Free Aerospace Composite Technician course (4 months)

Aerospace Composite Technician:

Brief Job Description: Aerospace Composite Technician is responsible for performing composite operation on aerospace parts and understanding the part drawings and its process sheets, and understanding the safety points and precautions for manufacturing composite parts. Personal Attributes: The individual should have basic communication ability and should be responsible in order to maintain procedures. He should understand work instructions, possess knowledge of layup of composite parts and vacuum bagging, and possess knowledge on the safety and handling of composite materials and parts.

Understand the composite parts fabrication process for aircraft components/structures

Performance Criteria:

Understanding composite parts for fabrication process

PC1. study and understand the component drawings for fabricating the composite parts mentioned in the drawings.

PC2. ensure availability of route book and plan lay-up sequence, procedure to manufacture a part

PC3. ensure understanding of required fabrication tolerances mentioned in the drawings

PC4. ensure process is finalised and required accessories are available to cut the material

PC5. check with shop supervisor/ designer to finalise the manufacturing process for open mould and closed mould composite parts

PC6. ensure that the forming tool is calibrated before start of tool cleaning; refer to the calibration sticker attached to the tool for the calibration date check

PC7. clean the tool layup surface using right cleaning agent as mentioned in the work instructions/ route book

PC8. ensure appropriate safety factors have been considered and precautions taken to avoid accidents

PC9. follow the various safety instructions mentioned in the work

instructions/ safety sign boards / process sheets

Organisational

Context

KA1. relevant standards & procedures followed in the company

KA2. different types of products manufactured by the company

KA3. different bagging process for different parts

KA4. process flow/ routing of various components in the composite shop/ organisation

Technical Knowledge

KB1. aerospace manufacturing standard and procedures such as ISO 9001, AS9100, etc

KB2. composite raw materials resin, fibre, pre-preg and consumables for processing such as release film, peel ply , bagging film etc.,

KB3. different types of composite manufacturing/ curing processes for parts

KB4. tool manufacturing procedures by wet lay-up process

KB5. different types of tools used in the fabrication of composite parts and their identification

KB6. use various jigs and fixtures and shop tools to orient parts into

pre-defined positions for part fabrication and assembly.

KB7. basic fundamental of hand layup, pre-preg layup & bagging operations

KB8. how to read process sheets and drawings

KB9. interpretation of orientations of layers as per the layup sequence

KB10. composite material properties/shelf life

KB11. basic principles of handling the vacuum bagged components

KB12. loading of components in to the autoclave

KB13. all safety features to be used during layup and bagging

KB14. quality checks after bagging

KB15. release of cured parts from tool , trimming of cured parts.

Skills:

Core Skills/ Generic Skills

Writing Skills

The user/ individual on the job needs to know and understand how to: SA1. write notes and observations on job cards, logs and record SA2. draw basic level drawings and charts

Reading Skills

The user/individual on the job needs to know and understand how to: SA3. read & comprehend documents and notes SA4. interpret/ comprehend the information given in the document monitoring tools SA5. read & interpret symbols given on equipment and work area. SA6. read program and interpret

Oral Communication (Listening and Speaking skills)

