Restoring mechanical components to usable condition by repair

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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 reforming, reworking the surface, replacing threads or the replacement of worn parts. You will also be required to select the appropriate equipment to use, based on the nature of the repair required, the operations that will need to be carried out and the accuracy required.

In restoring 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, or machine), drilling, reaming, grinding (hand or machine), filing, scraping or lapping, threading internal, threading external, turning, milling and thermal processes. Materials to be used may include ferrous, non-ferrous, non-metallic and composites, which may be in sheet form, bar sections (such as square/rectangular, round, angle), and part-machined components.

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 that 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 repair procedures to mechanical components. You will understand the function and operating conditions of the components being repaired, in sufficient depth to determine a suitable repair sequence 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 repair activities, especially those for isolating equipment. You will be required to demonstrate safe working practices throughout, and will understand your responsibility for taking the necessary safeguards to protect 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 the relevant specifications for the component to be repaired
3. prepare the component for repair
4. carry out the repairs within agreed timescales, using approved materials and components and methods and procedures
5. ensure that the repaired component meets the specified operating conditions
6. produce accurate and complete records of all repair work carried out

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1. how to work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
2. the isolation procedures or permit-to-work procedure that applies
3. the importance of wearing protective clothing (PPE) and other appropriate safety equipment during the repair process
4. the hazards associated with the operations being carried out  and how to minimise them and reduce any risks
5. where to obtain, and how to interpret, drawings, specifications, manufacturers' manuals, maintenance schedules and other documents identifying parameters of the equipment being repaired
6. how to carry out currency/issue checks on the specifications you are working with
7. the methods and techniques to be followed for repairing mechanical equipment, in compliance with company procedures
8. the types of repair that can be made to components in order to prolong their useful life
9. the factors to be taken into account when deciding if a repair is practical and possible
10. the need to liaise with other departments in order to have specialised operations carried out on the components
11. how to use filing, scraping and lapping to achieve the required surface finish
12. how to cut internal and external threads
13. how to produce a sliding or mating fit, and the techniques to be adopted
14. how to select saw blades for different materials and different operations
15. the types and application of portable power tools that can be used for the repair operations
16. how to check that portable power tools and extension cables are in a safe, tested and usable condition
17. how to use hand power tools and specialist equipment correctly
18. the operating requirements of the machine tools and accessories being used
19. the various shapes and types of tooling that can be used
20. how to handle and store tools and equipment, safely and correctly
21. factors which affect the selection of cutting feeds and speeds, and the depth of cut that can be taken
22. the application of cutting fluids with regard to a range of different materials and processes
23. the clamping of a workpiece in a chuck/workholding device (including safely secured for the process, not causing distortion in the finished components)
24. how to recognise machining faults, and how to identify when tools need re-sharpening/dressing
25. the operating requirements of the thermal processes and accessories being used (including any statutory regulations and quality standards to be observed, guards, workholding devices, fume extraction, gas storage)
26. the company recording procedures to be used following a repair, and how to apply them
27. the procedure for the safe disposal of waste materials
28. the types of problem associated with repairs, and how to resolve them
29. the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve

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1. Carry out all of the following during the maintenance activity:
   1. plan the repair activities to cause minimal disruption to normal working
   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
   3. ensure the safe isolation of equipment (such as mechanical, electricity, gas, air or fluids)
   4. provide and maintain safe access and working arrangements for the maintenance area
   5. carry out the repair activities using appropriate techniques and procedures
   6. record the repair in the appropriate methods or documentation
   7. dispose of waste items in a safe and environmentally acceptable manner, and leave the work area in a safe condition
2. Use appropriate techniques to carry out six of the following types of repair:
   1. reforming the component surface by adding metal
   2. replacement of internal thread (thread inserts)
   3. recondition a unit by replacement of worn components
   4. reworking the fit (shimming)
   5. sleeving worn components
   6. replacement/reworking of worn keys/keyways
   7. making stepped dowels, keys or studs
   8. replacing damaged or missing gear teeth
   9. cutting new keyways
   10. plugging holes
   11. making a temporary fix
   12. stopping cracks running, and filling them
   13. bushing worn holes
   14. reworking the surface finish (using techniques such as filing, scraping, lapping, grinding)
   15. other specific repair procedure
3. Use a range of methods and techniques to repair components, to include six of the following:
   1. sawing (such as hand, band, machine)
   2. filing
   3. turning
   4. drilling
   5. scraping or lapping
   6. milling
   7. reaming
   8. threading external
   9. thermal processes (such as brazing, welding, metal spraying)
   10. grinding (hand or machine)
   11. threading internal
4. Repair components made from different types of material, to include two from the following:
   1. low carbon steel
   2. aluminium
   3. plastic/synthetic
   4. high carbon steel
   5. brass/bronze
   6. composite
   7. cast iron
   8. stainless steel
5. Carry out repairs to mechanical components in compliance with one of the following:
   1. BS, ISO or BSEN standards and procedures
   2. organisational guidelines and codes of practice
   3. equipment manufacturer's operation range
   4. other accepted international standards

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3

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31 Mar 2028

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Current

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Original

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Enginuity

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SEMMME3104

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Engineering, Engineering and Manufacturing Technologies, Engineering Technicians

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3113

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Mechanical engineering; overhaul; restoring; mechanical components; usable condition; repair; reform; recondition; replace; rework; low carbon steel; high carbon steel; cast iron; aluminium; brass; bronze; stainless steel; plastic; synthetic; composite

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