Checking that completed assemblies comply with specification
Overview
This standard identifies the competences you need to carry out checks on mechanical assemblies on completion of maintenance activities, in accordance with approved procedures. You will be required to prepare the work area, ensuring that it is safe and free from hazards, obtaining all relevant and current documentation, and obtaining the tools and equipment required for checking the mechanical assemblies, and making sure that they are calibrated and in a safe and usable condition.
You will be expected to conduct ongoing trials, manual checks and operational checks throughout the overhaul re- assembly operations, and to check component parts and sub-assemblies, where appropriate. You will be responsible for confirming that the overhauled assembly is complete, fit for purpose, and meets the operational performance required by the specification. In carrying out checks on the mechanical assemblies, you will also be required to complete any relevant documentation accurately and legibly.
Your responsibilities will require you to comply with organisational policy and procedures for checking the overhauled mechanical assembly, and to report any problems with the re-assembly you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You will be expected to ensure that all tools and equipment used in checking the re-assembly are correctly accounted for on completion of the activities and returned to the correct location. 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 quality control techniques and procedures including, where appropriate, British, European and International standards. You will understand the mechanical product being overhauled and re-assembled, and its application, and will know about the tools and equipment used to check the assembly, in adequate depth to provide a sound basis for carrying out the activities to the required specification. You will understand the types of defect that can be found on the re-assembly, and how critical these defects are in determining the satisfactory performance of the completed product.
You will understand the safety precautions required when carrying out the re-assembly activities. 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 and make appropriate use of the specifications for the assembly being checked
- use all the correct tools and inspection equipment and check that they are in a useable condition
- carry out the checks, in an appropriate sequence, using approved methods and procedures
- identify and assess any defects or variations from the specification, and take appropriate action
- report completion of checking activities, in line with organisational procedures
Knowledge and Understanding
You need to know and understand:
- how to work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- regulations with regard to the substances used in the re-assembly process
- the hazards associated with checking mechanical assemblies, and how to minimise them and reduce any risks
- the personal protective equipment (PPE) and clothing to be worn during the re-assembly checking activities
- how to use and extract information from engineering drawings and related specifications (to include symbols and conventions to appropriate 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
- the use of relevant standards in determining if components and products are fit for purpose
- the general principles of quality assurance systems and procedures
- the various stages when the overhauled re-assembly should be checked, and to what level
- preparations to be undertaken before the re-assembly is checked
- the application of the various tools and equipment used to check the re-assembly
- the importance of ensuring that tools and equipment are set up correctly and are in a safe and useable condition
- the procedure and methods used to check that tools and equipment are within calibration date
- how to conduct any necessary checks to ensure the safety, accuracy, position, security, function and completeness of the re-assembly
- outline the quality control procedures to be followed when checking the assembly
- the types of defect that can be found on overhauled mechanical assemblies, and why they occur
- how to detect assembly defects, and what to do to rectify them
- the documentation to be completed to confirm that the overhauled assembly has been properly checked
- the importance of ensuring that all tools and equipment are returned to their correct location on completion of the re-assembly checking activities
- the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
Scope/range
Scope Performance
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- Carry out all of the following during the checking activities:
- obtain and use the appropriate documentation
- 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
- follow safe practice/approved inspection and checking techniques at all times
- check that all tools and measuring equipment are within current calibration/certification dates
- use lifting and slinging equipment in accordance with health and safety guidelines and procedures
- ensure that all exposed openings are maintained free from foreign objects, dirt or other contamination
- return all tools and equipment to the correct location on completion of the inspection activities
- leave the work area in a safe and appropriate condition on completion of the activities
- Check the mechanical assembly, using twelve of the following instruments and gauges:
- rule or tape
- dial test indicator
- pressure gauges
- levels
- squares
- flow meters
- straight edges
- gauges
- temperature gauges
- micrometers
- slip gauges
- optical equipment
- vernier guages
- torque wrench
- electrical measuring equipment
- feeler gauges
- protractors
- other specific equipment
- Use the relevant equipment to measure and check seven of the following features:
- flatness
- alignment
- fit/working clearance
- parallelism
- distortion
- squareness
- level
- angles
- position/location
- torque
- concentricity
- verticality
- dimensions
- bonding strength
- other specific feature
- Check the operational functions of the overhauled mechanical assembly, to include eight of the following:
- rotation
- speed
- movement
- tension
- sequence
- direction
- pressure
- balance
- electrical in/outputs
- distance/travel
- sliding
- flow
- vibration
- fluid power in/outputs
- noise
- timing
- reciprocation
- temperature
- safety mechanisms
- leakage
- power
- service supplies (water, gas, air, electrical supply)
- other specific function
- Ensure that the completed assembly meets the specification, using two of the following checks:
- trial
- under power
- fully operational
- manual check
- Check that the overhauled mechanical assemblies comply with one of the following:
- BS, ISO or BSEN standards and procedures
- customer standards and requirements
- company standards and procedures
- specific equipment requirements