Free Aircraft Powerplant Technician course (6months)

Aircraft Powerplant Technician:

Brief Job Description: Aircraft Powerplant Technician is responsible for assembly of engine modules, complete engine, engine accessories and LRU’s.

Personal Attributes: Key attributes for Aircraft Powerplant Technician would include good communication skills, excellent written communication skills and good interpersonal skills with a keen eye for details.

Aircraft Powerplant Technician

Safety and security procedures:-

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. coordinate with other resources at the workplace (within and outside the organisation) to achieve safe and secure environment

PC5. identify and mitigate any safety and security hazards like illness, accidents, fires or acts of unlawful interference if it falls within the limits of individual’s authority

PC6. report any hazards outside the individual’s authority to the relevant person in line with organisational procedures and regulatory guidelines

PC7. follow organisation’s emergency procedures for accidents, fires or acts of unlawful interference

PC8. identify and recommend opportunities for improving health, safety, and security to the designated person

PC9. ensure all health and safety records are updated and procedures are well defined.

Organisational Context:

KA1. hazard identification and risk management as defined within the organisational policy and procedures

KA2. regulatory 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. 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 and passengers

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 accurately a 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 Organize
The user/individual on the job needs to know and understand:
SB2. monitor efficient functioning of all activities
SB3. plan and organize 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 cordial 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.


Maintenance training - Training and flight ops - Airbus



The process of aero-engine assembly/disassembly:


Understanding the assembly/disassembly process
 
PC1. understand all types of drawings, sketches and work instructions at the beginning of the assembly/disassembly
PC2. understand of geometric dimensions and tolerances
PC3. understand the rigs, gauges, standard tools, torque wrenches etc.
PC4. understand the basics of aero engine and its parts
PC5. understand the various materials, parts and consumables used during assembly/disassembly process
PC6. understand the criticality of sub-assemblies of an aero engine.
PC7. understand the right assembly/disassembly methodology and various process parameters like torque application, fitting tolerances, bolting and fastening as mentioned in the work instruction/organisation maintenance manuals
PC8. understand 5 S related to the work area
PC9. while understanding the drawings and sketches,he/she must ensure that the observed problems are highlighted to concerned supervisor
PC10. understand the changes which may happen from time to time in assembly/disassembly process based on the approved engine configuration
PC11. red flagging of the deviations during the assembly of engine and raising it to concerned supervisor/Quality Inspectors.





Organisational Context 

KA1. relevant standards and procedures followed in the organisation
KA2. different types of aero-engines
KA3. different types of manuals containing work related information
KA4. 5S and safety norms practiced in the organisation
 
Technical
Knowledge
KB1. how to read engineering drawings, sketches, process sheet etc.
KB2. geometrical dimensioning and tolerance limits
KB3. use of standard tools like torque wrenches, spanners, sockets etc.
KB4. use of standard measuring instruments like dial gauges, comparators, bore gauges, passometers, vernier callipers, slip gauges etc
KB5. different types of assembling processes like fitting, bolting, torquing, tightening etc.
KB6. basic computer knowledge for verifying the drawings
KB7. basic knowledge regarding quality management
KB8. basic principles of 5S manufacturing-cleaning, sorting, scrap handling etc.
 
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 in the given format
SA3. write information documents to concerned departments/teams under guidance of supervisor
SA4. enter the information in Inspection record sheets, relevant registers etc.
 
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
SA6. read the organisation/manufacturer manuals and process documents
 
Oral Communication (Listening and Speaking skills)
The user/individual on the job needs to know and understand how to:
SA7. effectively discuss and communicate regarding targets, activities, processes etc with supervisor and co-workers
SA8. question supervisor in order to understand the nature of problem
 
 
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 Organize
The user/individual on the job needs to know and understand how to:
SB2. plan, organise and prioritise the job received from the production manager
SB3. validate all the process/equipment manuals so that the final process selection is correct
SB4. support the supervisor in scheduling tasks for timely completion of the job
 
Customer Centricity
The user/individual on the job needs to know and understand how to:
SB5. communicate with stakeholders in a courteous manner
SB6. maintain cordial working relationship
 
Problem Solving
The user/individual on the job needs to know and understand how to:
SB7. recognise a work place problem or a potential problem and take action
SB8. determine problems needing priority action
SB9. gather information and provide assistance as required to solve problems
 
