Assembling commercial and passenger carrying vehicle body sub-assemblies to produce a vehicle
Overview
This standard identifies the competences needed to assemble various sub-assemblies in order to produce a complete commercial and/or passenger-carrying vehicle, in accordance with approved procedures. You will be required to assemble a range of body sub-assemblies, which could include underbody frame, floor assembly, body side frame, front bulkhead, door assemblies, tanks/vessels, roof assemblies, run-under guards, internal and external panelling and glazing units to make a complete vehicle. This will be achieved by using a variety of assembly methods and techniques, such as welding, mechanical bolting, torque setting, fitting, packing and shimming, aligning components, setting clearances, drilling, riveting, sealing and bonding. You will also be expected to use a range of tools and specialist 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 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 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 the complete vehicle. You will understand the assembly methods and techniques used, and their application, and will know about the tooling and ancillary equipment, vehicle 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 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 the 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 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, and how to interpret them correctly
- how to identify the components to be used (including component identification systems)
- 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 (including jigs and fixtures)
- the various mechanical fasteners that will be used, and their method of installation (such as threaded fasteners, rivets)
- the application of sealants and adhesives within the assembly activities, and the precautions that must be taken when working with them
- how to set and operate the appropriate welding equipment safely and correctly
- the tools and equipment that are used for the assembly (hand and power tools)
- how to deal with sub-assemblies and components 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 or component 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 sub-assemblies and components into position, and how to check that the equipment is within its current certification dates
- the preparations to be undertaken on the sub-assemblies and components prior to fitting them to 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 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 assembly activities:
- obtain and use the appropriate documentation (such as job instructions, 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 safe, 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 lifting and slinging equipment in accordance with health and safety guidelines and procedures
- use safe and approved techniques to assemble the sub-assemblies and components to the vehicles
- return all tools and equipment to the correct location on completion of the assembly activities
- leave the work area in a safe and appropriate condition on completion of the activities
Assemble body, sub-assemblies and components to produce a complete vehicle body, to include five of the following:
- underbody frame
- roof assembly
- tanks or vessel
- external panelling
- floor assembly
- body side frame
- front bulkhead
- internal panelling
- doors (such as hinged, roller, sliding, powered)
- windscreens and glazing
- run-under guards
Assemble the sub-assemblies and components using three of the following devices:
- static jigs
- body side gates
- G-clamps
- self-grip wrenches
- portable jigs
- fixtures
- sash clamps
- lifting devices
Complete the vehicle using three of the following assembly methods and techniques:
- aligning components
- fitting
- shimming/packing
- filling/sealing/bonding
- setting clearances
- drilling
- torque setting
Join body sub-assemblies to make a vehicle, using two of the following methods:
- MIG welding
- mechanical bolts/fasteners
- adhesives
- TIG welding
- resistance spot welding
- riveting
Finish body components using all of the following:
- hand cutting tools
- power tools
- files
- abrasive discs/paper
Carry out the required quality checks, to include seven of the following:
- dimensions
- function
- torque loading of bolts
- component quality
- alignment
- positional accuracy
- component security
- completeness
- freedom from damage and foreign objects
Check that assemblies comply with one of the following quality and accuracy standards:
- legislation, industry standards, codes of practice and procedures
- specific system requirements
- customer standards and requirements
- company standards and procedures