Skilled Operator - Dynamic Composite Components - Level 3

JOB PURPOSE

The manufacture and inspection of Vital assemblies requires the utmost discretion to ensure aircraft safety.

Operators are expected to work flexibly in any of the following general areas with limited cross area flexibility:

• Composite manufacturing techniques
• Fitting techniques
• Maintaining techniques
• Process bath techniques
• Electrical techniques

KEY JOB ACCOUNTABILITIES

The Composite Fitter role includes but not restricted to, the following key accountabilities:

Main responsibilities will include, but not be limited to:

• Manufacture of Vital assemblies
• Manufacture of components and sub-assemblies in the production of Vital assemblies
• The ability to work in one of the following ‘work centres’ in DCC:
• Clean Room composite activity including material cutting, ‘laying up’ bagging and processing and the operation of various material processing machines including Desitech,X-Y table and automatic tape layers.
• Autoclave processing
• Detail/assembly pre-treatment techniques including operation of Vapormatt machine.
• Machine tool and roto-peening
• Process baths
• Final assembly detail fitting and caulking
• Press operation and cure cycle monitoring
• Test specimen manufacture
• Detail assembly de-flashing and trimming (fettling activities)
• Post survey repair work including strip and rebuild of main and tail rotor blades
• Support to other skilled disciplines within DCC as workloads and requirements dictate
• DIA operation (active on most products and is being introduced on all levels via a shop-led implementation team)

 ESSENTIAL KNOWLEDGE, SKILLS & EXPERIENCE

Recognised apprenticeship in a mechanical or aerospace discipline

• AQS techniques (I week)
• Manual Handling (1 day)
• Crane operation (1 day)
• Health & Safety Training (1 week)
• Essential knowledge of, working with and manufacturing process
• Ability to interpret engineering drawing techniques defining composite lay-up definition (not covered by BS908 drawing as normally taught in Colleges)
• Knowledge of WHPS specifications and plant control requirements e.g. process baths
• Knowledge of Company Quality Operating System and Planning Manual contents and interpretation
• Ability to operate various plant such as bond fixtures, presses, automated lay-up tools, traditional machine tools
• Traditional fitting and/or machining skills
• Ability to adapt to a wide range of manufacturing techniques
• Ability to apply caulking and sealing agents to the highest standards, understanding the aerodynamic importance of surface finish
• Cutting and laying up of intricate shapes and detailed ply patterns including the acquired skill of knowing how to drape and press down spar materials prior to tool closure.
• Clearance of Materials Laboratory to WHPS 644 (use of adhesive systems)
• Skilled removal/ clean-up of composite items without damage to structural matrix/ reinforcings.

Must have skills
City & Guilds / City & Guilds Engineering Apprenticeship