Assembling trim components to vehicles
Overview
This standard identifies the competences needed to assemble various trim components to the vehicle, in accordance with approved procedures. You will be required to assemble a range of hard and soft trim components and associated components to the vehicle, by using a variety of assembly methods and techniques. You will also be expected to use a range of tools and specialised equipment associated with the assembly methods, and to check that the 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 assembly process, or with the tools and equipment that are used, 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 carry out.
Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying procedures appropriate to the assembly of hard and soft trim components to the vehicle. You will understand the assembly methods and techniques used, and their application, and will know about the tooling and ancillary equipment, trim components 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 trim 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)
- the health and safety requirements of the work area and activities, and the responsibility they place on you
- the hazards associated with the activities (such as using adhesives, working in confined spaces) 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 assembly of trim components to the vehicle, and how to interpret them correctly
- how to identify the components to be used; component identification systems (codes and component orientation indicators)
- 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 prior to securing, and the tools and equipment that are used
- the various mechanical fasteners and other components that are used (threaded fasteners, set and self-tap screws, and fasteners)
- the application of sealants and adhesives within the assembly activities, and the precautions that must be taken when working with them
- the company coding procedure for component variants to meet customer requirements
- the function of the various trim components
- the importance of ensuring that fasteners are adjusted to the required settings
- the consumables, tools and equipment that are used for the assembly of trim components to vehicles
- the importance of using the specified fasteners for the assembly and why you must not use substitutes
- how to deal with components or fastening devices that are incorrectly assembled, damaged or have other faults
- 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 assembly produced
- how to recognise defects (incorrect assembly, ineffective fasteners, foreign object damage)
- the importance of ensuring that the completed assembly is free from left-over items and foreign objects
- 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
- 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
- the problems that can occur with the assembly operations and how they can be avoided
- 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 trim assembly activities:
- obtain and use the appropriate documentation (such as job instructions, trim assembly 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 trim components used are free from damage, foreign objects, dirt or other contamination before assembling them to the vehicle
- use safe and approved techniques to trim and assemble the components to the vehicles
- return all tools and equipment to the correct location on completion of the trim assembly activities
- leave the work area in a safe and appropriate condition on completion of the activities
Secure trim and associated components to the vehicle, to include all of the following:
- hard trim (such as plastics, wood, metal)
- soft trim (such as carpets, linings, foams)
- associated fixing components
Use a variety of assembly methods and techniques, to include three of the following:
- staples
- adhesives
- threaded fasteners
- push/clip fastenings
- rivets
Assemble trim components using three of the following devices:
- static jigs
- fixtures
- alignment devices
- portable jigs
- bucks
- mechanical fastening devices
- templates
Assemble trim components to vehicles, to include five of the following components:
- door pads
- sound deadeners/insulation
- carpets
- door furnishings (such as handles)
- roof linings and fittings
- dash assemblies
- front seat assemblies
- seat belt assemblies
- floor consoles
- rear squabs and cushions
- miscellaneous hard trims (such as finishers, décor strips)
Check assemblies comply with all of the following quality and accuracy standards:
- the assembly of trim components to the vehicle is complete
- the assembly is free from damage, tool marks and cuts
- surplus adhesive has been removed and components are clean
- all quality control checks have been carried out and the required standards achieved