Producing composite and/or metallic aircraft major assemblies
Overview
This standard identifies the competences you need to assemble major aircraft composite and metallic assemblies, in accordance with approved procedures. It covers both fixed wing and rotary winged aircraft. You will be required to select the appropriate tools and equipment to use, based on the assembly operations required and to check that they are in a safe and serviceable condition. In carrying out the assembly operations, you will be required to follow laid-down procedures and specific assembly techniques, in order to assemble the various components into major assemblies that make up front, rear and centre fuselage sections, floors, wings, large engine nacelles, fin and tail sections, nose sections, pressurized doors, cabins or cockpits. The assembly activities will also include making all necessary checks and adjustments to ensure that components are correctly positioned and have accurate skin lines, that fasteners are tightened to the correct torque and function as per the specification and that the assembly is free from damage and has an appropriate cosmetic appearance.
Your responsibilities will require you to comply with organisational policy and procedures for the assembly activities undertaken and to report any problems with the assembly activities, materials or equipment that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You will be expected to work with minimal supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.
Your underpinning knowledge will provide a good understanding of your work and will provide an informed approach to applying the assembly techniques and procedures. You will understand the structure being assembled and its application and will know about the equipment, relevant materials and fastening devices, in adequate depth to provide a sound basis for carrying out the activities to the required specification.
You will understand the safety precautions required when carrying out the assembly activities. You will be required to demonstrate safe working practices throughout and will understand the responsibility you owe to yourself and others in the workplace.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- follow the relevant instructions, assembly drawings and any other specifications
- ensure that the specified components are available and that they are in a usable condition
- use the appropriate methods and techniques to assemble the components in their correct positions
- secure the components using the specified connectors and securing devices
- check the completed assembly to ensure that all operations have been completed and the finished assembly meets the required specification
- deal promptly and effectively with problems within your control and report those that cannot be solved
- complete the relevant documentation, in accordance with organisational requirements
- leave the work area and assembly in a safe and appropriate condition, free from foreign object debris on completion of the activities
Knowledge and Understanding
You need to know and understand:
- the specific safety precautions to be taken whilst carrying out the assembly (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials)
- the health and safety requirements of the work area in which you are carrying out the assembly activities and the responsibility these requirements place on you
- the hazards associated with producing major aircraft assemblies and with the tools and equipment that are used and how to minimise them and reduce any risks
- the personal protective equipment and clothing (PPE) to be worn during the assembly activities
- the various types of drawing and specifications that are used during the assembly
- how to identify the components to be used; component identification systems (such as codes and component orientation indicators)
- preparations to be undertaken on the components prior to fitting them into the assembly
- the assembly methods and procedures to be used and the importance of adhering to the procedures
- how the components are to be aligned and positioned prior to securing, and the tools and equipment that are used, including jigs and fixtures
- the various mechanical fasteners that will be used and their method of installation (such as open and blind rivets, threaded fasteners, special securing devices)
- the importance of using the specified fasteners for the assembly and why you must not use substitutes
- dealing with components or fastening devices incorrectly assembled, damaged or having other faults
- the application of sealants and adhesives within the assembly activities, and the precautions that must be taken when working with them
- why electrical bonding is critical and why it must be both mechanically and electrically secure
- the quality control procedures to be followed during the assembly operations
- how to conduct any necessary checks to ensure the accuracy and quality of the assemblies produced
- recognising defects (such as skin blemishes, poor skin lines, ineffective fasteners, foreign object damage)
- the methods and equipment used to transport, handle and lift the components into position and how to check that the equipment is within its current certification dates
- how to check that the tools and equipment to be used are correctly calibrated and are in a safe, tested and serviceable condition
- the importance of ensuring that all tools are used correctly and within their permitted operating range
- why tool/equipment control is critical and what to do if a tool or piece of equipment is unaccounted for on completion of the activities
- the importance of ensuring that the completed assembly is free from dirt, swarf and foreign objects
- problems with the assembly operations and the importance of informing appropriate people of non-conformances
- the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
Scope/range
Scope Performance
Carry out all of the following activities during the assembly of components:
- obtain and use the appropriate documentation (such as job instructions, aircraft assembly drawings, planning and quality control documentation, aircraft procedures and specifications)
- adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
- provide and maintain a safe working environment for the assembly activities
- obtain the correct tools and equipment for the activity and check that they are in a safe, tested and usable condition and within current calibration date
- follow safe practice/approved assembly techniques and procedures at all times
- ensure that correct part numbers are used, including (where appropriate) left or right handed parts
- return all tools and equipment to the correct location on completion of the assembly activities
- dispose of waste materials in accordance with approved procedures
Produce one of the following aircraft major assemblies:
- front fuselage section
- floor
- fin
- tail plane
- centre fuselage section
- cockpit/cabin
- pressurized external/cargo doors
- nose
- cabin roof
- rear fuselage section
- large commercial turbofan nacelle
- wing
- side structures
- flying control surfaces
Apply all of the following assembly methods and techniques:
positioning and aligning components for cosmetic appearance
and skin lines to drawing requirements
- applying sealant/adhesives
- drilling and finishing holes (such as countersinking, deburring, spot facing)
- securing components, using mechanical fasteners (such as threaded devices, liquid shimming, riveting, taperlok, interference/clearance fit and bonding) to drawing requirements
- applying bolt locking methods (split pins, wire locking, lock nuts, stiff nuts)
- electrical bonding of components
Assemble components which include four of the following:
- ribs
- brackets
- jumper braids
- bonding clips
- earthing straps
- spars
- packers
- stringers
- doublers
- pipes, unions/joints
- skins/covers
- frames
Carry out quality and accuracy checks which include three from:
- cosmetic appearance
- freedom from damage
- electrical bonding and continuity
- accuracy of skin lines
- torque loading checks
Produce assemblies which comply with one of the following standards:
- Civil Aviation Authority (CAA)/European Aviation Safety Agency (EASA)
- Ministry of Defence (MoD)
- Military Aviation Authority (MAA)
- Federal Aviation Authority (FAA)
- Aerospace Quality Management Standards (AS)
- BS, ISO or BSEN standards and procedures
- customer standards and requirements
- company standards and procedures
- manufacturers standards and procedures
Complete the relevant paperwork, to include one from the following and pass it to the appropriate people:
- build records
- log cards
- job cards
- aircraft flight log
- other specific recording method
Scope Knowledge
Values
Behaviours
You will be able to apply the appropriate behaviours required in the workplace to meet the job profile and overall company objectives, such as:
- strong work ethic
- positive attitude
- team player
- dependability
- responsibility
- honesty
- integrity
- motivation
- commitment