Earn FMA’s Roll Form Operator
Skilled Trade Certificate
and leap your “advancement hurdles”!
FMA is pleased to announce a new Roll Form
Operator Skilled Trade Certificate Program that allows
you to:
• establish your credentials with employers.
• become known as the “go to” expert in roll forming
in your company.
• boost your present and potential earning power.
The Roll Form Operator Skilled Trade Certificate
confirms to employers the valuable technical skills you
bring to your position. Completing some basic program
requirements can pay off many times over in
promotability and income.
Why obtain the certificate?
Because employers are increasingly turning to
certificate programs to identify skilled workers, this is a
great opportunity to gain a competitive edge. Get their
attention, make their short list, and receive the offer.
Already where you want to be? The Roll Form
Operator Skilled Trade Certificate enhances your
perceived value and makes a strong case for the pay
you deserve.
How do I get the certificate?
Achieving the Roll Form Operator Skilled Trade
Certificate is a two-step process:
First, your current skills are evaluated and your
documentable on-the-job experience and schooling are
counted toward the certificate.
Second, your skills are supplemented with
strategic training. Classroom instruction—led by roll form
expert Steve Ebel and including hands-on exercises—is
followed by an exam. Upon successful completion,
you’ll be offered the Roll Form Operator Skilled Trade
Certificate.
Drawing on his 30+ years’
experience and Industrial Engineering
degree, instructor Steve Ebel has
geared his approach toward preparing
you for the most daunting challenges
you’ll encounter in your work. Steve’s
qualifications include leading a company specializing in
training and consulting for the roll form industry.
The classroom portion of the Roll Form Operator
Skilled Trade Certificate Program is offered twice a year.
However, companies with several employees qualified
for the coursework may request that Mr. Ebel come to
their facility for the classroom instruction and exam. ■
FMA’s Roll Form Operator Skilled Trade Certificate
is offered at four levels, with each successive level
requiring more advanced coursework and more
extensive on-the-job experience.
For course descriptions,
prerequisite course work, on-the-job
experience requirements, and an
application form, log on to
fmanet.org and click on Education
833 Featherstone Road • Rockford, Illinois 61107
fmanet.org • [email protected]
Toll-free 888-394-4362
Phone 815-399-8775 • Fax 815-381-1371
Roll Form Operator Skilled Trade Certificate Program
To receive consideration for the classroom portion of the Fabricators & Manufacturers Association, Intl.®, Roll Form Operator Skilled
Trade Certificate Program, please complete the application below and return it with a $250 nonrefundable application fee.
You must have completed the on-the-job (OTJ) hours and prerequisite course work required for the certificate level desired. See
attached certificate level descriptions.
Please attach documentation supplied by your employer(s) verifying your on-the-job experience. Also attach vocational or collegiate
transcripts verifying successful completion of the required courses. Contact information for both sources is required.
Personal Information
First name
1
Middle initial
Last name
Home address
City
Telephone
State
Zip
State
Zip
E-mail address
Professional Information
2
Employer
Employer address
City
Telephone
Fax
Years with current employer
Average hours per week operating line
Primary responsibilities
Previous employer
Dates
3
Average hours per week
operating line
Primary responsibilities
Please attach further detail if necessary.
Certificate level desired:
❏ Operator Level 1
❏ Operator Level 2
❏ Operator Level 3
❏ Roll Form Technician Level 4
Please check the prerequisite coursework completed (transcripts must be attached)
_____ Basic SPC
_____ Basic Welding
_____ GD & T
_____ Blueprint Reading
_____ Basic Die Design
_____ Metallurgy
_____ Industrial Safety
_____ Technical Math I
_____ Technical Communications
_____ Basic Machining
_____ Technical Math II
_____ Microsoft Excel
I attest that the information regarding my work experience and technical coursework is true and correct to the best of my knowledge.
I understand that if the information is found to be untrue I will not be considered for this program.
Signature
Thank you for your interest in FMA’s Roll Form Operator Skilled Trade Certificate Program. Best wishes for your professional success.
ed 07
Roll Form Operator Skilled Trade Certificate Program
The Certificate is offered at Levels 1 through 4, as outlined below with their respective Course Requirements, Technical Roll Form
Training (classroom portion of program), and On-the-Job Experience Requirements.
Level 1 (Operator Program)
Course Requirement:
• College or Equivalent:
- Basic SPC
- Blueprint reading
- Industrial Safety
On-the-Job (OTJ) Requirements:
• 1000 Hours Running a Roll Form Line
Level 4 (Roll Form Technician)
Course Requirements: (Prerequisite Level 3)
• College or Equivalent:
- Metallurgy
- Technical Math 2
- GD&T
• Roll Form Training:
- Advanced Roll Form Training (10 Hrs)
OTJ Requirements:
Level 2 (Operator Program)
Course Requirement: (Prerequisite Level 1)
• College or Equivalent:
- Basic Machining
- Basic Welding
- Basic Computer Programming
• Roll Form Training:
- Roll Form Tooling Installation (10 Hrs)
OTJ Requirements:
• 1000 Hours Running a Roll Form Line
• 1000 Hours Roll Form Tooling Setup
Level 3 (Operator Program)
Course Requirements: (Prerequisite Level 2)
• College or Equivalent:
- Technical Math 1
- Technical Communications
- Basic Die Design
• Roll Form Training:
- Roll Form Tooling and
Equipment Troubleshooting (10 Hrs)
OTJ Requirements:
• 1000 Hours Running a Roll Form Line
• 1000 Hours Roll Form Tooling Setup
• 1000 Hours Roll Form Tooling and
Equipment Troubleshooting
• 1000 Hours Running a Roll Form Line
• 1000 Hours Roll Form Tooling Setup
• 1000 Hours Roll Form Tooling and
Equipment Troubleshooting
• 1000 Hours Advanced Roll Form Troubleshooting
Roll Form Operator Skilled Trade Certificate Program
On-the-Job (OTJ) Experience Requirements
Through documented work experience, applicant must have achieved proficiency in:
Running a Roll Form Line
• Start up the roll form line
• Change coils
Tooling Setup
•
•
•
•
Changeover of roll form tooling
Follow a setup chart
Make minor adjustments
Adjust a straightener
Roll Form Tooling and Equipment Troubleshooting
•
•
•
•
Troubleshoot roll tooling and setup problems
Perform machine face alignments
Stack and wire roll form tooling
Troubleshoot material issues
Advanced Roll Form Troubleshooting
•
•
•
•
Roll form tooling design review
Basic roll tooling design
Tooling build specifications
Product and process development
Technical Roll Form Training
Classroom portion of the program.
