This standard identifies the competences you need to produce aircraft cableforms and looms, in accordance with approved procedures. You will be required to use appropriate drawings, wiring loom layout/templates, methods of manufacture, standards and specifications, to produce the various cableforms and looms. You will be expected to cut the appropriate cables to the required lengths, form and secure the loom assemblies, strip the appropriate amount of cable insulation, and solder and crimp the appropriate connectors to the cable ends, in the correct location, using the specified or appropriate techniques and fastening devices.

The equipment will include co-axial cable assemblies, heavy duty cable assemblies, aircraft system cable assemblies, secure speech cable assemblies, aircraft lighting assemblies, automatic flying control systems (AFCS) cable assemblies, and headset leads (mic-tel leads).

Your responsibilities will require you to comply with organisational policy and procedures for the production activities undertaken, and to report any problems with the 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 production of the cableforms 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 the cableform production techniques and procedures. You will understand the procedures and techniques for producing the aircraft 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 cableform/loom production 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.

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1. work safely at all times, complying with health and safety legislation, regulations, directives and other relevant guidelines
2. follow the relevant instructions, assembly drawings and any other specifications
3. ensure that the specified components are available and that they are in a usable condition
4. use the appropriate methods and techniques to assemble the components in their correct positions
5. secure the components using the specified connectors and securing devices
6. check the completed assembly to ensure that all operations have been completed and the finished assembly meets the required specification
7. deal promptly and effectively with problems within your control and report those that cannot be solved

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1. the specific safety precautions to be taken whilst carrying out the cableform/loom production activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials)
2. the health and safety requirements of the work area in which you are carrying out the cableform/loom production activities, and the responsibility these requirements place on you
3. the personal protective equipment and clothing (PPE) to be worn during the production activities
4. the hazards associated with producing aircraft cableforms/looms, and with the tools and equipment used, and how they can be minimised
5. the different types of drawing and specification that are used during the production activities, and how to interpret the various symbols and abbreviations
6. how to identify cables and the cable end fittings to be used; and associated identification systems (such as cable/component markers)
7. preparations to be undertaken on the cable and cable end fittings, prior to assembly (such as loom forming and soldering preparation)
8. the cable end fitting assembly methods and techniques used (to include soldering, crimping, heat shrinking and cable forming)
9. assembly of screened and unscreened plugs and sockets, and the difference between composite and metal plugs and sockets
10. different types of cable protection, and reasons for each type
11. how to deal with cables/components that are incorrectly assembled, damaged or have other faults
12. the quality control procedures to be followed during the production of the cableforms/looms
13. how to conduct any necessary checks to ensure the accuracy and quality of the assemblies produced
14. how to take electrostatic discharge (ESD) precautions, and why are they needed
15. the procedure for handling long lengths of cable
16. the precautions needed when handling completed looms
17. the importance of checking that the tools and equipment to be used are correctly calibrated, and are in a safe and serviceable condition
18. the importance of ensuring that all tools are used correctly and within their permitted operating range
19. problems with the assembly operations, and the importance of informing appropriate people of any non- conformances
20. the recording documentation to be completed for the production activities undertaken and, where appropriate, the importance of marking and identifying specific pieces of work in relation to the documentation
21. the extent of your own responsibility, and whom you should report to if you have problems that you cannot resolve

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1. Carry out all of the following during the production activities:

   1. ensure that you have the correct documentation for the cable production operations (such as drawings, job instructions, aircraft standards)
   2. adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations
   3. ensure that all tools and equipment used are within current calibration dates
   4. maintain safe access and working arrangements for the area in which the production activities take place
   5. dispose of waste items in a safe and environmentally acceptable manner, in line with company procedures
   6. return all tools and equipment to the correct location on completion of the activities
   7. leave the work area in a safe condition and free from foreign object debris

2. Assemble four of the following types of aircraft cableforms/looms:

   1. co-axial cable assemblies                  
   2. aircraft lighting cable assemblies
   3. heavy duty cable assemblies              
   4. AFCS cable assemblies
   5. aircraft system cable assemblies        
   6. headset leads (mic-tel leads)
   7. secure speech cables assemblies
   8. general aircraft cable assemblies
   9. other specific cable assembly

3. Use four of the following types of cables when producing the cableforms/looms:

   1. single core                                                 
   2. armoured                        
   3. coaxial
   4. multicore                                                    
   5. data/communication         
   6. ribbon cables
   7. PVC twin and earth                                     
   8. fibre-optics                      
   9. wiring loom/harness
   10. flexible (such as cotton or rubber covered)   
   11. screened
   12. mineral insulated

4. Carry out all of the following cableform/loom production activities:

   1. determining the correct type, size, colour/coding and lengths of cables required
   2. cutting cables to the required length (with allowance for termination)
   3. laying cables on the template/layout board
   4. ensuring that the correct cables break out at the required points
   5. securing cable forms/looms (such as cable ties/clips or plastic strapping, lacing, harnessing)
   6. attaching suitable cable identification

5. Carry out seven of the following cable termination activities:

   1. stripping the outer coating without damage to conductors or insulation
   2. stripping off an appropriate length of cable conductor insulation/protection
   3. making mechanical/screwed/clamped cable end connections
   4. making crimped cable end connections (such as spade end, loops, tags and pins)
   5. making snap/push on cable end connections            
   6. making a screened plug and socket assembly
   7. making soldered cable end connections                   
   8. making co-axial cable connections
   9. making an unscreened plug and socket assembly     
   10. applying heat shrinking (devices and boots)

6. Produce cableforms/looms which comply with one of the following standards:

   1. Civil Aviation Authority (CAA)          
   2. Ministry of Defence (MoD)              
   3. customer standards and requirements
   4. Federal Aviation Authority (FAA)     
   5. company standards and procedures

7. Complete the relevant paperwork, to include one from the following, and pass it to the appropriate people:

   1. build records
   2. job cards
   3. aircraft log

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​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

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2

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2020

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Current

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Original

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Semta

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SEMAER2-16

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Engineering, Engineering and Manufacturing Technologies, Engineering Professionals, Science and Engineering Technicians

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5234

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Aeronautical; Engineering; cut; cables; form and secure; loom assemblies; strip; cable insulation; solder and crimp; co-axial cable assemblies; heavy duty cable assemblies; aircraft system cable assemblies; secure speech cable assemblies;

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