Carrying out composite assembly operations

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This standard identifies the competences you need to produce composite assemblies from composite components, in accordance with approved procedures.  You will be required to use appropriate drawings, specifications and documentation to produce composite assemblies, using the approved techniques. You will produce a range of composite assemblies, incorporating a range 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 are outside your permitted authority, to the relevant people.  You will be expected to work to instructions under 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 and ensuring 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.

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1. work safely at all times, complying with health and safety, environmental and other relevant regulations, directives and guidelines
2. follow the relevant instructions, assembly drawings and any other specifications

3. check that the specified equipment, components and mouldings are available and that they are in a usable condition

4. produce composite assemblies using the approved methods and techniques to assemble the components in their correct positions

5. secure the mouldings using the specified securing devices

6. check the completed assembly to ensure that all operations have been completed and the finished assembly meets the required specification
7. deal promptly and effectively with problems within your control and report those that cannot be solved
8. complete relevant documentation
9. leave the work area in a safe and appropriate condition on completion of the activities

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1. the health and safety precautions to be taken and procedures used when working with composite materials, consumables, tools and equipment in the specific work area
2. the hazards associated with carrying out composite assembly activities and with the composite materials, consumables, tools and equipment used and how to minimise these and reduce any risks
3. the protective equipment (PPE) that is needed for personal protection and where required, the protection of others
4. the application of COSHH regulations in relation to the storage, use and disposal of composite materials and consumables
5. the specific environmental conditions the must be observed when assembling composite mouldings (such as temperature, humidity, fume/dust extraction systems and equipment)
6. how to identify and use information from engineering drawings and related documentation (to include symbols and conventions to appropriate BS, ISO or BSEN standards) in relation to work undertaken
7. how to interpret drawings, systems of measurement, workpiece reference points and system of tolerancing
8. the quality procedures used in the workplace to ensure production control (in relation to currency, issue, meeting specification) and the completion of such documents
9. the basic conventions and terminology used for assembly activities (such as metric and imperial threads, rivet specifications, clearances, types of fittings)
10. the component trimming/cutting methods used and preparation methods available
11. how to visually identify cured and non-cured composite materials
12. the correct assembly operations and their sequence
13. the method for handling composite assemblies throughout the assembly activities
14. the identification of defects in composite assemblies
15. the tools and equipment used in assembly activities and their care, preparation and safe handling
16. the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
17. the documentation to be completed during and/or on completion of the assembly activity

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1. Carry out all of the following during the assembly activities:

   1. use the appropriate documentation (such as job instructions, drawings, material data sheets, specifications, planning and quality control documentation)
   2. adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
   3. check that all tools and equipment to be used are correct for the operation to be carried out and are in a safe and usable condition
   4. maintain a safe working environment for the composite assembly activities
   5. check that all tools and equipment to be used are in a safe and usable condition
   6. follow safe practice/approved composite assembly techniques at all times
   7. return all tools and equipment to the correct location on completion of the assembly activities
   8. segregate and dispose of waste materials using the correct procedure

2. Carry out four of the following activities when preparing for the assembly activity:

   1. check that mouldings are correct and complete
   2. check for any defects in the mouldings
   3. check that components are correct and complete
   4. confirm that the equipment selected for the activity is correct
   5. check availability of ancillary materials required
   6. confirm that equipment is suitable for use
   7. identify and protect the moulding and components in the work area

3. Produce one of the following types of composite assembly:

   1. trial assemblies
   2. one-off assemblies
   3. batch assemblies
   4. assembly line

4. Produce assemblies that incorporate three of the following features:

   1. loose fit tolerances
   2. close fit tolerances
   3. non-permanent fixing
   4. shape location
   5. joggle joins
   6. permanent fixing
   7. return joins
   8. overlap joins
   9. strap joins
   10. other specified feature

5. Produce composite assemblies that require two of the following:

   1. fettling
   2. pinning
   3. clamping
   4. trial fitting
   5. aligning
   6. tongue and groove
   7. assembly jigs
   8. assembly sequences
   9. datum points
   10. orientation

6. Produce composite assemblies that use two of the following joining methods:

   1. thread inserts
   2. quick-release fasteners
   3. mechanical fasteners
   4. blind fasteners
   5. adhesive bonding
   6. anchor nuts
   7. pinning
   8. rivets
   9. thermo welding
   10. other (to be specified)

7. Produce composite assemblies that must include two of the following composite components:

   1. trim
   2. closing panels
   3. body panels
   4. tubes
   5. structural
   6. aerodynamic
   7. core materials
   8. sections
   9. casings/covers
   10. inserts
   11. housings
   12. other (to be specified)

8. Produce composite assemblies that must include one of the following non-composite components:

   1. brackets
   2. fixtures
   3. metal components
   4. fittings
   5. trim
   6. finishing tapes
   7. memory foam
   8. labels/decals
   9. surface films
   10. edge bands
   11. other (to be specified)

9. Produce a range of assemblies which comply with one of the following standards:

   1. BS, ISO or BSEN standards and procedures
   2. customer standards and requirements
   3. company standards and procedures
   4. recognised compliance agency/body standards

10. Complete the relevant documentation, to include one of the following:

    1. production documentation
    2. quality control documentation
    3. job cards

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You will be able to apply the appropriate behaviours required in the workplace to meet the job profile and overall company objectives, such as:

• strong work ethic
• positive attitude
• team player
• dependability
• responsibility
• honesty
• integrity
• motivation
• commitment

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2

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2021

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Current

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Original

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Semta

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SEMCOMP217

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Composite Fitter, Composite Technician, Laminator, Moulding Technician

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8114

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Engineering; produce; composite; mouldings; components; laminating; resin; fibre; assemblies; mark out; drawings

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