Carry out routine assembly of heavy goods and public service vehicle body parts and components

Business Sectors (Suites): Coachbuilding
Developed by: IMI
Approved on: 30 Mar 2020


This standard is about the routine assembly of non-complex vehicle body parts and components required in the process of heavy goods and public service vehicle body building where the component or part is quickly assembled, positioned and installed. The assembly methods used are pre-determined either by duplicating the original method or by following written or oral instructions and typically will not involve using more than two different joining techniques.

Performance criteria

You must be able to:

P1. use the appropriate personal protective equipment when assembling vehicle body **parts and components** 
P2. support your assembly activities by reviewing 

P2.1. vehicle technical data, drawing and diagrams 
P2.2. assembly procedures and techniques
P2.3. legal requirements 
P3. ensure that the specified components are available and that they are in a usable condition
P4. select, prepare and use correctly all the tools and equipment required following manufacturers' instructions  
P5. assemble body parts and components following: 

P5.1. manufacturers' data and instructions 
P5.2. your workplace manuals and procedures 
P5.3. health, safety, environmental and legal requirements 
P6. work in a way which minimises the risk of: 

P6.1. damage to other vehicle systems, parts and components 
P6.2. contact with leakage and hazardous substances 
P6.3. damage to your working environment
P6.4. injury to self and others
P7. use the appropriate methods and techniques to assemble the components in their correct positions 
P8. secure the components using the specified connectors and securing devices 
P9. check the completed assembly to ensure that all operations have been completed and the finished assembly meets the required specification 
P10. deal promptly and effectively with problems within your control and report those that cannot be solved
P11. ensure your records are accurate, complete and passed to the relevant person(s) within the agreed timescale and in the format required
P12. complete all assembly activities within the agreed timescale 
P13. promptly report any anticipated delays in completion to the relevant person(s) 

Knowledge and Understanding

You need to know and understand:

*Legislative and organisational requirements and procedures *
K1. the legal requirements relating to the vehicle (including road safety requirements)
K2. the implications on an Operator’s Licence of not carrying out repairs and inspections correctly
K3. the legislation and workplace procedures relevant to: 

K3.1. health and safety 
K3.2. the environment (including waste disposal) 
K3.3. appropriate personal and vehicle protective equipment 
K4. your workplace procedures for: 

K4.1. recording remove and replace information 
K4.2. the referral of problems
K4.3. reporting delays to the completion of work
K5. the work that needs to be done and the standard required 
K6. the extent of your own responsibility and to whom you should report if you have problems that you cannot solve.  
K7. who to refer to for the assembly tools and equipment that you are not responsible for maintaining 
K8. the importance of documenting assembly information
K9. the importance of working to agreed timescales and keeping others informed of progress
K10. how to select a cost effective repair method
K11. the relationship between time and costs
K12. the importance of promptly reporting anticipated delays to the relevant person(s) 
K13. the hazards associated with working on or near high voltage electrical vehicle components

Use of technical information
K14. how to find, interpret and use sources of relevant information to assist in determining the correct assembly techniques to be used 
K15. the importance of using the correct sources of technical information

Tools and equipment *
K16. how to select, check and use all the *tools and equipment required for routine assembly of vehicle body parts and components and to know the control procedures for reporting any defects 

K17. the methods used to support large, heavy and fragile materials during the assembly process, including working at heights

Assembly methods and techniques *
K18. the preparation methods *required for the assembly methods that you use, for example, substrate preparation when adhesive bonding 
K19. the different joining and fixing methods and techniques and when and how they should be used
K20. the assembly sequences used and the importance of adhering to them to ensure the work activity can be completed without hindrance 
K21. the need for assembling components temporarily, including, checking alignment, profile, dimensions, correct operation and to allow other work to be carried out without hindrance 
K22. the methods used to check compliance with specification, including checks for correct operation, accuracy, alignment and profile, and security of parts and components


1. Assembly **methods and techniques** include: 

1.1. fasteners and retainers 
1.2. adhesives 
1.3. gaskets (e.g. Indirect glazing) 
1.4. lifting and supporting equipment 
1.5. manual lifting and carrying 
1.6. positioning and securing 

2. Parts and components include:  

2.1. exterior claddings 
2.2. interior claddings 
2.3. frame and structural components 
2.4. interior trim 
2.5. xxterior trim 
2.6. body furniture and hardware 
2.7. glazing 
2.8. door parts 
2.9. mechanical components 
2.10. electrical components 

3. Tools and equipment are:

3.1. hand tools
3.2. manufacturer’s specified and specialist tools
3.3. workshop equipment
3.4. lifting equipment

Scope Performance

Scope Knowledge





*This section contains examples and explanations of some of the terms used but does not form part of the standard.*
**Agreed timescales**
Examples include: manufacturer’s recommended work times, job times set by your company or a job time agreed with a specific customer.
**Heavy goods and public service vehicles**
These are medium and large goods vehicles, buses and coaches of 3500kgs gross vehicle mass (GVM) and above.
**Sources of information**
Examples include: company procedures, assembly and detail drawings, data sheets, specifications, inspection sheets, vehicle records, workshop manuals, manufacturer's manuals and bulletins, wiring circuits and diagrams, repair schedules and insurance assessor reports, DVSA manual

Links To Other NOS

External Links

Version Number


Indicative Review Date

31 Mar 2024





Originating Organisation


Original URN


Relevant Occupations

Bus and Coach Body Repairer, Coachbuilder

SOC Code



Routine; assembly; heavy goods and public service vehicle; body; components; parts;