Producing aircraft electrical sub-assemblies, cableforms and looms
Overview
This standard identifies the competences you need to produce aircraft electrical sub-assemblies, cableforms and looms, in accordance with approved procedures. It covers both fixed wing and rotary winged aircraft. You will be required to use appropriate drawings, methods of manufacture, standards and specifications to produce the various sub-assemblies, cableforms, looms and panels. You will be expected to cut, strip, solder, crimp and form loom assemblies and to position and secure equipment in the correct location on panels, using the specified/appropriate techniques and fastening devices.
The cableforms/looms to be assembled will include aircraft system cable assemblies, heavy duty cable assemblies, aircraft lighting cables, co-axial cables, fibre-optic cable assemblies, secure speech cables, headset leads, aircraft flying control system (AFCS) cable assemblies, databus looms and amalgamated looms. The equipment to be assembled will include circuit breaker/switch panels, control/relay panels, flightdeck/cockpit panels and avionic trays.
Your responsibilities will require you to comply with organisational policy and procedures for the production activities undertaken and to report any problems with the production, components 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 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 production procedures. You will understand the procedures and techniques for producing the aircraft sub- assemblies, cableforms and looms, and will know about the tools and techniques, 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 operations. 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 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 activities (such as 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 electrical assemblies and with the tools and equipment used and how to minimise them and reduce any risks
what constitutes a hazardous voltage and how to recognise victims of electric shock
how to reduce the risks of a phase to earth shock (such as insulated tools, rubber matting and isolating transformers)
the various types of drawing and specification that are used during the assembly activities and how to interpret the various symbols and abbreviations
- how to identify cables/components to be used and associated identification systems (such as cable/component markers)
- preparations to be undertaken on cable/components prior to assembly (such as loom forming, soldering preparation, preparing fibre-optic cables, polishing fibre-optic connections, data bus stripping)
- the assembly methods and techniques used (such as soldering, crimping, heat shrinking and cable forming)
- the methods and techniques used for the termination of fibre-optic and databus cables and the types of connector that are used
- assembly of screened and unscreened plugs and sockets and the difference between composite and metal plugs and sockets
- different types of cable protection and reasons for each type
- electrical bonding specifications and their importance
- dealing with cables/components that are incorrectly assembled, damaged or that have other faults
- the quality control procedures to be followed during the manufacturing operations
- how to conduct any necessary checks to ensure the accuracy and quality of the assemblies produced
- how to take electrostatic discharge (ESD) precautions and why are they needed
- the procedure for handling long lengths of cable
- the precautions needed when handling completed looms
- the precautions required for handling discrete components
- the importance of checking 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
- 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 manufacturing activities:
- obtain and use the appropriate documentation (such as job instructions, aircraft drawings, standards, wiring diagrams, planning and quality control documentation, aircraft standards 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 and wiring activities
- obtain the correct tools and equipment for the activity, and check that they are in a safe and usable condition and within current calibration date
- ensure that correct part numbers are used, including (where appropriate) left or right handed parts
- use appropriate techniques and procedures to produce the required sub-assemblies, cableforms and looms
- return all tools and equipment to the correct location on completion of the activities
Assemble two of the following types of aircraft electrical sub-assembly:
- circuit breaker/switch panels
- flightdeck/cockpit panels
- control/relay panels
- avionic trays
- other specific sub-assembly
Assemble four of the following types of aircraft cableform and loom:
- co-axial cable assemblies
- fibre-optic cables/assemblies
- AFCS cable assemblies
- heavy duty cable assemblies
- aircraft lighting cable assemblies
- databus looms
- aircraft system cable assemblies
- headset leads (mic-tel leads)
- amalgamated system looms
- secure speech cable assemblies
- other specific cableform or loom
Apply twelve the following sub-assembly methods and techniques:
- solder sleeve fitting
- crimping
- loom forming
- braiding
- cable protection
- soldering
- cable stripping
- heat shrinking
- terminal block breakouts
- data bus stripping
- high density connectors
- panel wiring
- screened plug and socket assembly
- unscreened plug and socket assembly
- polishing fibre-optic connections
- preparing fibre-optic cables
Use fifteen of the following components:
- ring tongue terminals
- contacts (soldered)
- discrete components
- lacing cord
- gore cables
- heat shrink devices
- terminal blocks
- module blocks
- connectors (multi-contact)
- contactors
- panels (bare)
- connectors (co-axial)
- filters
- circuit breakers
- contacts (crimped)
- tray-mount connectors
- bonding leads
- identification markers
- polished fibre-optic contacts
- clipping points
- printed circuit boards
- fibre-optic connectors
- cable ties
- p-clips
- relays
- lamps
- busbars
- wire cables
- databus cables
- switches
- other specific component
Produce assemblies 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
- 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