Assembling aircraft airframe ancillary components
Overview
This standard identifies the competences you need to assemble aircraft airframe ancillary components, in accordance with approved procedures. You will be required to select the appropriate tools and equipment to use, based on the assembly operations required, 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 into detail assemblies. Typical assemblies to be produced will include trunking and ducting, box sections, stringers, frames, panels, trays, skins, ribs, tanks, galleys, avionic cabinets, mission consoles and other small assemblies, as appropriate.
Your responsibilities will require you to comply with organisational policy and procedures for the activities undertaken, and to report any problems with the assembly activities, materials or equipment used that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will need to ensure that all tools, equipment and materials used in the assembly are correctly accounted for on completion of the activities, and you must complete all necessary job/task documentation accurately and legibly.
You will be expected to work either with a high level of supervision or as a member of a team, and you will take personal responsibility for your own actions and for the quality and accuracy of the work that you carry out. Where team working is involved, you must demonstrate a significant personal contribution during the team activities in order to satisfy the requirements of this standard, and you must demonstrate competence in all the areas required by the standard.
Your underpinning knowledge will be sufficient to provide a sound basis for your work, and will provide an informed approach to applying assembly techniques and procedures. You will understand the components being assembled, and their application, and will know about the relevant materials and fastening devices, in adequate depth to provide a sound basis for carrying out the activities and for ensuring that the work 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 responsibilities 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 legislation, regulations, directives and other relevant 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
Knowledge and Understanding
You need to know and understand:
- the specific safety precautions to be taken whilst carrying out the assembly operations (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 protective clothing (PPE) to be worn during the assembly activities
- the hazards associated with producing aircraft assemblies, and with the tools and equipment used, and how they can be minimised
- how to identify the components to be used; component identification systems; codes used 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, and the tools and equipment that are to be used, including jigs and fixtures
- the methods used to hold the components in their correct position, prior to securing them with the appropriate fasteners
- the various mechanical fasteners that will be used, and their method of installation (including open and blind rivets, threaded fasteners, special securing devices)
- the importance of using the specified fasteners for the particular assembly, and why you must not use substitutes
- what to do if the components or fastening devices are not assembled correctly, are damaged, or have other faults
- the application of sealants and adhesives within the assembly activities, and the precautions that must be taken when working with various adhesives and sealants
- 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 check that the tools and equipment to be used are correctly calibrated, and are in a safe and useable condition
- the importance of using all tools in the correct manner, and within their permitted operating range
- the importance of ensuring that the completed assembly is free from dirt, swarf and foreign objects
- the problems that can occur with the assembly operations, and how these can be overcome
- the recording documentation to be completed for the assembly activities undertaken and, where appropriate, the importance of marking and identifying specific pieces of work in relation to the documentation
- the extent of your own authority within the assembly activities, and whom to report to if you have problems that you cannot resolve
Scope/range
Scope Performance
Carry out all of the following during the assembly activities:
- Ensure that you have the correct documentation for the assembly operations (such as drawings, job instructions, aircraft standards)
- adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations
- ensure that all tools and equipment used are within current calibration dates
- maintain safe access and working arrangements for the area in which the assembly activities take place
- dispose of waste items in a safe and environmentally acceptable manner, in line with company procedures
- return all tools and equipment to the correct location on completion of the activities
- leave the work area in a safe condition and free from foreign object debris
Produce aircraft airframe ancillary component assemblies, which include three of the following:
- trunking/ducting
- frames
- galley components
- tanks
- box sections
- panels
- avionic cabinets
- skins
- ribs
- mission consoles
- stringers
- trays
- stairs
- other specific small assemblies
Apply all of the following assembly methods and techniques:
- ensuring that correct part numbers are used
- ensuring that the correct hand of components is used (left or right handed)
- positioning and aligning components for cosmetic appearance and skin lines
- applying sealants/adhesives
- electrical bonding of components
- securing components, using mechanical fasteners (such as threaded devices, rivets)
- applying bolt locking methods (split pins, wire locking, lock nuts, stiff nuts)
Assemble components which include four of the following:
- detail components
- frames
- ribs
- cleats
- spars
- pipes, unions and joints
- brackets
- skins
- jumper braids, bonding clips, earthing straps
- angles
- stringers
- aircraft general supplies
Carry out quality and accuracy checks, including three from the following:
- cosmetic appearance
- freedom from damage
- electrical bonding and continuity
- accuracy of skin lines
- torque loading checks
Produce assemblies which comply with one of the following standards:
- Civil Aviation Authority (CAA)
- Ministry of Defence (MoD)
- customer standards and requirements
- Federal Aviation Authority (FAA)
- company 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 log
Scope Knowledge
Values
Behaviours
Additional Information
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