Modifying commercial and passenger carrying vehicles

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This standard identifies the competences you need to carry out modifications on commercial and passenger carrying vehicles, in accordance with approved procedures. The vehicle may have to be modified for a number of reasons, which could include performance out of specification, inherent design problems, changes to customer specification, or assembly problems. You will be required to prepare the work area, ensuring it is safe and free from hazards, to check the vehicle components requiring modification are available, to obtain all relevant and current documentation, and to obtain the tools and equipment required for the modification, checking that they are in a safe and usable condition.

The vehicle and its components could be modified using a number of methods and techniques, including, where appropriate, adjusting, removing and replacing, or by producing new components by machining, welding, fabricating or bonding. Vehicle components that are modified must be checked for accuracy, security, completeness, and that they function as per the specification.

Your responsibilities will require you to comply with organisational policy and procedures for the modification activities undertaken, and to report any problems with the modification activities, materials or equipment that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You will be expected to ensure that all tools, equipment and materials used in the modification are correctly accounted for on completion of the activities, and to complete all necessary job/task documentation accurately and legibly. 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 the modification methods, techniques and procedures. You will understand the vehicle components being modified, including their application and the reason for the modification, and will know about the tools and equipment required, 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 modification 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 the relevant specification and job instructions for the modification being performed
3. confirm the modification to be carried out to meet the specification
4. prepare the product for modification
5. ensure that any materials and equipment required are available and  they are in a usable condition
6. carry out the modification to achieve the required changes, in line with agreed instructions and specifications
7. deal promptly and effectively with problems within your control and report those that cannot be solved
8. ensure that work records are completed, stored securely and available to others as per organisational requirements
9.  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 work area and the activities, and the responsibility these requirements place on you
3. the hazards associated with the activities, and how to minimise them and reduce risks
4. the personal protective equipment and clothing (PPE) to be worn during the activities
5. the various types of drawing and specifications that are used during the modification
6. how to extract and use information from engineering drawings and related specifications (to include symbols and conventions to current industry standards and codes of practice)
7. how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing
8. the reasons why vehicle assemblies may require modification
9. the preparations to be undertaken on the vehicle components prior to carrying out the modification
10. the various methods that could be used to modify vehicle components (such as adjust, remove and replace, repair and manufacture)
11. the basic concepts and techniques that can be used, to modify the vehicle components (such as machining, welding, fabrication, bonding, mechanical fitting, electrical and electronic fitting)
12. the quality control procedures to be followed during the modification, and the importance of adhering to them
13. how to conduct any necessary checks to ensure the accuracy, position, security, function and completeness of the modification
14. the methods and equipment used to transport, lift and handle vehicle components and assemblies
15. how to check that the tools and equipment to be used are correctly calibrated and are in a safe, tested and serviceable condition
16. the importance of ensuring that all tools are used correctly and within their permitted operating range
17. the importance of ensuring that all tools, equipment and components are accounted for and returned to their correct location on completion of the modification activities
18. the problems associated with carrying out modifications on vehicle assemblies, and the importance of informing the appropriate people of non-conformances
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 modification activities:

   1. obtain and use the appropriate documentation (such as job instructions, modification 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 safe, tested and serviceable condition
   4. check that all tools and equipment to be used are within current calibration/certification dates
   5. ensure that components used are free from damage, foreign objects, dirt or other contamination before fitting them
   6. use safe and approved modification and repair techniques at all times
   7. return all tools and equipment to the correct location on completion of the modification activities
   8. leave the work area in a safe and appropriate condition on completion of the activities

2. Carry out the modification using three of the following methods:

   1. adjustment                                                       
   2. modify existing components/structures
   3. remove and replace with new components        
   4. produce new components

3. Complete the modification using four of the following techniques:

   1. dismantling and re-assembling                         
   2. adjusting
   3. hand fitting                                                       
   4. welding
   5. electrical fitting and assembly                           
   6. fabrication
   7. fluid power fitting and assembly                        
   8. machining
   9. bonding
   10. other specific techniques

4. Carry out modifications on three of the following parts of the vehicle:

   1. underbody frame                         
   2. roof assembly              
   3. power operated doors
   4. floor assembly                             
   5. front bulkhead              
   6. doors (such as hinged, roller, sliding)
   7. body side frame                          
   8. chassis                        
   9. windscreens and glazing
   10. tanks or vessels                       
   11. panelling                      
   12. ancillary units

5. Carry out the required quality checks using the correct tools and equipment, to include seven of the following

   1. dimensions                                 
   2. orientation                    
   3. function
   4. positional accuracy                      
   5. alignment                    
   6. earth bonding and electrical continuity
   7. freedom of movement                  
   8. completeness               
   9. freedom from damage or foreign
   10. operating/working clearances      
   11. component security     
   12. objects

6. Check the modifications comply with one of the following quality and accuracy standards:

   1. legislation, industry standards, codes of practice and procedures specific system requirements
   2. customer standards and requirements                     
   3. company standards and procedures

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2

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2023

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Current

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Original

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Semta

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SEMAUT3054

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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; modifying; commercial; passenger carrying; welding; fabrication; machining; bonding

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