SB10. refer problems outside area of responsibility to approach person
SB11. make decision in emergency conditions in case supervisor is not available
 
Analytical Skills
The user/individual on the job needs to know and understand how to:
SB12. 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:
SB13. analyse, evaluate and apply information gathered from observation, experience, reasoning or communication to act efficiently
 
 

Aircraft Powerplant Technician



Assembly/disassembly of aero-engine  
 
Performance Criteria
Disas semble aero-engine modules into piece parts
PC1. receive the modules at the workshop area and perform visual inspection of the modules to identify defects
PC2. receive the documentation received with the modules to ensure that all relevant deta ils are filled in the documents as per regulatory/organisational policies and procedures
PC3. install the modules on the disassembly rig and perform diassembly of the modules into piece parts
PC4. visually inspect the disassembled piece parts and record the defects observed on the piece parts to ascertain if the defects are within acceptable limits to certify airworthiness of the piece parts
PC5. tag the piece parts with the appropriate tags and ensure all relevant information is filled as per regulatory/organisation policy and procedures
PC6. dispatch the piece parts to the relevant component shops for inspection and repair as deemed necessary
 
Perform assembly of aero engine modules
PC7. receive the components and piece parts from the component shops and perform visual inspection to ensure no defects on the received parts
PC8. ensure that defects, if any , are within the airworthiness limits for module assembly
PC9. inspect and verify the airworthiness tags issued by the component shops and ensure that the tags are in line with regulatory/organisational policies and procedures
PC10. install the components and piece parts on the module assembly rig
PC11. perform assembly of the module
PC12. visually inspect the module post assembly to ensure that there are no defects on the module beyond the airworthiness requirements
PC13. issue the documentation and relavent tags for the module and dispatch the module for final engine assembly
 
Knowledge and Understanding
 
Organisational
Context
KA1. relevant standards and procedures followed in the organisation
KA2. different types of aero-engines
KA3. different types of manuals containing work related information
KA4. 5S and safety norms practiced in the organisation
 
Technical
Knowledge
KB1. how to read engineering drawings, sketches, process sheet etc.
KB2. geometrical dimensioning and tolerance limits
KB3. use of standard tools like torque wrenches, spanners, sockets etc.
KB4. use of standard measuring instruments like dial gauges, comparators, bore gauges, passometers, vernier callipers, slip gauges etc.
KB5. different types of assembling processes like fitting, bolting, torquing, tightening etc.
KB6. basic computer knowledge for verifying the drawings
KB7. basic knowledge regarding quality management
KB8. basic principles of 5S manufacturing-cleaning, sorting, scrap handling etc
 
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 in the given format
SA3. write information documents to concerned departments/teams under guidance of supervisor
SA4. enter the information in Inspection record sheets, relevant registers etc.
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
SA6. read the organisation/manufacturer manuals and process documents
Oral Communication (Listening and Speaking skills)
The user/individual on the job needs to know and understand how to:
SA7. effectively discuss and communicate regarding targets, activities, processes etc with supervisor and co-workers
SA8. question supervisor in order to understand the nature of problem
 
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 Organize
The user/individual on the job needs to know and understand how to:
SB2. plan, organise and prioritise the job received from the production manager
SB3. validate all the process/equipment manuals so that the final process selection is correct
SB4. support the supervisor in scheduling tasks for timely completion of the job
Customer Centricity
The user/individual on the job needs to know and understand how to:
SB5. communicate with stakeholders in a courteous manner
SB6. maintain cordial working relationship
Problem Solving
The user/individual on the job needs to know and understand how to:
SB7. recognize a work place problem or a potential problem and take action
SB8. determine problems needing priority action
SB9. gather information and provide assistance as required to solve problems
SB10. refer problems outside area of responsibility to approach person
SB11. make decision in emergency conditions in case supervisor is not available
Analytical Skills
The user/individual on the job needs to know and understand how to:
SB12. 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:
SB13. analyse, evaluate and apply information gathered from observation, experience, reasoning or communication to act efficiently
 