The user/individual on the job needs to know and understand how to: SA7. discuss task lists and job requirements with co-workers SA8. effectively communicate information to team members SA9. interact with supervisor and understand the nature of problem SA10. listen with full attention and comprehend the information given by the speaker   Professional Skills Plan and Organise The user/individual on the job needs to know and understand how to: SB1. persuade team members to wear the personal protective equipment as per the requirement SB2. ensure that the team understands the importance of using various machines/ equipment without creating any risk to human/machine   Critical Thinking The user/individual on the job needs to know and understand how to: SB3. analyse, evaluate and apply information gathered from observation, experience, reasoning or communication to act efficiently   Problem Solving The user/individual on the job needs to know and understand how to: SB4. recognise a work place problem or a potential problem and take action SB5. determine problems needing priority action SB6. gather information and provide assistance as required to solve problems SB7. refer problems outside area of responsibility to appropriate person SB8. make decisions in emergency conditions in case supervisor is not available. Analytical Skills This user/ individual on the job needs to know and understand how to: SB9. analyse best possible solutions (cost, time, effort, etc.) suited for operations   Critical Thinking The user/individual on the job needs to know and understand how to: SB10. concentrate on task at hand and complete it without errors SB11. apply balanced judgments to different situations     Perform manual fabrication process of the composites for aircraft components/structures     Performance Criteria   Tools and materials preparation   PC1. ensure the right tool are available for the part layup, refer workk instructions and the route book/ process sheet for the tool number and the part number PC2. ensure the tool is calibrated before start of tool cleaning; refer to the calibration sticker attached to the tool for the calibration date check PC3. clean the tool layup surface using right cleaning agent as mentioned in the work instructions/ route book.   Hand layup of composite parts and bagging   PC4. interpret and gather components drawings, route book, lay up sequence/ sketch for establishing the process control and development controls PC5. ensure the prepeg material should be kept for the required hours at room temperature before use PC6. ensure availability of required materials like prepregs, adhesives, cores, sheet metal details etc. required to start part/assembly fabrication PC7. ensure start lay-up of part as per the layup sequence/ sketch, refer to drawings where required and ensures correctness of material and orientation. Lay-up of travel coupon panels (TC panels) as required and the route book PC8. lay-up (monolithic or sandwich) as per approved drawings/ process sheet PC9. place the thermocouple between the tool surface after completion of lay-up, and lay-up to monitor the temperature during curing PC10. ensure the right bagging film, release film, breather and the sealant are used for bagging; check the shelf life of these materials with the supervisor PC11. prepare vacuum bag and seal the lay-up with vacuum bag, provide the vacuum valves PC12. carry out vacuum leak check, vacuum leak shall be within permissible limits PC13. trim the parts and de-burr as per the drawings. PC14. maintain a clean and safe working environment near the trimming place to avoid contaminated oil/ moisture absorption. PC15. prepare test specimens to the correct dimensions as per the standards/ work instructions   Knowledge and Understanding   Organisational   Context   KA1. relevant standards & procedures followed in the company KA2. different types of products manufactured by the company KA3. different bagging process for different parts KA4. process flow/ routing of various components in the composite shop/ organisation   Technical Knowledge   KB1. aerospace manufacturing standard and procedures such as ISO 9001, AS9100, etc KB2. different types of composite manufacturing/ curing processes KB3. different types of tools used in the fabrication of composite parts and their identification KB4. basic fundamental of hand layup & bagging operations KB5. how to read process sheets and drawings KB6. knowledge of all safety features to be used during layup and bagging KB7. knowledge in the interpretation of orientations of layers as per the layup sequence KB8. knowledge of loading of components in to the autoclave KB9. knowledge in quality checks after bagging KB10. knowledge of composite material properties/shelf life KB11. basic principles of handling the vacuum bagged components   Skills   Core Skills/ Generic Skills Writing Skills The user/ individual on the job needs to know and understand how to: SA1. write notes and observations on job cards, logs and record SA2. draw basic level drawings and charts   Reading Skills The user/individual on the job needs to know and understand how to: SA3. read & comprehend documents, notes SA4. interpret/ comprehend the information given in the document monitoring tools SA5. read & interpret symbols given on equipment and work area SA6. read program and interpret   Oral Communication (Listening and Speaking skills) The user/individual on