Producing aircraft piston engine assemblies
Overview
This standard identifies the competences you need to carry out assembly operations to produce aircraft piston engine assemblies, in accordance with approved procedures. It covers both fixed wing and rotary winged aircraft engines. You will be required to obtain all the required tools and equipment for the assembly operations and to check that they are in a safe and usable 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 and unit sub-assemblies into the piston engine assembly. The assembly activities will also include making all necessary checks and adjustments to ensure that components are correctly orientated positioned and aligned, that moving parts have the correct working clearances, all fasteners are tightened to the correct torque and that the assembled parts function as per the specification.
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 ensure that all tools, equipment and materials used in the installation are correctly accounted for on completion of the activities and to complete all necessary job/task documentation accurately and legibly. 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 the assembly techniques and procedures. You will understand the aircraft piston engine being assembled and its application and will know about the equipment, relevant components 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 aircraft piston engine/sub-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
- COSHH Regulations with regard to the substances used in the assembly process
- the hazards associated with producing aircraft piston engine assemblies and with the tools and equipment 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 to complete fitting practices, meeting regulatory and organisational requirements (such as torque tightening, wire locking, fitting wire thread inserts, fitting O-ring seals, fitting lock nuts and swage nuts, blue bedding components)
- 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 bolts, nuts, rivets, threaded fasteners, special securing devices)
- the importance of using the specified mechanical fastening devices for the assembly and why you must not use substitutes
- why electrical bonding is critical and why it must be both mechanically and electrically secure
- 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
- 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
- how to detect assembly defects and what to do to rectify them (such as ineffective fasteners, foreign object damage)
- how to move large components and assemblies; 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
- the importance of ensuring that the completed assembly is free from dirt, swarf and foreign objects
- the importance of ensuring that all tools, equipment and components are accounted for and returned to their correct location on completion of the assembly activities
- 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
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