/56 H/505/0974

EMan4.63 Carry out Maintenance Activities on Mechanical Equipment within an Engineered System

16/56

K/505/0975

EMan4.64 Carry out Maintenance Activities on Electrical Equipment within an Engineered System

16/56 M/505/0976

EMan4.65 Carry out Maintenance Activities on Fluid Power Equipment within an Engineered System

16/56 A/505/0978

EMan4.66 Carry out Maintenance Activities on Process Controller Equipment within an Engineered System

16/56

F/505/0979

Group D (1 unit must be selected from either Group D or E) Council for Administration units

EMan4.67 Build, support and manage a team

4/20 F/600/9682

EMan4.68 Develop, maintain and review personal networks

4/25

R/600/9587

EMan4.69 Review risk management processes in own area of responsibility

3/20 L/600/9622

EMan4.70 Provide leadership and direction for own

area of responsibility

5/30

T/600/9601

EMan4.71 Ensure compliance with legal, regulatory, ethical and social requirements

5/25

H/600/9609

EMan4.72 Implement change in own area of responsibility

6/25

M/600/9659

EMan4.73 Support individuals to develop and take responsibility for their performance

4/20

D/600/9690

EMan4.74 Know how to follow disciplinary procedures

4/20

H/600/9691

EMan4.75 Managing grievance procedures

3/10 K/600/9692

EMan4.76 Support the management of redundancies in own area of responsibility

3/15 M/600/9693

EMan4.77 Develop working relationships with colleagues and stakeholders

4/20

K/600/9661

EMan4.78 Support learning and development within own area of responsibility

5/25

M/600/9676

EMan4.79 Address performance problems affecting team members

3/20

F/600/9679

EMan4.80 Manage a tendering process

4/20 H/600/9738

EMan4.81 Develop and implement a risk assessment plan in own area of responsibility

6/20

L/600/9703

EMan4.82 Manage physical resources

3/25 K/600/9711

EMan4.83 Manage the environmental impact of work activities

5/10

M/600/9712

EMan4.84 Prepare for and support quality audits

4/20 Y/600/9798

EMan4.85 Develop and implement marketing plans

6/25 K/600/9790

EMan4.86 Analyse the market in which your organisation operates

5/25

M/600/9791

EMan4.87 Develop and evaluate operational plans for own area of responsibility

6/25

Y/600/9588

EMan4.88 Manage the achievement of customer satisfaction

5/25

A/600/9793

EMan4.89 Plan, allocate and monitor work in own area of responsibility

5/25

H/600/9674

EMan4.90 Manage budgets

5/29 T/601/2552

EMan4.91 Agree a budget

4/25 J/601/2552

EMan4.92 Make decisions in a business environment

4/25 H/601/2560

EMan4.93 Negotiate in a business environment

7/40 K/601/2561

EMan4.94 Prepare specifications for contracts

5/30 F/601/2565

Group E (1 unit must be selected from either Group D or E) Business Improvement Techniques units

EMan4.95 Leading workplace organisation activities

10/25 F/600/5406

EMan4.96 Leading continuous improvement (Kaizen) activities

14/32 M/600/5420

EMan4.97 Leading the development of visual management systems

9/25 M/600/5434

EMan4.98 Leading the creation of flexible production and manpower systems

7/25 K/600/5447

EMan4.99 Leading value stream mapping (VSM) activities

13/32 M/600/5563

EMan4.100 Leading statistical process control (SPC) activities

8/25 J/600/5665

EMan4.101 Leading value management (value engineering & value analysis) activities

11/32 A/600/5713

EMan4.102 Leading failure modes and effects analysis (FMEA) activities

9/25 L/600/5733

EMan4.103 Leading measurement systems analysis (MSA) activities

9/25 R/600/5748

EMan4.104 Carrying out design of experiments (DOE)

9/25 L/600/5862

EMan4.105 Leading mistake/error proofing (POKA YOKE) activities

9/25 K/600/5867

EMan4.106 Applying quality function deployment (QFD)

9/25 J/600/5875

EMan4.107 Leading the creation of standard operating procedures

8/25 F/600/5888

EMan4.108 Leading the application of Six Sigma methodology to a project

14/32 D/600/5896

EMan4.109 Leading the carrying out of Six Sigma process mapping

14/32 T/600/5905

EMan4.110 Leading the application of basic statistical analysis

10/25 T/600/5919

EMan4.111 Leading the application of Six Sigma metrics to a project

9/25 Y/600/5931

EMan4.112 Leading the production of a characteristic selection matrix

9/25 R/600/5944

EMan4.113 Leading the carrying out of capability studies

14/32 L/600/5957