Carrying out trimming operations on marine composite mouldings

This standard identifies the competencies you need to trim marine composite mouldings using hand tools, in accordance with approved procedures. You will be required to follow the appropriate instructions, drawings, specifications and documentation to trim various composite mouldings, using the correct trimming techniques.

You will be expected to select and use the correct tools and equipment for the trimming activity. You will trim a range of composite mouldings, incorporating a variety of features, by using cutting, sanding, drilling and polishing techniques and processes. Marine mouldings to be trimmed will include a range of resin and fibre materials.

Your responsibilities will require you to comply with organisational policy and procedures for the trimming activities undertaken, and to report any problems with the 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, 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 be sufficient to provide a good understanding of your work, and will provide an informed approach to applying trimming techniques and procedures to marine composite mouldings. You will have an understanding of the trimming techniques used, and their application, in adequate depth to provide a sound basis for carrying out the activities, recognising faults and ensuring that the trimmed mouldings are to the required specification.

You will understand the safety precautions required when carrying out the trimming 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 and other relevant regulations, directives and guidelines
2. follow relevant specifications for the component to be trimmed
3. obtain the appropriate tools and equipment for the trimming operations and check they are in a safe, tested and usable condition
4. trim the materials using appropriate methods and techniques
5. check that all the required trimming operations have been completed to the required specification
6. deal promptly and effectively with problems within your control and report those that cannot be solved
7. complete relevant paperwork, in accordance with organisational requirements
8. leave the work area in a safe and appropriate condition on completion of the activities

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1. 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 trimming composite materials, consumables, tools and equipment, and how to minimise these in the work area
3. protective equipment that is needed for personal protection (PPE) 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 workshop environmental conditions that must be observed when trimming marine mouldings (such as temperature, humidity, styrene levels to threshold limits, fume/dust extraction systems and equipment)
6. 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
7. how to interpret drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing
8. how to prepare for the trimming activities, and how to mark out the mouldings for the material to be removed
9. how to carry out drilling, hole sawing and finishing operations (such as countersinking), and the various tools that are used
10. how to carry out polishing activities on the mouldings, and the equipment and compounds that are used

11. quality procedures used in the workplace to ensure production control (in relation to currency, issue, meeting specification)

12. conventions and terminology used for trimming activities (such as scribe lines, sanding grades, types of cutting tools, speeds)

13. the different types of manual and power tools used in composite trimming operations
14. the different types of cutting tools and abrasives used in trimming composite materials, and their application
15. 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
16. the visual identification of cured composite materials
17. the identification of defects in composite mouldings
18. the methods used in the trimming of composite mouldings
19. the care and safe handling of composite mouldings throughout the trimming cycle
20. the extent of your own authority, and whom you should report to if you have problems that you cannot resolve
21. the documentation to be completed during and/or on completion of the trimming activity

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

   1. use the appropriate documentation (such as job instructions, drawings, specifications, correct issue number)
   2. use relevant health and safety documentation (such as material data sheets, COSHH sheets, risk assessments)
   3. use the correct tools and equipment for the activity, and ensure that they are safe to use
   4. apply safe and appropriate trimming techniques and working practices at all times
   5. keep the work area in a safe and tidy condition
   6. return all tools and equipment to the correct location on completion of the trimming activities

2. Carry out all of the following when preparing for the trimming activity:

   1. check that the moulding is correct and complete
   2. check for any defects in the moulding
   3. identify and protect the moulding in the work area

3. Mark out the mouldings using four of the following methods:

   1. scriber                           
   2. moulded scribe lines
   3. height gauge                  
   4. centre punch
   5. trimming templates

4. Trim mouldings using one the following methods:

   1. cutting wheels/discs            
   2. routers
   3. saws                                    
   4. trim jigs
   5. other (to be specified)

5. Sand the mouldings, using two of the following methods:

   1. rubbing blocks              
   2. pencil grinders
   3. diamond files                
   4. disc sanders
   5. belt sanders

6. Use a hand drill or pedestal drill to drill and finish mouldings, using two of the following:

   1. drill jigs                      
   2. counterbore tools
   3. hole saws                    
   4. countersink tools
   5. drill bits             
   6. threading devices
   7. other specific tool

7. Polish mouldings using three of the following methods:

   1. wet sanding                      
   2. polishing compound
   3. cutting compound            
   4. rubbing block
   5. orbital sander                  
   6. polisher

8. Trim mouldings using appropriate techniques for both of the following:

   1. resins (such as polyester, vinyl ester, epoxy, phenolic, bismaleimide, cyanate ester )
   2. fibres (such as polyethylene, glass, aramid, carbon, hybrid)

9. Trim mouldings that require, or incorporate, five of the following features:

   1. straight edges                      
   2. holes
   3. curved edges                     
   4. multiple hole sizes
   5. flat surfaces                       
   6. countersinks
   7. polished surfaces                
   8. counterbores
   9. shaped surfaces                   
   10. further lay-up stages
   11. radius corners                     
   12. inserts to be drilled
   13. returns                               
   14. inserts to be tapped
   15. nett edges                          
   16. solid cores
   17. joggle details                      
   18. honeycomb cores
   19. removal of join lines             
   20. edge filling
   21. other specific feature

10. Trim marine composite mouldings, in accordance with one or more 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's standards

11. Complete the relevant paperwork, to include one from the following and pass it to the appropriate people:

    1. build records
    2. quality/acceptance documentation
    3. system log
    4. job cards
    5. work authorisation documents
    6. other specific reporting method

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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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01 Feb 2021

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Current

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Original

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Semta

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SEMME2060

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Engineering, Engineering and Manufacturing Technologies

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5235

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Engineering; marine; trimming; composite; mouldings; cutting; sanding; drilling; polishing

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