Assembling composite vehicle components
Overview
This standard identifies the competences you need to produce vehicle composite assemblies from composite and non-composite components, in accordance with approved procedures. You will be required to use appropriate drawings, specifications and documentation to produce composite assemblies, using the correct techniques. You will produce a range of composite assemblies, incorporating a variety of features and using a range of techniques and processes.
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 activities, equipment or materials 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 composite assembly techniques and procedures. You will understand the composite assembly techniques used, and their application, in adequate depth to provide a sound basis for carrying out the activities, correcting faults, and ensuring that the finished assembly is to the required specification.
You will understand the safety precautions required when carrying out the assembly activities and when using the associated tools and equipment. 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 the activities, and the responsibility these requirements place on you
the hazards associated with the activities, and how to minimise them and reduce any risk in the work area
- the personal protective equipment and clothing (PPE) to be worn during the activities
- the application of regulations in relation to the storage, use and disposal of composite materials and consumables
- the specific workshop environmental conditions the must be observed when assembling composite mouldings (temperature, humidity, styrene levels to threshold limits, fume/dust extraction systems and equipment)
- how to extract and use information from engineering drawings and related specifications( to include symbols and conventions, current industry standards and codes of practice) in relation to work undertaken
- how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing
- quality procedures used in the workplace to ensure production control (in relation to currency, issue, meeting specification)
- conventions and terminology used for assembly activities (such as metric and imperial threads, specifications, clearances, types of fittings)
- the component trimming/cutting methods and preparation methods available
- the visual identification of cured composite materials
- assembly operations and their sequence
- the methods for handling composite assemblies throughout the assembly activities
- the identification and rectification of defects in composite assemblies
- the tools and equipment used in assembly activities, and their care, preparation and control procedures
- the problems that can occur with the assembly operations and how these can be overcome
- 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 composite assembly activities:
- obtain and use the appropriate documentation (such as job instructions, drawings, planning and quality control documentation, material data sheets, specifications)
- 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
- provide and maintain a safe working environment for the composite assembly activities
- obtain the correct tools and equipment for the activity, and check that they are in a safe, tested and usable condition
- follow safe practice/approved composite assembly techniques and procedures at all times
- return all tools and equipment to the correct location on completion of the composite assembly activities
- dispose of waste materials in accordance with approved procedures
- leave the work area in a safe and appropriate condition on completion of the activities
Prepare for assembly activity:
- check that mouldings are correct and complete
- select correct equipment for the activity
- check for any defects in the mouldings
- check that equipment is suitable for use
- check components are correct and complete
- check for any defects in the components
- check availability of ancillary materials required
- identify and protect the moulding and components in the work area
Produce two of the following types of composite assembly:
- trial assemblies
- one-off assemblies
- batch assemblies
- assembly line
Produce assemblies that incorporate four of the following features:
- loose fit tolerances
- non-permanent fixings
- joggle joins
- return joins
- close fit tolerances
- shape locations
- permanent fixings
- overlap joins
Produce composite assemblies that require four of the following methods to be used:
- fettling
- clamping
- aligning
- assembly sequences
- pinning
- trial fitting
- assembly jigs
Produce composite assemblies that use three of the following joining methods:
- thread inserts
- mechanical fasteners
- anchor nuts
- rivets
- quick-release fasteners
- other specific method
Ensure that composite components include three of the following:
- trims
- body panels
- structural
- core materials
- inserts
- closing panels
- tubes
- aerodynamic
- sections
- housings
Ensure that non-composite components include three of the following:
- brackets
- fixtures
- fittings
- trims
- tapes
- memory foam
- films
Check assemblies comply with all of the following quality and accuracy standards:
- meet company standards and procedures
- dimensionally accurate within specification tolerances
- all components are mechanically secure and free from damage or defects