Fabricate conveyor guard brackets to drawing

You are a second-year apprentice fabricator in Bay 2.

Simulated workplaceEntry missionCAQA Ironbark Engineering

What is going on

Mount Errol Quarries have ordered twelve conveyor guard brackets and six guard panels under job card JC-26-0412, and the job is behind schedule after a lifting near miss last week. The brackets are cut from 10 mm grade 350 plate received under REC-26-0881 with a traceable heat number, formed to the angle on drawing ME-2211 rev B, and fillet welded with the gas metal arc process to WPS-02. The brackets will be galvanised, so weld quality and freedom from trapped slag matter. Leanne Kowalski, the Fabrication Supervisor, has asked you to complete the remaining brackets today and to leave a complete record for the job card pack.

Leanne Kowalski, Fabrication Supervisor
Subject: Guard brackets for Mount Errol, JC-26-0412

The Mount Errol guard bracket job is behind after the sling near miss last week. I need you to pick up the remaining brackets on drawing ME-2211 rev B today. Read the drawing, prepare your JSA, get a hot work permit if you set up outside Bay 2, and use plate from receipt REC-26-0881 so the heat number is transferred. Book your hours to JC-26-0412 and complete the weld record before the parts go to blasting. Come and see me if any dimension on the drawing does not make sense.

Your brief

Interpret the drawing, plan and safely carry out the marking out, cutting, forming and welding of the guard brackets, transfer the heat number, complete the weld record and job safety analysis, and book your hours against the job card so the brackets are ready for inspection and blasting.

Work through it

You do not need to do it all. Doing a few of these will show you what the work is like. Your ticks and notes stay on this device.

Read the Job Card and Work Order Procedure and open JC-26-0412 in the Job Card Register to confirm the drawing number, revision and the required date.
Interpret drawing ME-2211 rev B: list the material, dimensions, bend angle, weld symbols and tolerances for the bracket and write down any query for the supervisor.
Prepare a Job Safety Analysis for marking out, cutting, forming and welding the brackets, including fume extraction, guarding and manual handling controls, and have it signed.
Check in the Materials and Certificate Register that receipt REC-26-0881 has its certificate on file, then mark out the brackets and transfer the heat number to every piece.
Confirm in the Welding Procedure and Welder Qualification Register that WPS-02 covers the fillet joint and that your welding supervisor is current for it.
Cut, form and weld the brackets, measuring each against the drawing with the comparison and measuring equipment, and record the weld details, consumable batch and welder identification on the weld record.
Report any hazard you find during the task, such as a blocked extraction arm, in the WHS Incident and Hazard Register.
Book your hours to JC-26-0412, update the job card status to Awaiting inspection and hand the drawing, JSA and weld record to the supervisor.

My notes: what did I enjoy, and what surprised me?

What someone in this role would produce

Completed Job Safety Analysis signed by the crew
Weld record with heat number, WPS number, consumable batch and welder identification
Dimensional check sheet against drawing ME-2211 rev B
Updated job card JC-26-0412 with hours and status

Printing this is a record of what you explored. It is not a certificate or a qualification.