the job needs to know and understand how to: SA7. discuss task lists and job requirements with co-workers SA8. effectively communicate information to team members SA9. interact with supervisor and understand the nature of problem SA10. listen with full attention and comprehend the information given by the speaker     Professional Skills   Plan and Organise   The user/individual on the job needs to know and understand how to: SB1. persuade team members to wear the personal protective equipment as per the requirement SB2. ensure that the team understands the importance of using various machines/ equipment without creating any risk to human/ machine     Critical Thinking   The user/individual on the job needs to know and understand how to: SB3. analyse, evaluate and apply information gathered from observation, experience, reasoning or communication to act efficiently     Problem Solving   The user/individual on the job needs to know and understand how to: SB4. recognise a work place problem or a potential problem and take action SB5. determine problems needing priority action SB6. gather information and provide assistance as required to solve problems SB7. refer problems outside area of responsibility to appropriate person SB8. make decisions in emergency conditions in case supervisor is not available   Analytical Skills   This user/ individual on the job needs to know and understand how to: SB9. analyse best possible solutions (cost, time, effort, etc.) suited for operations     Critical Thinking Skills   The user/individual on the job needs to know and understand how to: SB10. concentrate on task at hand and complete it without errors SB11. apply balanced judgments to different situations       Perform automatic fabrication process of the composites for aircraft components/structures   Performance Criteria   Tools and material preparation   PC1. interpret and understand the layup sequence mentioned in the drawing/ route card/ process sheet PC2. collect all the required tools from stores PC3. fill up required mixture of composite fibres and resins as mentioned in the process sheet in the hooper. PC4. prepare the prepregs material for moulding and store in the laying up machine   Layup using machine   PC5. ensure that the layup sequence is adhered as per drawings/ process sheet PC6. maintain the required gap between layup rollers and the bench PC7. roll the rollers such that there is continuity in laying up the prepreg material or fix up the ends of the fibre on the machine and fix up on the surface. Ensure procedure/ laying instructions as per the laying up machine are followed PC8. apply adhesives or appropriate bonding on the surface using another sets of roller on the machine PC9. ensure sufficient thickness is been achieved on the surface as per given process sheet/ work instruction PC10. trim the excess material using the cutters on the machine PC11. finish the edges as per procedures provided in the drawing PC12. maintain a clean and safe working environment near the machine to avoid contaminated oil/ moisture absorption   Specimen preparations PC13. prepare the test specimens to the correct dimensions as per the standards/ work instructions PC14. offer parts and specimen to Quality department for inspection   Knowledge and Understanding   Organisational   Context   KA1. relevant standards & procedures followed in the company   (Knowledge of the company / organisation and its processes   KA2. different types of products manufactured by the company KA3. different types of curing processes/tool available KA4. process flow/ routing of various components in the composite shop/ organisation   Technica Knowledge   KB1. aerospace manufacturing standard and procedures such as ISO 9001, AS9100, etc KB2. different types of composite manufacturing/ curing processes KB3. different types of tools used in the fabrication of composite parts and their identification KB4. basic fundamentals of trimming & its operations KB5. how to read process cure cycle drawings and curing the part to get cured components as defined in the process KB6. all safety features, preliminary checking of specimen dimensions KB7. specimen cutting and its standards   Skills   Core Skills/ Generic Skills Writing Skills The user/ individual on the job needs to know and understand how to: SA1. write basic level notes and observations SA2. draw basic level drawing and charts   Reading Skills The user/individual on the job needs to know and understand how to: SA3. read & comprehend documents and notes, process documentation & control plan SA4. interpret/ comprehend the information given in the document & notes SA5. read & interpret symbols given on equipment and work area. SA6. read engineering drawings, sketches, etc.   