Aircraft Powerplant Technician


Aero engine module disassembly/assembly
Performance Criteria
 
Disassemble aero-engine into modules
PC1. perform visual inspection of the bare assembled engine and record the visual findings on the engine
PC2. perform fuel and oil draining procedure on the engine prior to disassembly as per the procedures detailed in the job cards/manufacturer manuals/organisation maintenance manuals
PC3. remove the engine accessories installed on the engine cases as per the procedures detailed in the job cards/manfacturer manuals/organisation maintenance manuals
PC4. perform disassembly of the engine into its modules as per manufacturer manuals and organisation maintenance manuals
PC5. ensure blanking is performed on all required areas to prevent an foreign object entering the modules, accessories and LRU’s
PC6. perform visual inspection of the modules and record the visual findings on the modules
PC7. tag the modules with the relevant information as required under regulatory/organisational policies and procedures
PC8. dispatch the modules to the appropriate module shops for further disassembly
PC9. dispatch the accessories and other LRU’s to the respective component shops for testing and repair with appropriate tags
 
Perform assembly of aero engine, accessories and LRU’s
PC10. receive the modules from the respective modular shops and perform visual inspection on the modules to certify airworthiness of the modules
PC11. inspect the documentation received along with the modules to ensure completeness of the documentation in respect to airworthiness requirements set forth by regulator/organisational policy and procedures
PC12. assemble the modules in sequence as detailed in the job card/manufacturer manuals/organisation maintenance manuals
PC13. visually inspect the assembled modules to ensure no damage has occurred during assembly.
PC14. inspect and verify if any damage found is acceptable withint the airworthiness limits for engine operations
PC15. receive engine acessories and LRU’s from the component shops and inspect and verify that the accessories and LRU’s are airworthy to be installed on the engine
PC16. inspect the documentation received along with the modules to ensure completeness of the documentation in respect to airworthiness requirements set forth by regulator/organisational policy and procedures
PC17. install the accessories and LRU’s in sequence as detailed in the job card/manufacturer manuals/organisa tion maintenance manuals
PC18. visually inspect the installed accessories and LRU’s to ensure no damage has occurred during installation.
PC19. inspect and verify if any damage found is acceptable withint the airworthiness limits for engine operations
PC20. dispatch the assembled engine to the engine test cell
 
Knowledge and Understanding
Organisational
Context
KA1. relevant standards and procedures followed in the organisation
KA2. different types of aero-engines
KA3. different types of manuals containing work related information
KA4. 5S and safety norms practiced in the organisation
 
Technical
Knowledge
KB1. how to read engineering drawings, sketches, process sheet etc.
KB2. geometrical dimensioning and tolerance limits
KB3. use of standard tools like torque wrenches, spanners, sockets etc.
KB4. use of standard measuring instruments like dial gauges, comparators, bore gauges, passometers, vernier callipers, slip gauges etc.
KB5. different types of assembling processes like fitting, bolting, torquing, tightening etc.
KB6. basic computer knowledge for verifying the drawings
KB7. basic knowledge regarding quality management
KB8. basic principles of 5S manufacturing-cleaning, sorting, scrap handling etc.
 
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 in the given format
SA3. write information documents to concerned departments/teams under guidance of supervisor
SA4. enter the information in Inspection record sheets, relevant registers etc.
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
SA6. read the organisation/manufacturer manuals and process documents
Oral Communication (Listening and Speaking skills)
The user/individual on the job needs to know and understand how to:
SA7. effectively discuss and communicate regarding targets, activities, processes etc with supervisor and co-workers
SA8. question supervisor in order to understand the nature of problem
 
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 Organize
 
The user/individual on the job needs to know and understand how to:
 
SB2. plan, organise and prioritise the job received from the production manager
 
SB3. validate all the process/equipment manuals so that the final process selection is correct
 
SB4. support the supervisor in scheduling tasks for timely completion of the job
 
Customer Centricity
 
The user/individual on the job needs to know and understand how to:
 
SB5. communicate with stakeholders in a courteous manner
 
SB6. maintain cordial working relationship
 
Problem Solving
 
The user/individual on the job needs to know and understand how to:
 
SB7. recognize a work place problem or a potential problem and take action
 
SB8. determine problems needing priority action
 
SB9. gather information and provide assistance as required to solve problems
 
SB10. refer problems outside area of responsibility to approach person
 
SB11. make decision in emergency conditions in case supervisor is not available
 
Analytical Skills
 
The user/individual on the job needs to know and understand how to:
 
SB12. 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:
 
SB13. analyse, evaluate and apply information gathered from observation, experience, reasoning or communication to act efficiently
 



