Modifying aircraft armament systems and components
Overview
This standard identifies the competences you need to carry out modifications on aircraft armament systems and components, in accordance with approved procedures. It covers both fixed wing and rotary winged aircraft systems. The systems and components may have to be modified for a number of reasons, which could include performance being out of specification, inherent design problems, changes to customer specification, or assembly problems.
You will be required to prepare the work area, ensuring that it is safe and free from hazards, checking that the correct component parts requiring modification are available, obtaining all relevant and current documentation, obtaining the tools and equipment required for the modification and checking that they are in a safe and usable condition. In carrying out the modification, you will be required to follow all appropriate procedures and specified techniques.
The system and its components could be modified using a number of methods and techniques including, where appropriate, adjusting, removing, replacing, and repairing, or by manufacturing new components by machining, welding, fabricating or bonding. Component parts that are modified must be checked for accuracy, security and completeness and that they function as per the specification.
Your responsibilities will require you to comply with organisational policy and procedures for the modification activities undertaken and to report any problems with these activities that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You will ensure that all tools, equipment and materials used are correctly accounted for on completion of the activities and that all necessary job/task documentation is completed 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 necessary modification methods, techniques and procedures to the aircraft armament systems and components. You will understand the systems and components being modified, including the reasons for the modification and their application and you will know about the tools and equipment required, 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 modification. 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
- obtain the relevant specification and job instructions for the modification being performed
- confirm and agree what modification is to be carried out to meet the specification
- determine how the product and/or asset will be prepared for the modification
- check that any materials and equipment required are available and that they are suitable for the work to be carried out
- carry out the modification to achieve the required changes, in line with agreed instructions and specifications
- complete the relevant documentation, in accordance with organisational requirements
- deal promptly and effectively with problems within your control and report those that cannot be solved
- leave the aircraft and armament system 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 while carrying out modifications of aircraft armament systems and components (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 modification activities and the responsibility these requirements place on you
- COSHH regulations with regard to substances used in the modification process
- the requirements and importance of understanding and applying human factors as defined by the regulatory requirements and the potential impact if these are not adhered to
- the hazards associated with modifying aircraft armament systems and components 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 modification activities
the precautions to be taken to prevent electrostatic discharge (ESD) damage to circuits and sensitive components (such as use of earthed wrist straps)
- 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 modification activities
- how to extract and use information from engineering drawings and related specifications
- how to interpret first and third angle drawings, imperial and metric systems of measurement, work piece reference points and system of tolerance
- how to carry out currency/issue checks on the specifications you are working with
- the reasons why systems and components may require modification
- preparations to be undertaken on the components prior to carrying out the modification
- the various methods that could be used to modify assemblies (such as adjust, remove and replace, repair and manufacture)
- the techniques that can be used, where appropriate, to modify the assembly (such as fabrication, welding, bonding, mechanical fitting, electrical and electronic or fluid/air fitting, machining)
- the quality control procedures to be followed during the modification and the importance of adhering to them
- how to conduct any necessary checks to ensure the accuracy, position, security, function and completeness of the modification
- 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
- the importance of ensuring that all tools, equipment and components are accounted for and returned to their correct location on completion of the modification activities
- problems associated with carrying out modifications on aircraft armament systems and components 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 modification of the aircraft armament systems and components:
- obtain and use the appropriate documentation (such as job instructions, aircraft modification 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 modification 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 certification/calibration date
- obtain clearance to work on the aircraft components and observe all relevant isolation and safety procedures
- ensure that correct part numbers are used, including (where appropriate) left or right handed parts
- follow safe practice/approved modification techniques and procedures at all times
- return all tools and equipment to the correct location on completion of the modification activities
- dispose of waste materials in accordance with approved procedures
Carry out the modification, using two of the following methods:
- adjustment
- modify existing components
- remove and replace with new components
- manufacture of new components
Complete the modification, using two of the following techniques:
- dismantling and re-assembling
- fluid/air power fitting and assembly
- fabrication
- hand fitting
- bonding
- welding
- electrical fitting and assembly
- adjusting
- machining
Carry out modifications on three of the following types of aircraft armament assembly:
- holding mechanism
- drive mechanism
- pipework system
- operating system
- fluid power system
- safety mechanism
- control mechanism
- delivery system
- assembly structure (such as framework, casings, panels)
- other specific equipment
Use appropriate equipment to carry out quality checks on the modified equipment, to include eight of the following:
- dimensions
- orientation
- bearing end float
- positional accuracy
- alignment
- function
- freedom of movement
- completeness
- earth bonding and electrical continuity
- operating/working clearances
- component security
- freedom from damage or foreign objects
- other specific check
Carry out modifications to systems/components, in accordance 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
- computer records
- job cards
- aircraft service/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