Cold forming setter technician

This apprenticeship standard was approved for delivery by the Institute for Apprenticeships and Technical Education. However, starts on the apprenticeship will only be possible once a suitable end-point assessment organisation (EPAO) has obtained Ofqual recognition. Once the EPAO has obtained Ofqual recognition, funding for apprentice starts will be permitted and this message will be removed.

Key information

  1. Status: Approved for delivery (paused for starts)
  2. Reference: ST1355
  3. Version: 1.0
  4. Level: 3
  5. Typical duration to gateway: 36 months
  6. Typical EPA period: 3 months
  7. Route: Engineering and manufacturing
  8. Integration: None
  9. Maximum funding: £24000
  10. Date updated: 29/05/2025
  11. Approved for delivery: 29 May 2025
  12. Lars code: 813
  13. Class code: Z0001891
  14. EQA provider: Ofqual is the intended EQA provider
  15. Example progression routes:
  16. Review: this apprenticeship will be reviewed in accordance with our change request policy.
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Details of the occupational standard

Occupation summary

This occupation is found in the manufacturing supply chain of high value and strategically critical industries including automotive, aerospace, construction, military, renewable energy and general industry.

The broad purpose of the occupation is to set-up, configure, operate and monitor complex high value machinery that enables components to be mass produced in the most economically viable way. The process includes a series of steps using uniquely designed tooling and processes such as drawing, extrusion, upsetting, heading, piercing and trimming in order to make the completed component. The setter technician will interpret complex engineering drawings and diagrams to enable them to set up the machine appropriately. They are responsible for the set up, running, maintenance and management of the machinery and process to ensure that production meets tolerances and quality standards. They would also be expected to take part in the development of new products and have a considerable involvement in quality assurance activities and process efficiency improvements. Typical products produced using this process will include bolts, nuts, screws, bushes, rivets, solid and hollow formed parts. The cold forming process is extremely efficient compared to other manufacturing processes and results in significantly less product waste being produced.

In their daily work, an employee in this occupation interacts with managers or supervisors, technical or production personnel, purchasing, maintenance, quality and other operatives on the shop floor. A cold forming setter technician will typically spend most of their time working on the factory floor, with some time spent away from this environment if working on new product evaluation and feedback.

An employee in this occupation will be responsible for the complete set-up, operation and management of high value cold forming manufacturing equipment capable of high-volume production while meeting customer specifications and achieving consistently high tolerances and quality and environmental standards. They will also autonomously carry out a range of maintenance, quality assurance, process monitoring and adjustments, to ensure the machinery is operating at required efficiency and accuracy levels. A cold forming setter technician will work as part of a wider manufacturing team, however they will usually work autonomously and will exercise considerable responsibility and judgement on machine operation with a high-level of personal decision making and influence on the process. Depending on the size of the organisation, a cold forming machine setter technician would typically report to the production manager, supervisor or engineer. They will have an understanding of secondary operation processes such as thread rolling, pointing, fillet radius rolling as well as follow-on processes such as cleaning, heat treatment and coating. They need to work safely at all times taking into consideration the equipment being used and the working environment.

 

Typical job titles include:

Cold forming machine operator Cold forming machine setter Cold forming setter technician Heading operator Heading setter

Entry requirements

Typical academic entry requirements may be GCSE grades 4+ in subjects such as maths, English, a science or design and technology. Entrants may also come from other routes, such as within organisations working in a different role, or with vocational qualifications such as an NVQ in manufacturing, or from a relevant level two apprenticeship.

Occupation duties

Duty KSBs

Duty 1 Interpret complex engineering drawings and specifications to determine requirements.

K1 K29

S1

B1

Duty 2 Schedule and complete routine and preventative maintenance checks and activities, such as lubrication systems, mechanical mechanisms and pneumatic systems.

K19 K20 K25 K29 K32 K37

S10 S11 S17 S18 S21 S23 S24 S26 S27

B1 B4 B6 B7

Duty 3 Assist in diagnosing machine issues and variations to determine and complete reactive maintenance.

K3 K17 K19 K20 K25 K28 K29 K38

S1 S5 S8 S9 S11 S17 S20 S23

B1 B3 B4 B6 B7

Duty 4 Set up, adjust and operate the heading machine to run efficiently, producing parts within drawing tolerances. Make autonomous decisions to correct any abnormal conditions to produce precise progressions.

