Carrying out the installation of composite mouldings
Overview
This standard identifies the competences you need to install composite mouldings and assemblies in accordance with approved procedures. You will be required to use appropriate drawings, specifications and documentation to install composite mouldings and assemblies. You will be required to use the approved materials, tools and equipment to and use the correct techniques to complete the installation. You will also be expected to follow all necessary datums that are required to locate the components and assemblies correctly during the installation activities. You will complete a range of installations for composite mouldings and assemblies, using a range of techniques and processes.
Your responsibilities will require you to comply with organisational policy and procedures for the installation activities undertaken and to report any problems with the assembly activities, equipment or components 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. The installation activities will include making all necessary checks and adjustments to ensure that composite components and assemblies are correctly positioned and aligned and where appropriate, that they function correctly.
Your underpinning knowledge will provide a good understanding of your work and will provide an informed approach to applying installation techniques and procedures to composite mouldings. You will understand the installation requirements, techniques, fastening methods and their application, in adequate depth to provide a sound basis for carrying out the activities and ensuring the finished installation is to the required specification.
You will understand the safety precautions required when carrying out the installation activities with composite mouldings, especially when working in confined spaces and when using the associated materials, 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, environmental and other relevant regulations, directives and guidelines
- follow the relevant instructions, installation drawings and any other documentation
- check that the specified components are available and that they are in a usable condition
- use the correct tools and equipment for the installation operations and check that they are in a safe and usable condition
- use the approved methods and techniques to install, position and secure the assemblies in their correct positions
- check the completed installation to ensure that all operations have been completed and the installed mouldings meet the required specification
- deal promptly and effectively with problems within your control and report those that cannot be solved
- complete relevant documentation
- leave the work area in a safe and appropriate condition on completion of the activities
Knowledge and Understanding
You need to know and understand:
- 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
- the hazards associated with carrying out installation activities and with the composite materials, consumables, tools and equipment used and how to minimise these and reduce any risks
- the protective equipment (PPE) that is needed for personal protection and where required, the protection of others
- the application of COSHH regulations in relation to the storage, use and disposal of composite materials and consumables
- the specific environmental conditions the must be observed when installing composite mouldings
- the safe working practices that are required when working in confined spaces (such as ventilation, use of flammable materials) and emergency procedures that may need to be followed
- 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
- how to interpret drawings, systems of measurement, workpiece reference points and system of tolerancing
- the quality procedures used in the workplace to ensure production control (in relation to currency, issue, meeting specification) and the completion of such documents
- the basic conventions and terminology used for installation activities (such as thread sizes, rivet specifications, bonded join types, clearances, types of fittings)
- how to visually identify cured and no cured composite materials
- the importance of having to check that all services are available prior to starting the installation activity
- the preparation activities required prior to starting the installation activity
- the importance of following the approved installation methods, techniques and sequence
- the methods and equipment to be used for lifting, handling, supporting and manoeuvring the assemblies into their correct positions during and throughout the installation activities
- the techniques used to position, align, adjust and secure the components to the required surfaces without causing damage to the components or surrounding areas
- the types of fixing devices that are used to secure the structures to the required surfaces (such as screws, cavity fixing devices, adhesives, nuts and bolts, rivets and blind fasteners)
- the importance of using the correct fasteners for the particular installation
- the use of sealants and adhesives, and the precautions to be taken when using them
- how to conduct any necessary checks to ensure the integrity, functionality, accuracy and quality of the installation
- how to recognise installation defects (such as misalignment, ineffective fasteners and damage or contamination)
- the problems that can occur with the installation operations, and how these can be prevented
- the tools and equipment used in assembly activities and their care, preparation and control procedures
- the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
- the documentation to be completed during and/or on completion of the installation activity
Scope/range
Scope Performance
Carry out all of the following during the installation activities:
- use the appropriate documentation (such as job instructions, drawings, material data sheets, specifications, planning and quality control documentation)
- 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
- 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
- confirm, where applicable, that service supplies required are available
- check there is sufficient room to complete the installation
- follow additional safe working practices when working in confined spaces, where applicable
- maintain a safe working environment for the composite installation activities
- follow safe practice/approved composite installation techniques at all times
- return all tools and equipment to the correct location on completion of the installation activities
- segregate and dispose of waste materials using the correct procedure
Carry out four of the following activities when preparing for the installation activity:
- check that composite mouldings/assemblies are correct and complete
- check for any defects in the composite mouldings/assemblies
- check that additional components are correct and complete
- confirm that equipment selected is suitable for the installation activity
- confirm any ancillary materials required are available
- identify and protect mouldings and components in the work area
- determine datum points for the installation and composite mouldings/assemblies
Complete one of the following types of installation activity:
- trial installations
- one-off installations
- batch installations
- production line installations
- confined installations
- off-site installations
Use a range of measuring equipment and methods during the installation, to include two of the following:
- moulded datums
- tapes and rules
- laser trackers
- spirit levels
- laser levels
- alignment jigs/fixtures
- other (to be specified)
Use a range of tools and equipment during the installation, to include two of the following:
- hand tools
- power tools
- clamps/cramps
- lifting and handling equipment
- temporary fixing/supporting equipment
- other (to be specified)
Complete installations that require using three of the following features:
- loose fit tolerances
- close fit tolerances
- non-permanent fixing
- permanent fixing
- shape location
- joggle joins
- return joins
- overlap joins
- strap joins
- other specific feature
Install mouldings using two of the following joining methods:
- pinning
- screws
- nuts and bolts
- rivets
- threaded inserts
- cavity fixing devices
- anchor nuts
- quick-release fasteners
- special purpose fasteners
- blind fasteners
- trimming/fettling
- adhesive bonding
- thermo welding
- laminating
- other (to be specified)
Produce a range of assemblies which comply with one of the following standards:
- BS, ISO or BSEN standards and procedures
- customer standards and requirements
- company standards and procedures
- recognised compliance agency/body standards
Complete the relevant documentation, to include one of the following:
- production documentation
- quality control documentation
- job cards
Scope Knowledge
Values
Behaviours
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