Oral Communication (Listening and Speaking skills) The user/individual on the job needs to know and understand how to: SA7. discuss task lists and job requirements with co-workers SA8. effectively communicate information to team members SA9. question operator/ supervisor in order to understand the nature of the problem SA10. attentively listen with full attention and comprehend the information given by the speaker     Professional Skills   Decision Making     The user/individual on the job needs to know and understand how to: SB1. make decision on a suitable course of action or response       Plan and Organise     The user/individual on the job needs to know and understand how to: SB2. monitor smooth functioning of all activities SB3. plan and organise work     Customer Centricity The user/individual on the job needs to know and understand how to: SB4. communicate with internal customers with etiquette and share all relevant information SB5. take decisions favoring customers and make them satisfied SB6. maintain effective relationship with the peers   Problem Solving The user/individual on the job needs to know and understand how to: SB7. identify trends/ common causes for error and suggest possible solutions to the supervisor/ management SB8. identify and correct error   Analytical Thinking The user/ individual on the job needs to know and understand how to: SB9. analyse on best possible solutions (cost, time, effort, etc) suited for customer requirement   Critical Thinking The user/individual on the job needs to know and understand how to: SB10. concentrate on task at hand and complete it without errors SB11. apply balanced judgments to different situations   organisation safety and security procedures   Performance Criteria   Comprehending the safety and security procedures   PC1. comply with the organisation’s safety and security policies and procedures PC2. comply with the regulatory guidelines on safe conduct of operations and maintenance of conditions to thwart any acts of unlawful interference PC3. report any identified breaches of safety and security policies and procedures to the designated person PC4. report any theft of organisation property according to the organisation policy PC5. coordinate with other resources at the workplace (within and outside the organisation) to achieve a safe and secure environment PC6. identify and mitigate any safety and security hazards like illness, accidents, fires or acts of unlawful interference if it falls within the limits of the individual’s authority PC7. report any hazards outside the individual’s authority to the relevant person in line with organisational procedures and regulatory guidelines PC8. follow the organisation’s em ergency procedures for accidents, fires or acts of unlawful interference PC9. identify and recommend opportunities for improving health, safety, and security to the designated person PC10. ensure that all health and safety records are updated and procedures are well defined   Knowledge and Understanding   Organisational  context   KA1. hazard identification and risk management as defined within the organisational policy and procedures KA2. legislative requirements and organisation’s procedures for maintenance of safety and security standards and individual’s role and responsibilities in relation to this KA3. how and when to report hazards KA4. the limits of responsibility for dealing with hazards KA5. the organisation’s emergency procedures for different emergency situations and the importance of following these KA6. the importance of maintaining high standards of safety and security KA7. implications that any non-compliance with safety and security may have on individuals and the organisation   Technical Knowledge   KB1. different types of breaches of safety and security and how and when to report these KB2. evacuation procedures for workers KB3. how to summon medical assistance and the emergency services, where necessary KB4. how to use the health, safety and accident reporting procedures and the importance of these KB5. regulatory guidelines on dealing with safety and security emergencies   Skills   Core Skills/ Generic Skills Writing Skills The user/ individual on the job needs to know and understand how to: SA1. complete accurate, well written report in English language detailing the situations of emergency with attention to detail   Reading Skills The user/individual on the job needs to know and understand how to: SA2. read instructions, guidelines/procedures/rules   Oral Communication (Listening and Speaking skills) The user/individual on the job needs to know and understand how to: SA3. listen to and orally communicate information with all concerned     Professional Skills   Decision Making   The user/individual on the job needs to know and understand how to: SB1. make decisions on a suitable course of action or response if permitted by the authority matrix     Plan and Organise   The user/individual on the job needs to know and understand how to: SB2. monitor efficient functioning of all activities SB3. plan and organise work to achieve targets and deadlines     Customer Centricity   The user/individual on the job needs to know and understand how to: SB4. communicate with customers in a courteous manner SB5. maintain effective relationship with the customers   Problem Solving   The user/individual on the job needs to know and understand how to: SB6. identify trends/common causes for errors and suggest possible solutions to the supervisor / management SB7. identify and correct errors     Analytical Thinking   The user/individual on the job needs to know and understand how to: SB8. analyse best possible solutions (cost, time, effort, etc) suited for operations     Critical Thinking   The user/individual on the job needs to know and understand how to: SB9. concentrate on task at hand and complete it without errors SB10. apply balanced judgments to different situations     Maintain 5S at the work premises     Performance Criteria   Ensure sorting   PC1. follow the sorting process and check that the tools, fixtures & jigs that are lying on workstations are the