K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K16 K17 K18 K20 K29 K37 K38

S1 S2 S3 S4 S5 S7 S8 S9 S11 S17 S21 S25 S26 S27

B1 B2 B3 B4 B6 B7 B8

Duty 5 Configure process monitoring equipment to enable accurate feedback of process stability. Interpret the results and interrogate set-up of machine making micro adjustments and tool changes to improve process control.

K1 K7 K8 K9 K10 K12 K20 K29 K38

S3 S4 S5 S6 S7 S8 S9 S11 S12 S17 S24 S27

B1 B2 B3 B4 B6 B7 B8

Duty 6 Complete dimensional and visual inspections, including first off and last off inspections. Utilise gauges and measuring devices and record the results. Evaluate both statistical and visual results and make decisions on what action is required to correct any abnormalities or dimensional trends.

K1 K5 K8 K9 K10 K11 K13 K17 K26 K30 K38

S1 S4 S6 S7 S8 S9 S11 S17 S27

B1 B2 B3 B4 B6 B7 B8

Duty 7 Troubleshoot and correct abnormal production running issues, evaluating tooling and machine set-up to establish root cause. Make decisions when to change tooling and adjust machine positions, returning the process to normal operating conditions to maintain product quality.

K1 K2 K5 K6 K7 K8 K9 K10 K11 K12 K13 K15 K17 K20 K26 K29 K36 K38

S1 S3 S5 S7 S9 S11 S12 S17 S20 S24 S25 S28

B1 B2 B3 B4 B6 B7 B8

Duty 8 Identify, record and process non-conforming products using recognised problem-solving techniques in line with organisational procedures.

K1 K8 K9 K10 K11 K12 K13 K15 K16 K17 K21 K23 K26 K27 K28 K30 K33 K34 K36 K38

S1 S4 S5 S6 S8 S10 S11 S14 S17 S18 S20 S25 S26 S27

B1 B2 B3 B4 B6 B7 B8

Duty 9 Clean the work area to reduce risk of contamination, and return materials and equipment in line with organisational procedures.

K2 K5 K11 K20 K21 K26 K27 K29 K30 K34 K36 K37

S1 S10 S11 S17 S18 S22 S24 S25 S26 S27

B1 B2 B3 B4 B6 B7 B8

Duty 10 Identify and complete continuous improvement activities and report any anomalies outside of own remit to relevant stakeholders. Identify and complete professional development opportunities.

K1 K2 K5 K6 K7 K8 K9 K10 K11 K12 K14 K15 K16 K21 K23 K38

S1 S3 S5 S7 S8 S9 S10 S11 S13 S14 S15 S17 S20 S27 S28

B1 B2 B3 B4 B5 B6 B7 B8

Duty 11 Work to required environmental and quality standards to reduce waste and maintain process quality and address or raise concerns where appropriate.

K23 K27 K28 K29 K30 K33 K34 K36 K37

S1 S4 S5 S6 S8 S11 S17 S18 S20 S21 S25 S26 S27

B1 B2 B4 B5 B6 B7 B8

Duty 12 Complete documentation such as quality documentation, handover logs, maintenance sheets, daily production logs and process checks in line with organisational procedures.

K11 K13 K20 K25 K29 K30 K32 K37

S1 S6 S11 S17 S18 S25 S27 S28

B1 B2 B5 B6

Duty 13 Make technical contributions and recommendations for products and processes. Provide feedback and evaluation of tooling and optimum machine settings.

K11 K21 K31 K38

S1 S7 S8 S9 S10 S13 S14 S15 S16 S17 S27

B1 B2 B3 B4 B5 B6 B8

Duty 14 Develop and maintain effective working relationships with colleagues, technical support staff and other relevant stakeholders to ensure that customer and business requirements are met.

