Making vehicle trim prototypes and patterns

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This standard identifies the competences you need to make vehicle trim prototypes and patterns, in accordance with approved procedures. You will be required to make patterns from which material for trimming the vehicle, or for producing vehicle trim sub-assemblies, can be cut and shaped. You will also be required to make a range of prototype hard and soft trim components/sub-assemblies. To achieve this, you will be required to select the appropriate materials, to maintain and use hand/machine sewing and other equipment, and to produce vehicle trim prototype components and patterns, using a variety of assembly methods and techniques. You will also be expected to use a range of sewing and specialised equipment associated with the manufacturing process, and to check that the prototype 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 manufacturing activities undertaken, and to report any problems with the pattern/prototype development activities, or with the tools and equipment that are used, that you cannot personally 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 manufacturing procedures to the development of patterns and prototype trim components. You will understand the manufacturing methods and techniques used, and their application, and will know about the materials and equipment used in the development of trim prototypes and patterns, 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 pattern and trim prototype manufacturing 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.

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1. work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
2. follow instructions and any relevant specifications to produce the component
3. make the required trim and prototype components using appropriate manufacturing methods and techniques
4. check that the finished components meet the requirements and make any necessary adjustments
5. deal promptly and effectively with problems within your control and report those that cannot be solved
6. ensure that work records are completed, stored securely and available to others as per organisational requirements
7. leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements

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1. 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)
2. the health and safety requirements of the area in which you are carrying out the  activities and the requirements they place on you
3. the personal protective equipment and clothing (PPE) to be worn during the activities
4. the hazards associated with the activities (such as using cutters, machines, staplers), and how to minimise them and reduce any risks
5. the procedure for obtaining drawings, job instructions and other related specifications, and how to interpret them correctly
6. the procedures for generation of the build criteria relating to the development of the prototype and where appropriate, the interpretation of the customer's requirements
7. how to develop work schedules, devise a manufacturing process and determine resources, in the absence of any stated specifications
8. the consumables, tools and equipment that are used for prototype build of trim assemblies, and how to check that the tools and equipment are set for correct operation
9. component preparation prior to assembly, and the importance of ensuring that they are free from dirt, defects or foreign bodies
10. how to identify the materials that are to be used, their orientation within the assembly, pile direction, mirror match, elasticity and pattern match, as appropriate
11. how to identify faults in the materials that could affect finish and quality, and the procedure to be adopted to overcome them
12. the assembly methods and techniques for different materials, relating to hard and soft trim components
13. the order in which the parts are to be manufactured and assembled, and the importance of adhering to this procedure
14. the procedure to be adopted for the safe disposal of waste materials of all kinds
15. the procedure to check that the trim prototypes meet quality control procedures
16. the correct use of lifting and handling devices, and the procedure for the safe handling of components and equipment
17. how to check that tools and equipment are free from damage or defects, and are in a safe and usable condition 
18. the problems that can occur with assembling trim components and how these can be overcome
19. the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
20. how to access, use and maintain information to comply with organisational requirements and legislation

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1. Carry out all of the following during the manufacture of the vehicle trim prototypes and patterns:

   1. obtain and use the appropriate documentation (such as job instructions, trim/prototype pattern drawings, quality control documentation)
   2. 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
   3. check that all cables, extension leads or air supply hoses are in a tested and serviceable condition
   4. check that all tools and equipment to be used are within current calibration/certification dates
   5. ensure that trim/pattern materials and components used are free from damage, foreign objects, dirt or other contamination before using them
   6. use safe and approved techniques to manufacture the trim prototypes and patterns
   7. return all tools and equipment to the correct location on completion of the activities
   8. leave the work area in a safe and appropriate condition on completion of the activities

2. Produce patterns and prototypes to meet two of the following vehicle development needs:

   1. new product development                                  
   2. research into alternative materials
   3. development of existing components                   
   4. customise to customer requirements

3. Manufacture trim prototypes including four of the following:

   1. development of a pattern                                                 
   2. adhering
   3. cutting and preparing hard or soft trim materials               
   4. stapling
   5. sewing by hand or machine                                             
   6. plastic welding
   7. modelling/shaping fibreglass                                           
   8. developing substrates

4. Select, prepare and use a range of material in the construction, to include three of the following:

   1. paper/card                                            
   2. foam                       
   3. PVC
   4. leather                                                  
   5. fibreglass                
   6. composites
   7. cloth (wool, cotton, nylon)                      
   8. ABS plastic              
   9. wood
   10. laminates

5. Make prototype trim components using three of the following devices:

   1. clamping devices          
   2. wood machines            
   3. bucks                           
   4. fixtures and fixings
   5. alignment devices         
   6. jigs                               
   7. clip/stapling devices      
   8. sewing machines

6. Produce trim prototypes for two of the following vehicle sub-assemblies:

   1. door pads                                   
   2. carpets                                       
   3. roof linings
   4. front seat                                     
   5. floor console                               
   6. headrests
   7. rear seat                                     
   8. door panels                                 
   9. fibreglass substrates
   10. audio/visual housings                  
   11. arm rests                                     
   12. other specific items

7. Check patterns and prototypes comply with all of the following quality and accuracy standards:

   1. all components are free from damage, tool marks and cuts, and adhesives
   2. where appropriate, pattern match has been achieved
   3. all quality control checks have been carried out and the required standards achieved 
   4. the prototype meets the required specification

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2

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31 Mar 2023

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Current

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Original

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Semta

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SEMAUT3019

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Engineering, Engineering and Manufacturing Technologies, Science and Engineering Technicians, Vehicle Trades

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5231

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engineering; automotive; manufacturing; making; prototype; trim; patterns; door trim; carpets; door furniture

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