Repairing and modifying aircraft mechanical assemblies and components
Overview
This standard identifies the competences you need to carry out modifications on aircraft mechanical assemblies and components, in accordance with approved procedures. It covers both fixed wing and rotary winged aircraft assemblies and components. The assemblies or components may have to be modified for a number of reasons, which could include performance out of specification, inherent design problems, changes to customer specification, or assembly problems. You will be required to prepare the work area, ensuring it is safe and free from hazards, to check the correct component parts requiring modification are available, to obtain all relevant and current documentation and to obtain the tools and equipment required for the modification, checking that they are in a safe and usable condition. In carrying out the modification, you will be required to follow the appropriate company or customer procedures and specified techniques.
The aircraft assembly and its components could be modified using a number of methods and techniques including, where appropriate, adjusting, removing and replacing, or repairing, or by manufacturing new components by machining, welding, fabricating or bonding. Component parts that are modified must be checked for accuracy, security, 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 the modification activities, materials or equipment that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to ensure that all tools, equipment and materials used in the modification 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 modification methods, techniques and procedures in an aeronautical manufacturing environment. You will understand the aircraft mechanical product being modified, including its application and reason for the modification and will know about the tools and equipment required, in adequate depth to provide a sound basis for carrying out the activities to the required aircraft specification.
You will understand the safety precautions required when carrying out the modification 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
- 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 mechanical assembly 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
carry out quality checks on the completed modification
complete 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 work area and assembly in a safe and appropriate condition 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 on aircraft mechanical assemblies (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 modification activities and the responsibility these requirements place on you
- 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
- COSHH regulations with regard to the substances used in the modification process
- the hazards associated with modifying mechanical assemblies and how to minimise them and reduce any risks
- the personal protective equipment and clothing (PPE) to be worn during the modification activities
- the various types of drawing and specifications that are used during the modification
- how to extract and use information from engineering drawings and related specifications (to include symbols and conventions to appropriate CAA, FAA, 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
- the reasons why aircraft mechanical assemblies 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, modify or manufacture new parts)
the concepts and techniques that can be used, where appropriate, to modify the assembly (such as machining, welding, fabrication, bonding, mechanical fitting, electrical and electronic fitting)
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
- the methods and equipment used to transport, lift and handle components and assemblies
- 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 mechanical assemblies 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 activities:
- obtain and use the appropriate documentation (such as job instructions, modification drawings, quality control documentation, planning documentation)
- 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
- follow safe practice/approved modification and repair techniques at all times
- check that all cables, extension leads or air supply hoses are in a tested and serviceable condition
- check that all tools and measuring equipment are within current calibration/certification dates
- use lifting and slinging equipment in accordance with health and safety guidelines and procedures
- ensure that all components to be assembled are free from damage, foreign objects, dirt or other contamination before assembling them
- return all tools and equipment to the correct location on completion of the assembly activities
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 power fitting and assembly
- welding
- hand fitting
- bonding
- fabrication
- electrical fitting and assembly
- adjusting
- machining
- other specific technique
Carry out modifications on one of the following parts of the assembly:
- holding mechanism
- drive mechanism
- transfer system
- operating system
- fluid power system
- pipework system
- control mechanism
- delivery system
- safety mechanism
- assembly structure (such as framework, casings, panels)
- compressor
- combustion
- turbine
- other specific mechanism
Carry out the quality checks, to include eight from the following, using appropriate equipment:
- dimensions
- orientation
- bearing end float
- positional accuracy
- alignment
- function
- freedom of movement
- completeness
- earth bonding and electrical continuity
- operating/working clearances
- component security
- free from damage or foreign objects
Ensure that the repairs and modifications comply with one of the following quality and accuracy standards:
- Civil Aviation Authority (CAA)/European Aviation Safety Agency (EASA)
- Ministry of Defence (MoD)
- Military Aviation Authority (MAA)
- Federal Aviation Authority (FAA)
- Aerospace Quality Management Standards (AS)
- BS, ISO or BSEN standards and procedures
- customer standards and requirements
- company standards and procedures
- specific system requirements
- 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 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