Assembling marine composite components
Overview
This standard identifies the competences you need to produce marine composite assemblies from composite components and non-composite components, in accordance with approved procedures. You will be required to work to instructions, specifications and documentation to produce the composite assemblies, using the correct techniques. The marine composite assemblies produced will include items such as bulkheads, hulls, superstructure, masts, spars, fairings, air intakes, steering equipment, rudders, skegs, tanks, casings and coverings, davits and internal fitments such as berths, vanity standards, consoles, seating, and shower standards.
Your responsibilities will require you to comply with organisational policy and procedures for the composite 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 with either a high level of supervision or as a member of a team. You will take personal responsibility for your own actions and for the quality and accuracy of the work that you carry out. Where team working is involved, you must demonstrate a significant personal contribution during the team activities in order to satisfy the requirements of the standard, and competence in all the areas required by the standard must be demonstrated.
Your underpinning knowledge will be sufficient to provide a good understanding of your work, and will provide an informed approach to applying assembly techniques and procedures to marine composite components. You will have an understanding of the composite assembly techniques used, and their application, in adequate depth to provide a sound basis for carrying out the activities, recognising faults, and ensuring that 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.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- follow the relevant instructions, assembly drawings and any other specifications
- ensure that the specified components are available and that they are in a usable condition
assemble the components in their correct positions using appropriate methods and techniques
secure the components using the specified connectors and securing devices
produce marine composite assemblies to the relevant standards
check the completed component assembly to ensure that all operations have been completed and the finished assembly meets the required specification
- deal promptly and effectively with problems within your control and report those that cannot be solved
- complete relevant paperwork, in accordance with organisational requirements
- 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 in the specific work area, when working with composite materials, consumables, tools and equipment
- the hazards associated with assembling composite materials, and with the consumables, tools and equipment used, and how to minimise these in the work area
- the protective equipment that is needed for personal protection (PPE) 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 workshop environmental conditions that must be observed when producing marine mouldings (such as temperature, humidity, styrene levels to threshold limits, fume/dust extraction systems and equipment)
- how to use and extract information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS, EN or ISO standards) in relation to work undertaken
- how to use imperial and metric systems of measurement, workpiece reference points and system of tolerancing
- preparations to be undertaken on the composite components prior to assembly
- the assembly/joining methods, techniques and procedures to be used, and the importance of adhering to these procedures
- how the components are to be aligned, adjusted, positioned and clamped prior to assembly, and the tools and equipment that is used for this
- the importance of using the specified basic components and joining devices for the assembly, and why you must not use substitutes
- where appropriate, the application of sealants and adhesives within the assembly activities, and the precautions that must be taken when working with them
- the quality control procedures to be followed during the assembly operations
- methods for handling composite assemblies throughout the assembly activities
- tools and equipment used in assembly activities, and their care, preparation and control procedures
- why tool/equipment control is critical and what to do if a tool or piece of equipment is unaccounted for on completion of the activities
- the problems that can occur with the assembly activities and how they can be avoided
- the extent of your own authority, and whom you should report to if you have problems that you cannot resolve
- the documentation to be completed during and/or on completion of the assembly activity
Scope/range
Scope Performance
Carry out all of the following during the marine composite assembly activities:
- use the correct issue of assembly documentation (such as job instructions, drawings, specifications)
- use relevant health and safety documentation (such as material data sheets, COSHH sheets, risk assessments)
- maintain a safe working environment for the moulding activities
- use the correct tools and equipment for the activity, and ensure that they are safe to use
- ensure that components to be used are of the correct type, and that all mouldings are free from defects
- apply safe and appropriate assembly techniques at all times
- keep the work area in a safe and tidy condition
- return all tools and equipment to the correct location on completion of the assembly activities
Produce one of the following types of marine composite assembly:
- one-off assemblies
- batch assemblies
- assembly line
Produce marine composite assemblies that incorporate two of the following features:
- loose fit tolerances
- non-permanent fixing
- staggered joins
- return joins
- close fit tolerances
- shape location
- permanent fixing
- overlap joins
- other specific feature
Produce marine composite assemblies that require two of the following methods to be used:
- fettling
- clamping
- aligning
- pinning
- trial fitting
- assembly jigs
- other specific method
Produce marine composite assemblies that use one of the following joining methods:
- thread inserts
- laminating
- adhesive bonding
- quick-release fasteners
- mechanical fasteners
- pins
- rivets
- anchor nuts
- other (to be specified)
Assemble marine composite components, which include two of the following:
- hull
- masts
- berths
- fairings
- vanity standards
- rudder
- spars
- air intakes/vents
- hatches
- steering equipment
- wheel houses
- skegs
- shower standards
- consoles
- superstructure
- cabins
- casings/coverings
- davits
- bulkheads
- tanks
- radar/navigational domes
- seating
- other marine assemblies
Produce marine composite assemblies which include one of the following non-composite components:
- brackets
- trim
- memory foam
- fixtures
- tapes
- films
- fittings
- other specific fitting
Produce marine composite assemblies in accordance with one of the following standards:
- BS, ISO or BSEN standards and procedures
- company standards and procedures
- customer standards and requirements
- recognised compliance agency/body's standards
Complete the relevant paperwork, to include one from the following and pass it to the appropriate people:
- build records
- quality/acceptance documentation
- system log
- job cards
- work authorisation documents
- other specific reporting method
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