Set-out and assemble 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 setting out and assembly of heavy goods and public service vehicle body parts and components as part of a complex/specialist build, modification or conversion. It includes selection of the most efficient and effective assembly method to use considering build factors and typically may involve more than two different joining techniques where the materials/components to be assembled may be non-standard, difficult to obtain or expensive.

If, in the course of the work activity, the work specification requires changing or modifying, it is expected that you would use your knowledge, skills and experience to initiate an alternative route without compromising the quality of the assembly.

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 work 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/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 reporting the progress and completion of the build including the provision of information on the parts used, follow up work and potential problems
K10. workplace procedures for determining the most cost effective/time efficient option
K11. the relationship between time, costs and productivity
K12. the hazards associated with working on or near high voltage electrical vehicle components

Use of technical information
K13. How to find, interpret and use sources of relevant information to assist in determining the correct assembly techniques to be used 

Tools and equipment *
K14. how to select, check and use all the *tools and equipment required for the assembly of vehicle body parts and components and to know the control procedures for reporting any defects
K15. the methods used to support large, heavy and fragile materials during the assembly process, including working at heights 

*Assembly methods and techniques *
K16. the preparation methods required for the assembly methods that you use, for example, substrate preparation when adhesive bonding  
K17. the assembly sequences used, for example, riveting roof panels and fitting glazing units 
K18. the need for adherence to the assembly sequence to ensure the work activity can be completed without hindrance and/or modified to cater for contingencies
K19. the need for assembling components temporarily, including, checking alignment, profile, dimensions, correct operation and to allow other work to be carried out
K20. the conflicting and supporting variables which determine the choice of assembly method used, for example, tolerance, quality, customer requirements, the materials being joined, costs and timescales
K21. the methods used to check compliance with work specification, including checks for correct operation, accuracy, alignment and profile, and security of components/parts


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 
1.7. setting out to include alignment and dimensional accuracy
2. **Parts and components** include:  
2.1. exterior claddings 
2.2. interior claddings 
2.3. floor structure
2.4. frame and structural components 
2.5. interior trim 
2.6. exterior trim 
2.7. body furniture and hardware 
2.8. glazing 
2.9. door units 
2.10. mechanical components 
2.11. 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, work 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


SOC Code



Set-out; assemble; heavy goods vehicle; public service vehicle; body; components; parts