Producing aircraft composite assemblies

This standard identifies the competences you need to produce aircraft composite assemblies from composite components and non-composite components, in accordance with approved procedures. It covers both fixed wing and rotary winged aircraft. You will be required to use appropriate drawings, specifications and documentation to produce aircraft composite assemblies, using the correct techniques. You will produce a range of aircraft composite assemblies, incorporating a variety of features and using a range of techniques and processes.

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, equipment or materials that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of 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 aircraft composite assembly techniques and procedures. You will understand the aircraft composite assembly techniques used and their application, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring that the finished assembly is to the required specification.

You will understand the safety precautions required when carrying out the assembly activities and when using the associated tools and equipment. You will be required to demonstrate safe working practices throughout and will understand the responsibility you owe to yourself and others in the workplace.

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1. work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
2. follow the relevant instructions, assembly drawings and any other specifications
3. ensure that the specified components are available and that they are in a usable condition
4. use the appropriate methods and techniques to assemble the components in their correct positions
5. secure the components using the specified connectors and securing devices
6. check the completed assembly to ensure that all operations have been completed and the finished assembly meets the required specification
7. deal promptly and effectively with problems within your control and report those that cannot be solved
8. complete the relevant documentation, in accordance with organisational requirements
9. leave the work area and assembly in a safe and appropriate condition, free from foreign object debris on completion of the activities

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1. health and safety precautions to be taken and procedures used when working with aircraft composite materials, consumables, tools and equipment in the specific work area
2. the hazards associated with producing aircraft composite assemblies and with the materials, consumables, tools and equipment used and how to minimise them and reduce any risks in the work area
3. protective equipment that is needed for personal protection (PPE) and where required the protection of others
4. the application of COSHH regulations in relation to the storage, use and disposal of aircraft composite materials and consumables
5. the specific workshop environmental conditions the must be observed when assembling aircraft composite mouldings (such as temperature, humidity, styrene levels to threshold limits, fume/dust extraction systems and equipment)
6. how to extract and use information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS, ISO or BSEN standards) in relation to work undertaken
7. how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing
8. quality procedures used in the workplace to ensure production control (in relation to currency, issue, meeting specification) and the completion of such documents
9. conventions and terminology used for assembly activities (such as metric and imperial threads, rivet specifications, clearances, types of fittings)
10. the types of component trimming/cutting methods and preparation methods available
11. the visual identification of cured aircraft composite materials
12. assembly operations and their sequence
13. why electrical bonding is critical and why it must be both mechanically and electrically secure
14. methods for handling composite assemblies throughout the assembly activities
15. the identification and rectification of defects in aircraft composite assemblies
16. tools and equipment used in assembly activities and their care, preparation and control procedures

17. 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

18. the problems that can occur with the activities and how these
    can be overcome

19. the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve

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1. Carry out all of the following during the assembly activities:

   1. obtain and use the appropriate documentation (such as job instructions, assembly drawings, planning and quality control documentation, material data sheets, specifications)
   2. 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
   3. provide and maintain a safe working environment for the composite assembly activities
   4. obtain the correct tools and equipment for the activity and check that they are in a safe and usable condition
   5. follow safe practice/approved composite assembly techniques and procedures at all times
   6. return all tools and equipment to the correct location on completion of the composite assembly activities
   7. dispose of waste materials in accordance with approved procedures

2. Carry out all of the following activities when preparing for the assembly activity:

   1. check that mouldings are correct and complete     
   2. select the correct equipment for the activity
   3. check for any defects in the mouldings                 
   4. check that the equipment is suitable for use
   5. check that components are correct and complete   
   6. check the availability of required ancillary materials
   7. identify and protect the moulding and components in the work area

3. Produce two of the following types of composite assembly:

   1. trial assemblies   
   2. one-off assemblies    
   3. batch assemblies    
   4. assembly line

4. Produce assemblies that incorporate four of the following features:

   1. loose fit tolerances     
   2. non-permanent fixing 
   3. joggle joins              
   4. return joins
   5. close fit tolerances       
   6. shape location        
   7. permanent fixing          
   8. overlap joins
   9. strap joins

5. Produce composite assemblies that require four of the following methods to be used:

   1. fettling   
   2. clamping    
   3. aligning      
   4. assembly sequences
   5. pinning     
   6. trial fitting 
   7. assembly jigs
   8. tongue and groove
   9. datum points
   10. orientation

6. Produce composite assemblies that use three of the following joining methods:

   1. thread inserts          
   2. mechanical fasteners
   3. anchor nuts    
   4. blind fasteners
   5. adhesive bonding
   6. pinning
   7. thermo welding
   8. rivets
   9. quick-release fasteners   
   10. click bonds
   11. other specific joining method

7. Include three of the following composite components in the aircraft assemblies:

   1. trim                     
   2. body panels 
   3. structural     
   4. core materials   
   5. inserts
   6. closing panels       
   7. tubes                
   8. aerodynamic 
   9. sections               
   10. housings
   11. casings/covers
   12. other specific components

8. Include three of the following non-composite components in the aircraft assemblies:

   1. brackets
   2. fixtures
   3. metal components
   4. non-metallic components
   5. fittings     
   6. trim     
   7. finishing tapes   
   8. memory foam
   9. labels/decals
   10. surface films
   11. edge bands
   12. other specific component

9. Produce a range of aircraft composite assemblies which comply with one of the following standards:

   1. Civil Aviation Authority (CAA)/European Aviation Safety Agency (EASA)
   2. Ministry of Defence (MoD)
   3. Military Aviation Authority (MAA)
   4. Aerospace Quality Management Standards (AS)
   5. Federal Aviation Authority (FAA)

   6. BS, ISO or BSEN standards

   7. company standards and procedures

   8. customer standards and requirements
   9. manufacturers standards and procedures

10. Complete the relevant paperwork, to include one from the following and pass it to the appropriate people:

    1. build records                    
    2. job cards.
    3. log cards                        
    4. aircraft flight log
    5. other specific recording method

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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

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3

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2024

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Current

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Original

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Enginuity

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SEMAE3026

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Engineer, Engineering, Engineering and Manufacturing Technologies, Engineering Technicians

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5234

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engineering; aeronautical; manufacture; composite assemblies; double curvature; stiffened composite; methods; resin; fibre

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