Roll Form Tooling Installation 10 Hours (Level 2)
•
•
•
•
•
•
•
RFS – 101 Roll Form Tooling Definitions and Capabilities
RFS – 102 Roll Form Tooling Design Terms
RFS – 103 Roll Form Machine and Tooling Terms
RFS – 104 Roll Form Tooling Manufacture
RFS – 105 Typical Roll Forming Processes
RFS – 107 Roll Form Tooling Installation
RFS – 108 Product Terms and Conditions
Roll Form Tooling and Equipment Troubleshooting 10 Hours (Level 3)
•
•
•
•
•
RFS – 106 Machine Face Alignment
RFS – 109 Troubleshooting and Maintenance
RFS – 110 Straightening and Sweeping
RFS – 111 Material Conditions
RFS – 112 Roll Forming Lubricants
Advanced Roll Form Troubleshooting 10 Hours (Level 4)
•
•
•
•
•
•
•
RFS – 113 Roll Form Tooling Design Review
RFS – 204 Product Design Considerations for Roll Forming
RFS – 207 Basic Roll Tooling Design
RFS – 210 Product Development and Prototyping
RFS – 303 Roll Form Tooling Approval Process
RFS – 304 Roll For Tooling Build Specifications
RFS – 305 Determining the Proper Roll Forming Process
Roll Form Operator Skilled Trade Certificate Program
Required Courses
College-or-equivalent courses must meet the following criteria for curriculum content:
SPC (Statistical Process Control)
Basic Machining
The course must instruct the students in the methods and techniques for improving quality and
productivity in all types of industries. The course must
be project oriented and team based.
The course must provide theory and hands on
experience in the practical aspects of machining.
Topics Covered:
• Operating a prevention system versus a
detection system of quality control
• Defining and identifying inhibitors to quality
and how to overcome them
• Chart construction
• Problem solving using Pareto Analysis
• Process flow charts
Topics Covered:
• Industrial Safety
• Precision Measuring
• Common Manufacturing materials
• Fasteners
• Operation of Basic Machine Tools
- Grinders
- Drill Presses
- Mills
- Lathes
• Cause and effect diagrams
Basic Welding
Blueprint Reading
The course must teach the individual to visualize
and interpret prints.
Topics Covered:
The course must cover the theory and practice of
arc welding and of oxyacetylene welding and cutting.
Topics Covered:
• Setup of welding equipment
• Introduction to drafting
• Fuse welding
• Drafting and blueprint reading procedures
• Brazing
• Title block
• Soldering
• Materials
• Cutting with a torch
• Notes and drawing changes
• Hot forming of metal
• Machining specifications
• TIG and MIG welding
• Reading blueprints in specialized areas
• Current practices, symbols, and terminology
• Reading advanced blueprints
Basic Computer Programming
Industrial Safety
This course must teach a first aid, prevention, and
cardiopulmonary resuscitation (CPR/AED) to prepare
individuals to respond to injuries and illnesses that
may arise in the workplace.
Topics Covered:
This course must cover BASIC computer
programming language as well as the use of
spreadsheets and document control. Microsoft Word
and Microsoft Excel required.
Topics covered:
• Mathematical computation
• Provides workplace knowledge and skills
necessary to prevent, recognize, and provide
basic care for injuries and sudden illnesses
until advanced medical personnel arrive to
take over
• Data handling and editing
• Basic safety laws (OSHA and HAZMAT)
• Sequential file processing
• Branching
• Subroutines
• Array manipulation
• Design, write, test, and document programs
- Microsoft Word
- Microsoft Excel
Roll Form Operator Skilled Trade Certificate Program
Required Courses – page 2
Technical Math 1
Metallurgy
The course must present the fundamentals of
algebra and geometry as applied to the technical and
industrial field.
This course must cover the study of physical,
chemical, and electrical properties of metals and their
alloys, as well as the effect on these properties of
various mechanical and thermal treatments. The many
indications of these properties, and tests to establish
their magnitude, must also be included.
Technical Communications
This course must cover technical communication,
both oral and written, for industry, with the major
emphasis placed on effective written communications.
Topics Covered:
• Intercultural communication strategies
Technical Math 2
The course must provide a thorough study of
basic trigonometry, with applications to technical and
industrial problems.
• Revision and proofreading skills
• Technical correspondence, i.e., operator
and setup instructions and technical reports
• Develop and organize thoughts
• Write clearly, accurately, and quickly
• Technical writing styles, formats, and
techniques
Basic Die Design
This course must cover basic fundamentals
in die design, with standard die components and
fundamental die design concepts stressed.
Topics Covered:
• Design of blanking dies
• Design of compound blank and pierce dies
• Design of progressive dies
• Design of shear dies
GD&T
This course must cover the study and interpretation
of Geometric Dimensioning and Tolerancing as
specified in the National Standard, Y14.5M, published
by the American Society of Mechanical Engineers.