 
Prevent FOD during engine assembly/disassembly
 
 
Performance Criteria
 
Prevent FOD during assembly/disassembly
 
PC1. ensure the availability of blanking, cover etc. at the work place
PC2. ensure that no FOD is available near the assembly/disassembly area
PC3. ensure proper availability of tools, fixtures and parts
PC4. ensure proper accounting of material and tools used during assembly/diassembly
PC5. ensure all the open cavities are properly blanked/ covered after the completion of work
 
Knowledge and Understanding
 
Organisational
 
Context
KA1. relevant standards and procedures followed in the Company
KA2. different types of aero-engines
KA3. different types of assembly/disassembly processes
KA4. quality management practices of the organisation
KA5. 5S and Safety norms practiced in the organization
Technical
Knowledge
KB1. how to read and interpret engineering drawings, sketches, process sheet etc.
KB2. different types of FOD’s that can occur at the workplace
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. how to use lifting tools like hoists, cranes, clamps etc.
KB6. basic computer knowledge for verifying the Drawings
KB7. basic knowledge regarding quality management
KB8. basic principles of 5S manufacturing-cleaning, sorting, scrap handling etc.
 
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
 
Decision Making
The user/individual on the job needs to know and understand:
SB1. make decisions on a suitable course of action or response if permitted by the authority matrix
 
Plan and Organize
The user/individual on the job needs to know and understand:
SB2. plan, organise and prioritise the job received from the Production Manager
SB3. validate all the process/equipment manuals so that the final process selected is correct
SB4. support the supervisor in scheduling tasks for tool and die making
 
Customer Centricity
The user/individual on the job needs to know and understand:SB5. communicate with stakeholders in a courteous manner
SB6. maintain cordial work relationship
 
Problem Solving
The user/individual on the job needs to know and understand how to:
SB5. recognise a work place problem or a potential problem and take action
SB6. determine problems needing priority action
SB7. gather information and provide assistance as required to solve problems
SB8. refer problems outside area of responsibility to approach person
SB9. make decision in emergency conditions in case of supervisor are not available
 
Analytical Thinking
The user/individual on the job needs to know and understand how to:
SB10. 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:
SB11. analyse, evaluate and apply information gathered from observation, experience, reasoning or communication to act efficiently
 
Maintain 5S at the work premises
Performance Criteria
 
Ensure sorting
 
PC1. follow the sorting process and check that the tools, fixtures and 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 (organizing, streamlining
 
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
KB9. substances on the process/ environment/ machinery/ human body
KB10. have knowledge of best ways of cleaning & waste disposal
KB11. understand the importance of standardization in processes
KB12. understand the importance of sustainability in 5S
KB13. have knowledge of TQM process
KB14. have knowledge of various materials and storage norms
KB15. 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 comply with the information given by the speaker during 5S training programs
 
 
Professional Skills
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:
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:
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
 
 

Model Curriculum
Aircraft Powerplant T echnician:

Follow safety and security procedures
 
 comprehend the organisation’s safety and security policies and procedures
 comprehend the regulatory guidelines on safe conduct of operations and main tenance of conditions to thwart any acts of unlawful interference
 report any identified breaches of safety, and security policies and procedures to the designated person
 coordinate with other resources at the workplace (within and outside the organization) to achieve safe and secure environment
 identify and mitigate any safety and security hazards like illness, accidents, fires or acts of unlawful interference if it falls within the limits of individual’s authority
 report any hazards outside the individual’s authority to the relevant person in line with organisational procedures and regulatory guidelines
 follow organisation’s emergency procedures for accidents, fires or acts of unlawful interference
 identify and recommend opportunities for improving health, safety, and security to the designated person
 complete all health and safety records are updates and procedures well defined
 
Understand the process of aero engine assembly
 
understand all types of drawings, sketches and work instructions at the beginning of the assembly/disassembly
 understand of geometric dimensions and tolerances
 understand the rigs, gauges, standard tools, torque wrenches etc.
 understand the basics of aero engine and its parts
 understand the various materials, parts and consumables used during assembly/disassembly process
 understand the criticality of sub-assemblies of an aero engine
 understand the right assembly/disassembly methodology
 
and various process parameters like torque application, fitting tolerances, bolting and fastening as mentioned in the work instruction/organisation maintenance manuals
 understand 5 S related to the work area
 while understanding the drawings and sketches,he/she must ensure that the observed problems are highlighted to concerned supervisor
 understand the changes which may happen from time to time in assembly/disassembly process based on the approved engine configuration
 red flagging of the deviations during the assembly of engine and raising it to concerned supervisor/Quality Inspectors
 