ones in use and un- necessary items are not cluttering the workbenches or work surfaces. PC2. ensure segregation of waste in hazardous/ non hazardous waste as per the sorting work instructions PC3. follow the technique of waste disposal and waste storage in the proper bins as per sop PC4. segregate the items which are labeled as red tag items for the process area and keep them in the correct places PC5. sort the tools/ equipment/ fasteners/ spare parts as per specifications/ utility into proper trays, cabinets, lockers as mentioned in the 5S guidelines/ work instructions PC6. ensure that areas of material storage areas are not overflowing PC7. properly stack the various types of boxes and containers as per the size/ utility to avoid any fall of items/ breakage and also enable easy sorting when required PC8. return the extra material and tools to the designated sections and make sure that no additional material/ tool is lying near the work area PC9. follow the floor markings/ area markings used for demarcating the various sections in the plant as per the prescribed instructions and standards     Ensure proper documentation and storage   PC10. follow the proper labeling mechanism of instruments/ boxes/ containers and maintaining reference files/ documents with the codes and the lists PC11. check that the items in the respective areas have been identified as broken or damaged PC12. follow the given instructions and check for labeling of fluids, oils. lubricants, solvents, chemicals etc. and proper storage of the same to avoid spillage, leakage, fire etc. PC13. make sure that all material and tools are stored in the designated places and in the manner indicated in the 5S instructions   Ensure cleaning of self and the work place   PC14. check whether safety glasses are clean and in good condition PC15. keep all outside surfaces of recycling containers are clean PC16. ensure that the area has floors swept, machinery clean and generally clean. in case of cleaning, ensure that proper displays are maintained on the floor which indicate potential safety hazards PC17. check whether all hoses, cabling & wires are clean, in good condition and clamped to avoid any mishap or mix up PC18. ensure workbenches and work surfaces are clean and in good condition PC19. follow the cleaning schedule for the lighting system to ensure proper illumination PC20. store the cleaning material and equipment in the correct location and in good condition PC21. ensure self-cleanliness – clean uniform, clean shoes, clean gloves, clean helmets, personal hygiene   Ensure sustenance   PC22. follow the daily cleaning standards and schedules to create a clean working environment PC23. attend all training programs for employees on 5S PC24. support the team during the audit of 5S PC25. participate actively in employee work groups on 5S and encourage team members for active participation PC26. follow the guidelines for what to do and what not to do to build sustainability in 5S as mentioned in the 5S check lists/ work instructions   Knowledge and Understanding   Organisational  context   KA1. relevant standards, procedures and policies related to 5S followed in the company   Technical Knowledge   KB1. have basic knowledge of 5S procedures KB2. know various types 5s practices followed in various areas KB3. understand the 5S checklists provided in the department/ team KB4. have skills to identify useful & non useful items KB5. have knowledge of labels , signs & colours used as indicators KB6. have knowledge on how to sort and store various types of tools, equipment, material etc. KB7. how to identify various types of waste products KB8. understand the impact of waste/ dirt/ dust/unwanted substances on the process/ environment/ machinery/ human body KB9. have knowledge of best ways of cleaning & waste disposal KB10. understand the importance of standardisation in processes KB11. understand the importance of sustainability in 5S KB12. have knowledge of TQM process KB13. have knowledge of various materials and storage norms KB14. understand visual controls, symbols, graphs etc   Skills   Core Skills/ Generic Skills Writing Skills The user/ individual on the job needs to know and understand how to: SA1. write basic level notes and observations SA2. note down observations (if any) related to the process SA3. write information documents to internal departments/ internal teams   Reading Skills The user/individual on the job needs to know and understand how to: SA4. read 5S instructions put up across the plant premises   Oral Communication (Listening and Speaking skills) The user/individual on the job needs to know and understand how to: SA5. effectively communicate information to team members inform employees in the plant and concerned functions about 5S SA6. question the process head in order to understand the 5S related issues SA7. listen with full attention and comprehend the information given by the speaker during 5S training programs     Professional Skills Judgmental Thinking The user/individual on the job needs to know and understand how to: SB1. use common sense and make judgments during day to day basis SB2. use reasoning skills to identify and resolve basic problems using 5S   Persuasion The user/individual on the job needs to know and understand how to: SB3. persuade co team members to follow 5S SB4. ensure that the co-team members understand the importance of using 5S tool   Creativity The user/individual