Trimming of body components for vehicles
Overview
This standard identifies the competences needed to trim body components for fitting to vehicles, in accordance with approved procedures. You will be required to select materials, and to produce vehicle trim components, by using a variety of assembly methods and techniques. You will also be expected to use and maintain a range of hand and machine joining equipment associated with the manufacturing process, and to check that the final assembly has been completed to the level of accuracy and quality required by the specification.
Your responsibilities will require you to comply with organisational policy and procedures for the assembly activities undertaken, and to report any problems with the process that you cannot 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 produce.
Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying procedures appropriate to the sewing of vehicle trim components. You will understand the manufacturing methods and techniques used, and their application. You will also know about the sewing and ancillary equipment, and the properties and workability of trim materials and consumables, 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 trimming and assembly 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
- 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
- assemble the components in their correct positions using appropriate methods and techniques
- 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
- ensure that work records are completed, stored securely and available to others as per organisational requirements
- leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements
Knowledge and Understanding
You need to know and understand:
- the specific safety precautions to be taken whilst carrying out the activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials used)
- the health and safety requirements of the work area and activities and the responsibility they place on you
- the hazards associated with the activities, and how to minimise them and reduce any risks
- the personal protective equipment and clothing (PPE) to be worn during the activities
- the procedures for obtaining the various types of drawing, job instructions and specifications that are used during the trimming of body components, and how to interpret them correctly
- how to identify the materials that are to be used, their orientation within the assembly, pile direction, elasticity and pattern
- the assembly methods and procedures to be used, and the importance of adhering to these procedures
- the company coding procedure for component variants to meet customer requirements
- how to identify faults in the materials that could affect finish and quality, and the procedure to overcome them
- the procedure to be adopted for the safe disposal of waste materials of all kinds
- the consumables, tools and equipment that are used for assembling trim components; how to check that the tools and equipment are set for correct operation
- the quality control procedures to be followed during the trimming of body components
- the routine maintenance procedures for trimming machines
- how to conduct any necessary checks to ensure the accuracy and quality of the assembly produced
- how to recognise defects (incorrect assembly, ineffective fasteners, damage to materials)
- the methods and equipment used to transport, handle and lift the components into position, and how to check that the equipment is within its current certification dates
- the preparations to be undertaken on the components and fixing points, prior to fitting the components into the vehicle
- how to check 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
- problems with the trimming and 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
- how to access, use and maintain information to comply with organisational requirements and legislation
Scope/range
Scope Performance
Carry out all of the following during the trimming and assembly activities:
- obtain and use the appropriate documentation (job instructions, drawings, quality control documentation)
- adhere to procedures or systems in place for risk assessment, hazardous substances, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
- check that all cables, extension leads or air supply hoses are in a tested and serviceable condition
- check that all tools and equipment to be used are within current calibration/certification dates
- ensure that sub-assemblies and components used are free from damage, foreign objects, dirt or other contamination before assembling them
- use safe and approved techniques to trim and assemble the body components to the vehicles
- return all tools and equipment to the correct location on completion of the trimming activities
- leave the work area in a safe and appropriate condition on completion of the activities
Select and prepare material to be assembled, to include three of the following:
- leather
- wool
- velour
- nylon
- cotton
- linz
- moquette
- PVC
- foams/composites
Select material and assemble vehicle trim components, to include all of the following:
- pre-sewn assemblies
- multi-fabric/material builds
- pattern matching
- sub-frame trimming
Use a variety of manufacturing methods and techniques, to include three of the following:
- cutting to pattern
- adhering
- stapling
- hog ring fixing
- plastic welding
- hand sewing
Assemble vehicle trim components, to include three of the following:
- door pad assemblies
- rear cushion assembly
- arm rests assembly
- front seat assembly
- rear squab assembly
- floor console assembly
Assemble the trim components using the appropriate equipment, to include four of the following:
- staple devices
- fixtures
- cutting devices
- hog ring machines
- alignment devices
- plastic welding device
- bucks
- jigs
- templates
Check trim assemblies comply with all of the following quality and accuracy standards:
- the assembly of trim components is complete
- where appropriate, pattern matches are achieved
- the assembly is free from damage, cuts, adhesive and marks
- surplus material has been removed and components are clean
- all quality control checks have been achieved