Flattening and polishing vehicle bodies

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This standard identifies the competences needed to flatten and polish vehicle body surfaces, in accordance with approved procedures. You will be required to flatten and polish the body vehicle panels ready for final inspection, by using a variety of flattening and polishing methods and techniques.  You will be expected to carry out this process to the level of accuracy and quality required by the relevant specifications.

Your responsibilities will require you to comply with organisational policy and procedures for the flattening and polishing of vehicle body surfaces and to report any problems with the process or with the tools and equipment 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 vehicle body preparation procedures. You will understand the methods and techniques used to flatten and polish the body panels and the associated equipment used in the process. You will also know about the surface finishes used and the application of abrasives and polishing compounds, 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 flattening and polishing 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, environmental and other relevant regulations, directives and guidelines
2. ensure the surfaces to be finished are suitably prepared for the activities to be carried out
3. check that the finishing equipment, materials and treatment solutions are set up and maintained at satisfactory operating conditions and levels
4. carry out the flattening and polishing process in accordance with operating procedures and the specification requirements
5. ensure that the polished surfaces achieves the required characteristics and meets the finishing specification
6. deal promptly and effectively with problems within your control and report those that cannot be solved
7. ensure that work records are completed, stored securely and available to others, as per organisational requirements
8. 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. how to check that the tools and equipment to be used are in a safe, tested and serviceable condition and what to do if they are not
6. the importance of ensuring that all tools are used correctly and within their permitted operating range
7. the methods and equipment used to transport, handle and lift the panels into position and how to check that the equipment is within its current certification dates
8. the procedures for obtaining the various types of drawing, job instructions and specifications that are used during the vehicle body flattening and polishing process and how to interpret them correctly
9. how to prepare, maintain and clean equipment used in the body finishing process
10. how to ensure that adequate lighting is available and the best methods for lighting the panels
11. how to identify defects in body panels and how to resolve them
12. how to identify various grades and types of abrasive/polishing media and their applications
13. the process to follow during the flattening and polishing activities
14. the techniques to be used during the flattening and polishing of the vehicle panels (including the correct angle, speed and pressure of power tools used)
15. how to carry out visual assessment of body panels for colour and brightness
16. the procedure to be adopted in checking the body finish throughout the process and the procedure to rectify faults
17. the quality control procedures to be followed during the flattening and polishing activities
18. problems with the flattening and polishing operations and the importance of informing appropriate people of non-conformances
19. the correct and safe procedure to be adopted for the disposal of all waste materials
20. the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
21. 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 flattening and polishing activities:

   1. obtain and use the appropriate documentation (such as job instructions, material data sheets, 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 adequate lighting is available
   6. ensure that body panels and components are free from damage
   7. use safe and approved techniques to flatten and polish the vehicle body surfaces
   8. return all tools and equipment to the correct location on completion of the flattening and polishing activities
   9. leave the work area in a safe and appropriate condition on completion of the activities

2. Carry out detail sanding on three of the following vehicle body materials:

   1. composite
   2. aluminium
   3. carbon fibre
   4. steel
   5. other specific material

3. Carry out flattening and polishing processes on three of the following vehicle body materials:

   1. composite
   2. aluminium
   3. carbon fibre
   4. steel
   5. other specific material

4. Carry out flattening and polishing processes on two of the following:

   1. dark colours
   2. light colours
   3. medium colours
   4. special colours

5. Carry out final finishing of the vehicle body, using three of the following:

   1. finishing paste
   2. wax
   3. lambs wool pads
   4. synthetic pads
   5. rotary polishers
   6. orbital or dual action polishers

6. Check the vehicle surfaces for three of the following characteristics:

   1. evenness of surface finish     
   2. inclusions in the surface
   3. colour and brightness           
   4. surface roughness (visible or quantitative, as required)

7. Check the final body finish complies with all of the following quality and accuracy standards:

   1. requirements of the production standard
   2. specification and customer requirements
   3. is free from contaminants and defects
   4. all quality control checks have been achieved

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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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SEMAUT3145

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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; panel preparation; surface finishing; flattening; polishing; sanding

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