Trimming marine composite mouldings
Overview
This standard identifies the competences you need to trim marine composite mouldings using hand tools, in accordance with approved procedures. You will be required to use appropriate drawings, specifications and documentation, and to use the correct trimming techniques to trim various mouldings.
You will be expected to select the correct tools and equipment for the trimming activity. You will trim a range of composite mouldings incorporating a variety of features, and will use cutting, sanding, drilling and polishing techniques and processes. Mouldings 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 trimming 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 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 provide a good understanding of your work, and will provide an informed approach to applying composite moulding trimming techniques and procedures. You will understand the trimming techniques used, and their application, in adequate depth to provide a sound basis for carrying out the activities 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.
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 relevant specifications for the component to be produced
- obtain the appropriate tools and equipment for the trimming operations and check they are in a safe, tested and usable condition
- trim the materials using appropriate methods and techniques
- check that all the required trimming operations have been completed to the required specification
- deal promptly and effectively with problems within your control and report those that cannot be solved
- complete relevant documentation in line with organisational procedures
Knowledge and Understanding
You need to know and understand:
- 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 trimming composite materials, and with the consumables and tools and equipment used, and how to minimise these in the work area
- 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 workshop environmental conditions the must be observed when trimming marine mouldings (such as temperature, humidity, styrene levels to threshold limits, fume/dust extraction systems and equipment)
- how to use and extract information from drawings and related specifications (to include symbols and conventions to appropriate BS or ISO standards) in relation to work undertaken
- how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing
- quality procedures used in the workplace to ensure production control (in relation to currency, issue, meeting specification), and the completion of appropriate documents
- conventions and terminology used for composite trimming activities (such as scribe lines, sanding grades, types of cutting tools, speeds)
- how different materials can effect the selection of tip tool geometry when cutting and trimming composite mouldings
- the different types of manual and power tools used in the trimming operations
- the various types of cutting tools and abrasives that are used, and their applications
- the different types of resins, fibres and reinforcement that are used, how they effect the trimming activities, and the tools and equipment that may be used
- the visual identification of cured composite materials
- how to mark out the mouldings in preparation for the trimming activities, and the tools and equipment to be used
- the methods used in the trimming of composite mouldings
- how to carry out polishing activities on the mouldings, and the equipment and compounds that are used
- how to carry out drilling, hole sawing and finishing operations (such as countersinking), and the various tools that are used
- tools and equipment used in the trimming activities, and their care, preparation and control procedures
- the care and safe handling of composite mouldings throughout the trimming cycle
- the problems that can occur with the trimming operations, and what to do if they occur
- the extent of your own responsibility and whom you should report to if you have problems that you cannot resolve
Scope/range
Scope Performance
Carry out all of the following during the composite trimming activities:
- use the correct issue of production documentation (such as drawings, manuals, specifications, job cards)
- use relevant health and safety documentation (such as material data sheets, COSHH sheets, risk assessments)
- use the correct tools and equipment for the activity, and ensure that they are safe to use and suitably stored
- keep the work area in a safe and tidy condition
Carry out all of the following activities when preparing for the trimming activity:
- check that the moulding is correct and complete
- check that equipment is suitable for use
- check for any defects in the moulding
- identify and protect the moulding in the work area
- select the correct equipment for the activity
Mark out mouldings using all of the following methods:
- scriber
- moulded scribe lines
- height gauge
- centre punch
- trimming templates
Cut mouldings using three the following methods:
- cutting wheels/discs
- routers
- hacksaws
- trim jigs
- jigsaws
Sand mouldings using three of the following methods:
- rubbing blocks
- pencil grinders
- diamond files
- disc sanders
- belt sanders
Produce and finish holes, using three of the following:
- drills
- counterbores
- hole saws
- countersinks
- threading devices
Polish mouldings using four of the following methods:
- wet sanding
- polishing compound
- orbital sander
- cutting compound
- rubbing block
- polisher
Trim mouldings manufactured from two of the following resin types:
- polyester
- epoxy resin
- vinyl ester
- phenolic resin
Trim mouldings manufactured from two of the following fibre types:
- polyethylene
- aramid
- hybrid
- glass
- carbon
Trim mouldings that require, or incorporate, eight of the following features:
- straight edges
- nett edges
- further lay-up stages
- curved edges
- joggle details
- inserts to be drilled
- flat surfaces
- removal of join lines
- inserts to be tapped
- polished surfaces
- multiple holes
- solid cores
- shaped surfaces
- multiple hole sizes
- honeycomb cores
- radiused corners
- countersinks
- edge filling
- returns
- counterbores
Trim a range of mouldings which comply with one of the following standards:
- BS, ISO or BSEN standards and procedures
- customer (contractual) standards and requirements
- company standards and procedures
- 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
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