Free Aerospace Jigs and Fixture Technician course (6 months)

Aerospace Jigs and Fixture Technician:

Brief Job Description of Aerospace Jigs & Fixture Technician: Aerospace Jigs & Fixture Technician is responsible for getting the jigs and fixtures assembled for various purposes and carry out repairs and maintainance of tooling including dies, jigs and fixtures within predetermined timescales.

Personal Attributes: The individual should have basic communication ability and should be responsible in order to maintain procedures. He should possess numerical and computational abilities, openness to learning, ability to plan and organise own work and identify and solve problems in the course of working, understanding the need to take initiative and manage self and work to improve efficiency and effectiveness.

jig and fixture assembly operations for producing aircraft parts:-

Performance Criteria

Jigs & fixture pre-assembly

PC1. check the assembly drawing of jigs and fixture and interpret the specifications, manuals and plan assembly operations

PC2. ensure all components are available for the assembly and are free from surface defects

PC3. ensure the right tools required for assembly and fabrication of jigs and fixture are available

PC4. ensure availability of joining parts like clamps, brackets, nuts, bolts, fasteners, collars, adhesives, sealants etc. at the assembly platform

PC5. check the lifting portion is appropriately marked on the component

PC6. check availability of crane, fork-lift, hand pulled truck etc for material handling.

Assembly of jigs and fixture:-

PC7. set up the components as per assembly sequence

PC8. match the components as per assembly drawing / work instruction / process sheet

PC9. perform drilling, reaming, bolting, riveting etc as per required fitment provided in the assembly drawing

PC10. use crane, fork-lift etc incase of lifting heavy components

PC11. assemble the components together as per assembly drawing / work instruction / process sheet

PC12. carry out load test on the jigs & fixtures as defined in the process sheet / work instruction

PC13. ensure the dimensions of jigs and fixture are as per assembly drawing and use measuring instruments or CMM or laser tracker to measure it

PC14. make necessary engineering changes to suit the job

PC15. ensure all do’s and don’ts are adhered while assembling the components together.

Jig and Fixture inspection and documentation–

PC16. conduct the trial tests of fixture to ensure conformance to the standards

PC17. send the completed jigs and fixtures for dispatch to the required next process level

PC18. ensure all records related to production of jigs and fixtures are maintained in the format used by the organisation/ process mentioned in the work instructions PC19. ensure that proper data related to rejections and bad quality is separately maintained as per internal processes.

Knowledge and Understanding:

Organisational

Context

KA1. relevant standards & procedures followed in the company

KA2. different types of products manufactured by the company

KA3. different types of manufacturing processes

KA4. quality management practices of the organisation

KA5. 5S & safety norms practiced in the organisation.

Technical

Knowledge

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

KB2. how to read and interpret engineering drawings, sketches, process sheet etc.

KB3. how to use machine manuals and the standard measuring instruments and gauges

KB4. how to read and interpret the standard measuring instruments and gauges

KB5. different types of machining processes like drilling, turning, milling, grinding, boring, cutting etc.

KB6. other manufacturing processes like heat treatment, plating, wire cut EDM, CNC machining etc.

KB7. to operate hand held tools for reaming, drilling , torque wrench etc.,

KB8. different types of assembling processes like fitting, bolting, torque tightening etc.,

KB9. different types of joining processes like welding, brazing, riveting, bolting associated with these processes

KB10. how to use lifting tools like hoists, cranes, clamps etc.

KB11. basic computer knowledge for verifying the drawings

KB12. basic knowledge regarding quality management

KB13. how to visualise the final product and the impacts of various physical parameters on the properties of the final outputs

KB14. manufacturing defects associated with the machining and related processes and impact of the defects on the final product output

KB15. basic principles of 5S manufacturing-cleaning, sorting, scrap handling etc.

KB16. basic knowledge of six sigma tools and quality measurement metrics.

Core Skills/ Generic Skills:

Writing Skills

The user/ individual on the job needs to know and understand how to: SA1. document the available information SA2. note down observations (if any) in the given format SA3. write information documents to concerned departments/teams under guidance of supervisor SA4. enter the information in online ERP systems under guidance of the supervisor   Reading Skills The user/individual on the job needs to know and understand how to: SA5. read and interpret engineering drawings, sketches and symbols used in both SA6. read and understand various tolerances and technical specifications of the product SA7. read the equipment manuals and process documents SA8. read and interpret technical customer drawings Oral Communication (Listening and Speaking skills) The user/individual on the job needs to know and understand how to: SA9. effectively discuss and communicate regarding Targets, activities, processes etc. with supervisor and co-workers SA10. question Supervisor in order to understand the nature of problem     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: SB3. analyse, evaluate and apply information gathered from observation, experience, reasoning or communication to act efficiently   Problem Solving   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 approach person SB8. make decisions in emergency conditions in case of supervisor are not available Analytical Skills The 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     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 emergency 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       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 Cri teria   Ensure sorting PC1. follow the sorting process and check that thetools, fixtures & jigs that are lying on workstations are the ones in use and unnecessary itemsare 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. know , 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.   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. attentively 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 jobs needs to know and understand how to: SB3. persuade co team members to follow 5 S SB4. ensure that the co team members unde rstand 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 behaviour to seek feedback and question on the existing set patterns of work 20 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 SB11. ensure self-cleanliness on a daily basis SB12. 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   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 successfully clear the assessment. 7. In case of unsuccessful completion, the trainee may seek reassessment on the Qualification Pack.