on the job needs to know and understand how to: SB5. use innovative skills to perform and manage 5S activities at the work desk and the shop floor SB6. exhibit inquisitive behavior to seek feedback and question on the existing set patterns of work   Self-Discipline The user/individual on the job needs to know and understand how to: SB7. do what is right, not what is a popular practices SB8. follow shop floor rules& regulations and avoid deviations; make 5S an integral way of life SB9. ensure self-cleanliness on a daily basis SB10. demonstrate the will to keep the work area in a clean and orderly manner   Work effectively in a team   Performance Criteria   Support the work team PC1. display courteous and helpful behaviour at all times PC2. take opportunities to enhance the level of assistance offered to colleagues PC3. meet all reasonable requests for assistance within acceptable workplace timeframes PC4. complete allocated tasks as assigned PC5. seek assistance when difficulties arise PC6. use questioning techniques to clarify instructions or responsibilities, PC7. identify and display a non-discriminatory attitude in all contacts with customers and other staff members   Maintain personal presentation PC8. observe appropriate dress code and presentation as required by the workplace, job role and level of customer contact PC9. follow personal hygiene procedures according to organisational policy   Develop effective work habits PC10. interpret, confirm and act on workplace information, instructions and procedures relevant to the particular task PC11. interpret, confirm and act on legal requirements with regards to anti- discrimination, sexual harassment and bullying PC12. ask questions to seek and clarify workplace information PC13. plan and organise daily work routine within the scope of the job role PC14. prioritise and complete tasks according to required timeframes PC15. identify work and personal priorities and achieve a balance between competing priorities   Knowledge and Understanding   Organisational Context KA1. policies and procedures relating to the job role KA2. the value system of the organisation KA3. employee rights and obligations   Technical Knowledge KB1. ask questions to identify and confirm requirements KB2. follow routine instructions through clear and direct communication KB3. use language and concepts appropriate to cultural differences KB4. use and interpret non-verbal communication KB5. the scope of information or materials required within the parameters of the job role KB6. consequences of poor team participation on job outcomes KB7. work health and safety requirements   Skills Core Skills/ Generic Skills Writing Skills, On the job the individual needs to be able to: SA1. complete documentation accurately SA2. write simple reports when required Reading Skills On the job the individual needs to be able to: SA3. read information accurately SA4. read and interpret data sheets Oral Communication (Listening and Speaking skills) The user/individual on the job needs to know and understand how to: SA5. listen to and orally communicate information with all concerned   Professional Skills   Decision Making   On the job the individual needs to be able to: SB1. make appropriate decisions regarding the responsibilities of the job role   Plan and Organise   The user/individual on the job needs to know and understand how to: SB2. monitor efficient functioning of all activities SB3. plan and organise work to achieve targets and deadlines   Customer Centricity   The user/individual on the job needs to know and understand how to: SB4. communicate with customers and other stakeholders in a courteous manner SB5. maintain effective work relationship Problem Solving   The user/individual on the job needs to know and understand how to: SB6. identify trends/common causes for errors and suggest possible solutions to the supervisor / management SB7. identify and correct errors   Analytical Thinking   The user/individual on the job needs to know and understand how to: SB8. analyse best possible solutions (cost, time, effort, etc.) suited for operations   Critical Thinking   The user/individual on the job needs to know and understand how to: SB9. concentrate on task at hand and complete it without errors SB10. apply balanced judgments to different situations       Guidelines for Assessment 1. Criteria for assessment for each Qualification Pack will be created by the Sector Skill Council. Each Performance Criteria (PC) will be assigned marks proportional to its importance in NOS. SSC will also lay down proportion of marks for Theory and Skills Practical for each PC. 2. The assessment for the theory part will be based on knowledge bank of questions created by the SSC. 3. Assessment will be conducted for all compulsory NOS, and where applicable, on the selected elective/option NOS/set of NOS. 4. Individual assessment agencies will create unique question papers for theory part for each candidate at each examination/training center (as per assessment criteria below). 5. Individual assessment agencies will create unique evaluations for skill practical for every student at each examination/training center based on this criterion. 6. To pass the Qualification Pack, every trainee should score a minimum of 60% of aggregate marks to successf ully clear the assessment. 7. In case of unsuccessful completion, the trainee may seek reass essment on the Qualification Pack.