Assembling aircraft transparencies
Overview
This standard identifies the competences you need to assemble aircraft transparencies, in accordance with approved procedures. It covers both fixed wing and rotary winged aircraft. You will be required to use appropriate manufacturing drawings, specifications and documentation to assemble aircraft transparencies ready for use. Assembly techniques will include the use of rubber edge sealing and bonding, mechanical fasteners and adhesive bonding, as applicable.
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 used 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 transparency assembly methods and procedures. You will understand the assembly methods used, and their application and will know about the materials, tools and equipment used, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring that the completed assembly is 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 aircraft transparency 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/or aircraft 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 personal protective equipment and clothing (PPE) to be worn during the assembly activities
- the hazards associated with producing aircraft transparency assemblies and how to minimise them and reduce any risks
- 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)
- how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing
- 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 these procedures
- how the components are to be aligned and positioned prior to securing, and the tools and equipment that are used (including jigs, fixtures and support trolleys)
- the various mechanical fasteners that will be used and their method of installation
- 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, adhesives and gaskets within the assembly activities and the precautions that must be taken when working with them
- the use of gaskets within the assembly activities and the precautions/procedures that must be taken/observed when assembling them
- 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 excess adhesives/sealants, ineffective fasteners, foreign object damage)
- the methods and equipment used to transport, lift and handle the components 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 and serviceable condition
- the importance of ensuring that all tools are used correctly and within their permitted operating range (such as vacuum suckers, drilling and de-burring equipment and applicator guns for adhesives)
- 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 during the assembly activity:
- 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
- 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 two the following types of aircraft transparency assembly:
- aircraft windows
- aircraft pilot's windscreens
- aircraft canopies
- other specific assemblies
Assemble aircraft transparencies using all of the following methods and techniques:
- rubber edge sealing and bonding
- mechanical fastener attachments
- adhesive bonding
- gasket sealing
Assemble transparencies using all of the following types of component:
- moulded acrylic transparencies
- moulded windscreen assemblies
- moulded polycarbonate transparencies
Assemble transparencies in compliance with one of the following standards:
- Civil Aviation Authority (CAA)/European Aviation Safety Agency (EASA)
- Ministry of Defence (MoD)
- Military Aviation Authority (MAA)
- Aerospace Quality Management Standards (AS)
- customer standards and requirements
- Federal Aviation Authority (FAA)
- company standards and procedures
- BS, ISO or BSEN 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
- job cards
- log 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