Checking that completed assemblies comply with specification Overview This unit identifies the competences you need to carry out checks on mechanical assemblies, in accordance with approved procedures. You will be required to prepare the work area, ensuring it is safe and free from hazards, to obtain all relevant and current documentation, and to obtain the tools and equipment required for the checking of mechanical assemblies, making sure that they are calibrated and in a safe and usable condition. You will be expected to conduct ongoing trials, manual checks and operational checks throughout the assembly operations, and checks on component parts and sub-assemblies will also be carried out, where appropriate. You will be responsible for confirming the assembly is complete, fit for purpose, and meets the operational performance required by the specification. In carrying out checks on mechanical assemblies, you will also be required to complete any relevant documentation accurately and legibly. Your responsibilities will require you to comply with organisational policy and procedures for checking the mechanical assembly, and to report any problems with the assembly you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to ensure that all tools and equipment used in checking the assembly are correctly accounted for on completion of the activities and returned to the correct location. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out. Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying quality control techniques and procedures including, where appropriate, British, European and International standards. You will understand the mechanical product being assembled, and its application, and will know about the tools and equipment used to check the assembly, in adequate depth to provide a sound basis for carrying out the activities to the required specification. You will understand the types of defect that can be found on the assembly, and how critical these defects are in determining the satisfactory performance of the completed product. You will understand the safety precautions required when carrying out the assembly activities. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace. SEMMME3-073 1
Performance criteria You must be able to: P1 work safely at all times, complying with health and safety and other relevant regulations and guidelines P2 follow and make appropriate use of the specifications for the product or asset being checked P3 use all the correct tools and inspection equipment and check that they are in useable condition P4 carry out the checks in an appropriate sequence using approved methods and procedures P5 identify and assess any defects or variations from the specification and take appropriate action P6 report completion of compliance activities in line with organisational procedures SEMMME3-073 2
Knowledge and understanding You need to know and understand: K1 the specific safety precautions to be taken while carrying out the mechanical assembly checks (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials) K2 the health and safety requirements of the work area in which you are carrying out the assembly checking activities, and the responsibility these requirements place on you K3 COSHH Regulations with regard to the substances used in the assembly process K4 the hazards associated with checking mechanical assemblies, and how to minimise them and reduce any risks K5 the personal protective equipment and clothing to be worn during the assembly checking activities K6 how to extract and use information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS, ISO or BSEN standards) in relation to work undertaken K7 how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing K8 the use of British, European and international standards used in determining if components and products are fit for purpose K9 the general principles of quality assurance systems and procedures K10 the various stages when the assembly should be checked, and to what level K11 preparations to be undertaken before the assembly is checked K12 the application of the various tools and equipment used to check the assembly K13 the importance of ensuring that tools and equipment are set up correctly and are in a safe and useable condition K14 the procedure and methods used to check that tools and equipment are within calibration date K15 the quality control procedures to be followed when checking the assembly K16 how to conduct any necessary checks to ensure the safety, accuracy, position, security, function and completeness of the assembly K17 the types of defect that can be found on mechanical assemblies, and why they occur K18 how to detect assembly defects, and what to do to rectify them K19 the factors to be considered when determining if assembly components or products should be scrapped or modified K20 the documentation to be completed to confirm that the assembly has SEMMME3-073 3
been properly checked K21 the importance of ensuring that all tools and equipment are returned to their correct location on completion of the assembly checking activities K22 the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve SEMMME3-073 4
Additional Information Scope/range related to performance criteria You must be able to: 1. Carry out all of the following during the checking activities: 1.1 obtain and use the appropriate documentation (such as job instructions, drawings, quality control documentation, specifications) 1.2 adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work 1.3 follow safe practice/approved inspection and checking techniques at all times 1.4 check that all tools and measuring equipment are within current calibration/certification dates 1.5 use lifting and slinging equipment in accordance with health and safety guidelines and procedures 1.6 ensure that all exposed openings are maintained free from foreign objects, dirt or other contamination 1.7 return all tools and equipment to the correct location on completion of the inspection activities 1.8 leave the work area in a safe and appropriate condition on completion of the activities 2. Check the mechanical assembly using twelve of the following instruments and gauges: 2.1 rule or tape 2.2 micrometers 2.3 vernier gauges 2.4 protractors 2.5 dial test indicator 2.6 levels 2.7 feeler gauges 2.8 slip gauges 2.9 squares 2.10 temperature gauges 2.11 straight edges 2.12 gauges 2.13 torque wrench 2.14 flow meters 2.15 optical equipment 2.16 electrical measuring equipment 2.17 pressure gauges 2.18 other specific equipment SEMMME3-073 5
3. Use the relevant equipment to measure and check seven of the following features: 3.1 flatness 3.2 alignment 3.3 fit/working clearance 3.4 parallelism 3.5 distortion 3.6 squareness 3.7 level 3.8 angles 3.9 position/location 3.10 torque 3.11 concentricity 3.12 verticality 3.13 dimensions 3.14 bonding strength 4. Check the operational functions of the mechanical assembly, to include ten of the following: 4.1 rotation 4.2 speed 4.3 movement 4.4 tension 4.5 sequence 4.6 direction 4.7 pressure 4.8 balance 4.9 electrical in/outputs 4.10 distance/travel 4.11 sliding 4.12 flow 4.13 vibration 4.14 fluid power in/outputs 4.15 noise 4.16 timing 4.17 reciprocation 4.18 temperature 4.19 safety mechanisms 4.20 leakage 4.21 power 4.22 service supplies (such as water, gas, air, electrical supply) 5. Ensure that the completed assembly meets the specification, using two of the following checks: SEMMME3-073 6
5.1 trial 5.2 under power 5.3 fully operational 5.4 manual check 6. Check that mechanical assemblies comply with one of the following quality and accuracy standards: 6.1 BS, ISO or BSEN standards and procedures 6.2 customer standards and requirements 6.3 company standards and procedures 6.4 specific system requirements SEMMME3-073 7
Developed by SEMTA Version number 1 Date approved December 2008 Indicative review date Validity Status Originating organisation Original URN Relevant occupations December 2013 Current Original SEMTA O45NMME3-73 Engineering and manufacturing technologies; Engineering; Engineering Technicians Suite Mechanical Manufacturing Engineering Suite 3 2008 Key words Engineering, manufacturing, mechanical, checking, mechanical assemblies, operational function, specification, calibration, dimensions, tolerance SEMMME3-073 8