K11 K14 K21 K22 K24 K28 K31 K32 K33 K35

S10 S13 S14 S15 S16 S17 S19 S27

B3 B5 B6 B7 B8

KSBs

Knowledge

K1: Principles of reading and interpreting engineering drawings and documentation. Back to Duty

K2: Part numbers for tooling and wire. Back to Duty

K3: Types of cold forming machinery. The differences between machines and the mechanisms that they use. Back to Duty

K4: Wire: loading, setting the drawer and feeding into the machine Back to Duty

K5: Tooling: visual inspection, assembly and securing. Back to Duty

K6: Principles of setting-up a cold forming machine. Back to Duty

K7: Principles of high-volume metal cold forming techniques in a continuous production environment to build and form the progressions to achieve final shape. Back to Duty

K8: Gauges and measurement systems used in cold forming. Back to Duty

K9: How to complete visual inspection of the parts as they are made and how to recognise defects and tooling wear. Back to Duty

K10: Tooling failure mechanisms. How tools fail and the impact that the set-up of the machine has on tooling failure. Back to Duty

K11: Documentation: methods and requirements – electronic and paper. Back to Duty

K12: Process monitoring equipment: what the process monitor does and why it is required. How it is used to check machine set-up and to monitor variation in the process. Back to Duty

K13: Statistical Process Control (SPC) data input and how to interpret SPC charts. Back to Duty

K14: Team working principles. Back to Duty

K15: Problem solving techniques for root cause analysis: 5 Whys, Fishbone Diagram, PDCA (Plan Do Check Act), Pareto Chart, Change Analysis, Fault Tree Analysis, FMEA (Failure Mode Effects Analysis), DMAIC (Define, Measure, Analyse, Improve, Control). Back to Duty

K16: Principles of properties of materials. Metallurgical properties of metals: mild steel, carbon steel, stainless steel, titanium, copper, brass and aluminium. Effect on materials during the forming process. Back to Duty

K17: Principles of steel and wire manufacturing processes. Back to Duty

K18: Principles of tooling materials and manufacturing processes. Back to Duty

K19: Machine mechanisms, lubrication, air and drive systems. Back to Duty

K20: Awareness of health and safety regulations, relevance to the occupation and the technician’s responsibilities: Control of Substances Hazardous to Health (COSHH), electrical safety and compliance, emergency evacuation procedures, Health and Safety at Work Act – responsibilities, isolation and emergency stop procedures, Lifting Operations and Lifting Equipment Regulations (LOLER), manual handling, near miss reporting, noise regulations, Provision and use of Work Equipment Regulations (PUWER), Reporting of Injuries, Diseases and Dangerous Occurrences Regulations (RIDDOR), safe systems of work, safety equipment: guards, signage, fire extinguishers, situational awareness, slips, trips and falls, types of hazards, Personal Protective Equipment (PPE), working at height, working in confined spaces. Back to Duty

K21: Verbal communication techniques. Giving and receiving information. Matching style to audience. Barriers in communication and how to overcome them. Engineering terminology. Back to Duty

K22: Non-verbal communication techniques: gestures, facial expressions, tone of voice, eye contact, body language. Back to Duty

K23: Continuous improvement techniques: lean, 6-sigma, KAIZEN, 5S (sort, set shine, standardise and sustain), SMED (Single minute exchange of dies). Back to Duty

K24: Equality Act. Equality, diversity and inclusion in the workplace. Unconscious bias. Back to Duty

K25: Maintenance practices and techniques: planned, preventative, predictive and reactive methods and their frequency. Back to Duty

K26: Stock requirements. Control systems. Stock rotation. Stock considerations: availability, stock lead times, stock value, faulty stock, salvageability of parts removed. Back to Duty

K27: Standard operating procedures (SOP). What they are and why they are important. What they need to cover and why. Visuals and symbols used in SOP. Back to Duty

K28: Escalation procedures. Back to Duty

K29: Manufacturers’ guidelines: what they are and how to use them. Warranties: what they are and the impact on engineering work. Back to Duty

K30: Quality management standards. Quality assurance principles and practice. Record keeping. Back to Duty

K31: The cold forming industry. Types of organisations. Types of products. Supply chain. Customers. Customer requirements. Impact on product demand. Back to Duty

K32: Planning, prioritising, work scheduling, workflow and time management techniques. Work management systems. Work categorisation systems. Back to Duty

K33: Business operation considerations: efficiency, customer satisfaction, competitiveness, minimising risks to operation and ethical issues. Back to Duty