Assembly/disassembly of aero-engine
 
receive the modules at the workshop area and perform visual inspection of the modules to identify defects
 receive the documentation received with the modules to ensure that all relevant details are filled in the documents as per regulatory/organisational policies and procedures
 install the modules on the dis-assembly rig and perform dis-assembly of the modules into piece parts
 visually inspect the disassembled piece parts and record the defects observed on the piece parts to ascertain if the defects are within acceptable limits to certify airworthiness of the piece parts
 tag the piece parts with the appropriate tags and ensure all relevant information is filled as per regulatory/organisation policy and procedures
 dispatch the piece parts to the relevant component shops for inspection and repair as deemed necessary
 To be competent, the user/individual on the job must be able to:
 receive the components and piece parts from the component shops and perform visual inspection to ensure no defects on the received parts
 if any defects found, ensure that the defects are within the airworthiness
limits for module assembly
 inspect and verify the airworthiness tags issued by the component shops and ensure that the tags are in line with regulatory/organisational policies and procedures
 install the components and piece parts on the module assembly rig
 perform assembly of the module
 visually inspect the module post assembly to ensure that there are no defects on the module beyond the airworthiness requirements
 issue the documentation and relevant tags for the module and dispatch the module for final engine assembly
 
Perform aero-engine module
disassembly/assembly
 
perform visual inspection of the bare assembled engine and record the visual findings on the engine
 perform fuel and oil draining procedure on the engine prior to disassembly as per the procedures detailed in the job cards/manufacturer manuals/organisation maintenance manuals
 remove the engine accessories installed on the engine cases as per the procedures detailed in the job cards/manfacturer manuals/organisation maintenance manuals
 perform disassembly of the engine into its modules as per manufacturer manuals and organisation maintenance manuals
 ensure blanking is performed on all required areas to prevent an foreign object entering the modules, accessories and LRU’s
 perform visual inspection of the modules and record the visual findings on the modules
 tag the modules with the relevant information as required under regulatory/organisational policies and procedures
 dispatch the modules to the appropriate module shops for further disassembly
 dispatch the accessories and other LRU’s to the respective component shops for testing and repair with appropriate tags
 To be competent, the user/individual
 
on the job must be able to:
 receive the modules from the respective modular shops and perform visual inspection on the modules to certify airworthiness of the modules
 inspect the documentation received along with the modules to ensure completeness of the documentation in respect to airworthiness requirements set forth by regulator/organisational policy and procedures
 assemble the modules in sequence as detailed in the job card/manufacturer manuals/organisation maintenance manuals
 visually inspect the assembled modules to ensure no damage has occurred during assembly.
 If any damage found, inspect and verify if the damage is acceptable within the airworthiness limits for engine operations
 receive engine accessories and LRU’s from the component shops and inspect and verify that the accessories and LRU’s are airworthy to be installed on the engine
 inspect the documentation received along with the modules to ensure completeness of the documentation in respect to airworthiness requirements set forth by regulator/organisational policy and procedures
 install the accessories and LRU’s in sequence as detailed in the job card/manufacturer manuals/organisation maintenance manuals
 visually inspect the installed accessories and LRU’s to ensure no damage has occurred during installation.
 If any damage found, inspect and verify if the damage is acceptable within the airworthiness limits for engine operations
 dispatch the assembled engine to the engine test cell
 
Prevention of FOD during engine assembly/disassembly
 
ensure the availability of blanking, cover etc. at the work place
 ensure that no FOD is available near the assembly/disassembly area
 ensure proper availability of tools, fixtures and parts
 ensure proper accounting of material and tools used during assembly/disassembly
 ensure all the open cavities are properly blanked/ covered after the completion of work
 
Maintain 5S at the work premises
 
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.
 ensure segregation of waste in hazardous/ non Hazardous waste as per the sorting work instructions
 follow the technique of waste disposal and waste storage in the proper bins as per SOP
 segregate the items which are labeled as red tag items for the process area and keep them in the correct places
 sort the tools/ equipment/ fasteners/ spare parts as per specifications/ utility into proper trays, cabinets, lockers as mentioned in the 5S guidelines/ work instructions
 ensure that areas of material storage areas are not overflowing
 properly stack the various types of boxes and containe rs as per the size/ utility to avoid any fall of items/ breakage and also enable easy sorting when required
 return the extra material and tools to the designated sections and make sure that no additional material/ tool is lying near the work area
 follow the floor markings/ area markings used for demarcating the various sections in the plant as per the prescribed instructions and standards
 follow the proper labeling mechanism of instruments/ boxes/ containers and maintaining reference files/ documents with the codes and the lists
 check that the items in the respective
 
