Restoring mechanical components to usable condition by repair
Overview
This standard identifies the competences you need to restore mechanical components to usable condition by repair, in accordance with approved procedures. You will be required to restore a range of mechanical components and equipment to operational condition, by repairing assemblies/sub-assemblies and components, by reworking the surface, recutting threads, or by the replacement of worn parts. You will also be required to select the appropriate equipment to use, based on the nature of the repair, the operations that will need to be carried out and the accuracy to be achieved.
In producing the components, you will be expected to use a range of hand tools, machine tools, portable power tools, and shaping and fitting techniques, appropriate to the type of material and repair being performed. These activities will include such processes as sawing (hand, band), drilling, reaming, grinding (hand or pedestal), filing, scraping or lapping, threading (internal or external), machining (turning, milling) and thermal processes.
Your responsibilities will require you to comply with organisational policy and procedures for the repairing activities undertaken, and to report any problems with these activities or with the tools, equipment or materials used, that you cannot personally resolve or are outside your permitted authority, to the relevant people. You will be expected to work to instructions, alone or in conjunction with others, taking personal responsibility for your own actions, and for the quality and accuracy of the work that you carry out.
Your underpinning knowledge will be sufficient to provide a sound basis for your work, and will provide an informed approach to applying component repair procedures. You will have an understanding of the function and operating conditions of the components being repaired, in sufficient depth to determine if a suitable repair can be made and to ensure that the repairs carried out are safe and practical in operation. You will also understand the organisational policy on repairing components, and its application.
You will understand the safety precautions required when carrying out the repairing activities, especially those for isolating the equipment. You will also understand your responsibilities for safety and the importance of taking the necessary safeguards to protect yourself and others in the workplace.
Performance criteria
You must be able to:
P1 work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
P2 follow the relevant specifications for the component to be repaired
P3 prepare the component for repair
P4 carry out the repair activities within agreed timescale using approved materials and components and methods and procedures
P5 ensure that the repaired component meets the specified operating conditions
P6 complete and store all relevant documentation in accordance with organisational requirements
Knowledge and Understanding
You need to know and understand:
K1 how to work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
K2 the isolation procedure or permit-to-work procedure that applies
K3 the importance of wearing the appropriate personal protective equipment (PPE), and of keeping the work area clean and tidy
K4 how to obtain and interpret information from job instructions and other documentation used in the repairing activities
K5 the methods, techniques and company procedures to be followed for repairing mechanical equipment
K6 the types of repairs that can be made to components in order to prolong their life span
K7 how to use a range of hand tools
K8 how to select saw blades (for different materials and different operations)
K9 the types and application of portable power tools that can be used for the repairing operations
K10 how to confirm that portable power tools and extension cables are in a safe, tested and usable condition
K11 the operating requirements of the machine tools and accessories being used
K12 how to handle and store tools and equipment, safely and correctly
K13 the application of cutting fluids
K14 the company recording procedures to be used following a repair, and how to apply them
K15 the issues associated with repairing mechanical components, and how to resolve them
K16 the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
Scope/range
Scope Performance
1. Carry out all of the following activities during the repairing activity:
1.1. undertake the repairing activities to cause minimal disruption to normal working
1.2. adhere to procedures or systems in place for risk assessment, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
1.3. use the correct issue of drawings, job instructions and procedures
1.4. check that tools and equipment to be used are fit for purpose
1.5. use correct lifting techniques and equipment (where appropriate), in accordance with health and safety guidelines and procedures
1.6. ensure that repaired components are clean, and free from contamination and foreign objects
1.7. record the repair, using appropriate methods or documentation
1.8. dispose of waste items in a safe and environmentally acceptable manner
1.9. leave the work area in a safe and tidy condition
2. Carry out four of the following types of repair activities:
2.1. reforming component surface by adding metal
2.2. replacement of internal thread (inserts)
2.3. recondition unit by replacement of worn components
2.4. rework fit (shimming)
2.5. rework surface finish (using techniques such as filing, scraping, grinding)
2.6. making new or stepped keys
2.7. replacing damaged or missing gear teeth
2.8. sleeving worn components
2.9. plugging holes
2.10. making stepped dowels or studs
2.11. stopping cracks running and filling them
2.12. cutting new keyways
2.13. make temporary fix
2.14. bushing worn holes
2.15. other specific repair procedures
3. Carry out repair activities on mechanical components, using four of the following methods
3.1. sawing (hand, band)
3.2. threading external
3.3. drilling
3.4. threading internal
3.5. reaming
3.6. turning
3.7. grinding (hand or machine)
3.8. milling
3.9. filing
3.10. thermal processes (such as brazing, welding, metal spraying)
3.11. scrapping or lapping
4. Carry out repair activities to mechanical equipment, in accordance with one of the following:
4.1. organisational guidelines and codes of practice
4.2. equipment manufacturer’s operation range
4.3. BS, ISO and/or BSEN standards
5. Complete one of the following records, and pass it to the appropriate person:
5.1. job cards
5.2. permit to work/formal risk assessment and/or sign-on/off procedures
5.3. maintenance log or report
5.4. organisational-specific documentation
5.5. electronic reports