K34: Principles of sustainability and circular economy. Energy efficiency and reuse of materials. Recycling procedures. Principles of control and management of emissions and waste. Efficient use of resources. Back to Duty

K35: Continued professional development: planning and accessing development opportunities. Back to Duty

K36: Principles and requirements of restoring the work area. Back to Duty

K37: Principles of hazard identification and risk assessment. Back to Duty

K38: Principles of recognising variation in the process when conducting dimensional and visual inspection and making adjustments to the process to maintain control. Back to Duty

Skills

S1: Read and interpret information. For example, text, data, engineering drawings, job card, work instructions, risk assessments, method statements, operation manuals, permits to work, instructions. Back to Duty

S2: Load, set and feed wire onto the cold forming machine. Back to Duty

S3: Select, inspect, assemble, fit and clamp tooling components. Back to Duty

S4: Build progressions across multiple stations incorporating processes such as forward and backward extrusion, upsetting, heading, trimming and piercing. Back to Duty

S5: Use gauges and measuring equipment. Back to Duty

S6: Input and assess charts using Statistical Process Control (SPC). Back to Duty

S7: Make adjustments to the process to maintain control. Back to Duty

S8: Assess condition of components and equipment. Identify action required such as monitoring tooling for wear during process and make changes. Back to Duty

S9: Troubleshoot machine running issues and take corrective action. Escalate issues. Back to Duty

S10: Communication with others verbally for example, colleagues and stakeholders. Back to Duty

S11: Apply health and safety procedures and safe systems of work in compliance with regulations and standards. Back to Duty

S12: Use process monitoring equipment. Back to Duty

S13: Create, maintain and enhance productive working relationships. Back to Duty

S14: Apply continuous improvement techniques. Devise suggestions for improvement. Back to Duty

S15: Carry out and record planned and unplanned learning and development activities. Back to Duty

S16: Apply team working principles. Back to Duty

S17: Record or enter information – paper based or electronic. For example, energy usage, job sheets, risk assessments, equipment service records, test results, handover documents and manufacturers’ documentation, asset management records, work sheets, checklists, dimensional records, waste environmental records and any legal reporting requirements. Back to Duty

S18: Apply environmental and sustainability procedures in compliance with regulations and standards. for example, segregate resources for reuse, recycling and disposal. Back to Duty

S19: Follow equality, diversity and inclusion procedures. Back to Duty

S20: Apply problem solving techniques. Back to Duty

S21: Identify and document hazards and risks in the workplace. Back to Duty

S22: Restore the work area on completion of the activity. Back to Duty

S23: Apply maintenance practices. For example, check levels, parts wear, pressure and sensors and grease and lubricate. Back to Duty

S24: Obtain and check stock and supplies. Complete returns. Back to Duty

S25: Apply standard operating procedures (SOP). Back to Duty

S26: Identify, organise and use resources to complete tasks with consideration for cost, quality, safety, security and environmental impact. Back to Duty

S27: Plan work. Back to Duty

S28: Apply quality assurance principles and practices Back to Duty

Behaviours

B1: Take responsibility for completing work. Back to Duty

B2: Act professionally. Back to Duty

B3: Committed to continued professional development (CPD) to maintain and enhance competence in their own area of practice. Back to Duty

B4: Respond and adapt to work demands and situations. Back to Duty

B5: Take account of diversity and inclusion requirements. Back to Duty

B6: Has a focus on quality and promotes improvement. Back to Duty

B7: Take personal responsibility for and promote health and safety. Back to Duty

B8: Considers the environment and sustainability. Back to Duty

Qualifications

English and Maths

English and maths qualifications must be completed in line with the apprenticeship funding rules.

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Version log

Version Change detail Earliest start date Latest start date
1.0 Approved for delivery 29/05/2025 Not set
Employers involved in creating the standard: Atlas Copco, Carlo Salvi UK, Clevedon Fasteners, Complex Cold Forming, Fixfast Ltd, Gesipa, Howmet, JCS Hi-Torque, LISI Aerospace, National Machinery, Optimas, PCC Aerostructures
Other stakeholders involved in creating the standard: Confederation of British Metalforming

Crown copyright © 2025. You may re-use this information (not including logos) free of charge in any format or medium, under the terms of the Open Government Licence. Visit www.nationalarchives.gov.uk/doc/open-government-licence

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