areas have been identified as broken or damaged
 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.
 make sure that all material and tools are stored in the designated places and in the manner indicated in the 5S instructions
 check whether safety glasses are clean and in good condition
 keep all outside surfaces of recycling containers are clean
 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
 check whether all hoses, cabling & wires are clean, in good condition and clamped to avoid any mishap or mix up
 ensure workbenches and work surfaces are clean and in good condition
 follow the cleaning schedule for the lighting system to ensure proper illumination
 store the cleaning material and equipment in the correct location and in good condition
 ensure self-cleanliness – clean uniform, clean shoes, clean gloves, clean helmets, personal hygiene
 follow the daily cleaning standards and schedules to create a clean working environment
 attend all training programs for employees on 5S
 support the team during the audit of 5 S
 participate actively in employee work groups on 5S and encourage team members for active participation
 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
 
 
Unique equipment used;
 Cut-out model of a typical aero engine
 Ground Power Unit (GPU)
 Fire extinguisher
 Aircraft engine hoists
 
Performing aerospace welding operations
 
 ensure wearing of Personnel Protective Equipment (PPE) that suits the task such as flame-resistant aprons, safety helmet & hand shields, ear plugs, footwear, safety goggles etc.
 comply with organisations Occupational Health & Safety (OHS) standards
 ensure that work area around the welding transformer, gas discharge unit, flux wire are clean as mentioned in the work instruction / Standard Operating Procedure (SOP) of organisation
 ensure that the welding work area is not around explosives or ignitable material and adequate ventilation is available for exhaust of fumes and gases
 check for correctness of power, coolant and operating parts of the machine
 escalate any queries to the supervisor
 ensure that the required welding material (electrodes, flux wire etc) is issued from the stores
 setup welding equipment as per selected welding process or approved Welding Procedure Specification (WPS) and Procedure Qualification Records (PQR)
 ensure work piece / test piece are clean from burrs
 prepare the edge of work piece / test piece as per the approved drawing specification and welding procedures
 
ensure appropriate clamps, jigs and fixtures are available to hold the work piece / test piece to be welded
 select appropriate wire / electrode as per engineering drawings, type of welding joints or approved WPS & PQR
 select appropriate gas, pressure, amperage and voltage as per approved WPS & PQR
 perform the required welding process / technique on a test coupon as per approved WPS and PQR in the presence of supervisor, client or under supervision of third party approver
 get the test coupon approval for welding positions from supervisor, client or by third party approver
 assist supervisor in maintaining a log book with name, approved certificate no., approved welding position etc.
 select appropriate wire / electrode as per engineering drawings, type of welding joints or approved WPS & PQR
 select appropriate gas, pressure, amperage and voltage as per approved WPS & PQR
 register the work piece / section to be welded to the shop supervisor
 understand the fabrication tolerances, root gap, hot pass margins as per the welding specification and approved WPS & PQR for type of weld joint
 perform tag welding to the work piece and obtain approval from supervisor
 perform full weld as per WPS & PQR and avoid over welding
 finish the surface by filing, brushing etc.
 inform supervisor about completion and perform self-check of the finished output and send it for the next process as per instructions
 
 
Unique equipment used;
 Gas cylinder
 Safety gagets (gloves, apron, goggles, nose mask & ear plugs)
 Welding helmets
 TIG welding machine, with foot pedal
 Special Tool Kit
 Mechanical tool box
 Welding material (Inconel & SS321)
 Fillet
 
 
Guidelines for Assessment
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.
The assessment for the theory part will be based on knowledge bank of questions created by the SSC.
Assessment will be conducted for all compulsory NOS, and where applicable, on the selected elective/option NOS/set of NOS.
Individual assessment agencies will create unique question papers for theory part for each candidate at each examination/training center (as per assessment criteria below
Individual assessment agencies will create unique evaluations for skill practical for every student at each examination/training center based on this criterion.
To pass the Qualification Pack , every trainee should score a minimum of 70% of aggregate marks to successfully clear the assessment.
In case of unsuccessful completion, the trainee may seek reassessment on the Qualification Pack.
 
 
 

 
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