Model Curriculum. Aerospace Avionics Technician

Transcription

1 Model Curriculum Aerospace Avionics Technician SECTOR: AEROSPACE AND AVIATION SUB-SECTOR: MANUFACTURING & ASSEMBLY OCCUPATION: AIRCRAFT ASSEMBLING AND TESTING REF ID: AAS/Q1603, V1.0 NSQF LEVEL: 4 Aerospace Avionics Technician

2 Aerospace Avionics Technician

3 TABLE OF CONTENTS 1. Curriculum 1 2. Trainer Prerequisites 8 3. Annexure: Assessment Criteria 9 Aerospace Avionics Technician

4 Aerospace Avionics Technician CURRICULUM / SYLLABUS This program is aimed at training candidates for the job of a Aerospace Avionics Technician, in the Aerospace and Aviation Sector/Industry and aims at building the following key competencies amongst the learner Program Name Qualification Pack Name & Reference ID. Aerospace Avionics Technician AAS/Q1603 Version No. 1.0 Version Update Date Pre-requisites to Training Training Outcomes I.T.I in Electrical trade After completing this programme, participants will be able to; Carry out PCB assembly, manual assembly, cleaning, adhesive bonding and visual inspection. Assemble avionics components and carry out PCB repair activities as per aerospace industry requirement. Ensure safety and security procedures Apply 5S methodology in workshop organisation Ensure efficient team work Aerospace Avionics Technician 1

5 This course encompasses 4 out of 4 National Occupational Standards (NOS) of Aerospace Avionics Technician Qualification Pack issued by Aerospace and Aviation Sector Skill Council (AASSC). Sr. Module Key Learning Outcomes Equipment Required No. 1 Perform assembly of Interpret the avionics component White/Black board/ Chart avionics components and layout and ascertain the required paper, Markers/Computer PCBs tools and equipment to carry out and projector, trainer s assembly is available. guide, student handbook, Theory Duration Inspect visually to ensure that the Charts regarding health & avionics components are defect free hygiene 190:00 Undertake equipping and testing of the components using circuit testers/ Practical Duration oscilloscopes/ voltmeters or any other testing tool/ equipment as per 274:00 organisation procedures Install avionics components, Corresponding NOS assemblies and systems in the Code aircraft/rig using hand tools, power AAS/N1603 tools or soldering irons Assemble components such as sensors, diodes, electrical controls, junction boxes etc. Using relevant tools as per organisation assembly procedures Connect components to assemblies such as communication systems, instruments, magnetos, inverters, and in-flight refueling systems, using hand tools and soldering irons Set up and operate ground support and test equipment to perform functional flight tests of avionics systems Ensure the ESD protection and contamination prevention standards Take anti-static precautions before work and wear ESD wrist straps or aprons Read the PCB loading kit list Check the component before insertion, after receiving from bonded store Ensure the leads performed are correct fit Ensure correct insertion location of the leads according to process layout instructions Insert the components in the prescribed order, with smaller components inserted first Check the placement and that inserted components are straight Cut the component leads extending through the holes Use standard operating instructions to apply adhesive to glue the components after insertion Aerospace Avionics Technician 2

6 Sr. No. Module Key Learning Outcomes Equipment Required Mount the components on the board using hand tools as per circuit diagram Ensure that the component is firmly placed and does not fall during movement Solder the components in the circuit boards using soldering station Ensure proper wetting of the solder Ensure work-bench does not have other loose components Hand over the assembled boards to testing technician Cross check against process layout (PL) and components received prior to assembly Visually check assembled PCB for missing or wrong components against PL/ simple PCB Route electrical, avionics, mission & weapon looms on aircraft as per wire harness drawings. Perform loom integration of various looms as per wiring drawings Carry out continuity and Megger checks after integration of looms as per inspection schedules to ensure correctness & conformance of work instructions/ loom drawings. Rectify if any snag noticed. Record the data. Finalise connectors as per wiring drawings by crimping/ soldering using proper stripping & crimping tools. Check proper stripping, crimping & locking of pins, insert dummy pins & finalise back shells of connectors. Finalise relays, connector brackets, earth modules and junction modules, tie looms with p-clamps, tyraps for proper harnessing with aircraft structure Check electrical LRU's to be installed have correct part numbers, modification status, hardware & software version, serviceability and shelf life. Install LRU as per applicable maintenance manual by ensuring appropriate adjustment and alignment with mechanical interface Use proper tools as prescribed in equipping manuals. Ensure use of calibrated tools, testers and torque wrenches. Proper torqueing of fasteners as per specification manual/ drawing Achieve specified bonding values for Aerospace Avionics Technician 3

7 Sr. No. 2 Follow organisation safety and security procedures Theory Duration 19:00 Practical Duration 29:00 Module Key Learning Outcomes Equipment Required Corresponding NOS Code AAS/N Maintain 5S at the work premises Theory Duration 09:00 Practical Duration 23:00 each LRU by using bonding tester Put identification labels near each LRUs Inspect proper installation of LRU and offer the installation to quality Ensure components are placed with 100% accuracy as per latest documents/ drawing/ PL Ensure the components are damage free Ensure good quality of solder joints Deliver in time to the next process Ensure zero defects in mounting Comply with the organisation s safety and security policies and procedures Comply with the regulatory guidelines on safe conduct of operations and maintenance of conditions to thwart any acts of unlawful interference Report any identified breaches of safety and security policies and procedures to the designated person Report any theft of organisation property according to the organisation policy Coordinate with other resources at the workplace (within and outside the organisation) to achieve a 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 the individual s authority Report any hazards outside the individual s authority to the relevant person in line with organisational procedures and regulatory guidelines Follow the 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 Ensure that all health and safety records are updated and procedures are well defined Follow the sorting process and check that the tools, fixtures & jigs that are lying on workstations are the ones in use and unnecessary items are not cluttering the workbenches or work surfaces Ensure segregation of waste into hazardous/ non-hazardous waste as per the sorting work instructions Follow the technique of waste White/Black board/ Chart paper, Markers/Computer and projector, trainer s guide, student handbook, Charts regarding health & hygiene White/Black board/ Chart paper, Markers/Computer and projector, trainer s guide, student handbook, Charts regarding health & hygiene Aerospace Avionics Technician 4

8 Sr. No. Module Key Learning Outcomes Equipment Required Corresponding NOS Code ASC/N0021 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 material storage areas are not overflowing 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 Return 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 maintain 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. Ensure 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 clean Ensure that the area has clean floors, clean machinery and is generally clean. While cleaning is in progress, 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 Aerospace Avionics Technician 5

9 Sr. No. 4 Work Effectively in a Team Theory Duration 14:00 Practical Duration 18:00 Module Key Learning Outcomes Equipment Required Corresponding NOS Code AAS /N0503 mix up Ensure that workbenches and work surfaces are clean and in good condition Follow the cleaning schedule for the lighting system to ensure proper illumination Store cleaning material and equipment in the correct location and in good condition Ensure self-cleanliness - clean uniform, clean shoes, clean gloves, clean helmets, and personal hygiene Follow the daily cleaning standards and schedule to create a clean working environment Attend all training programs for employees on 5s Support the team during the audit of 5s 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 Display courteous and helpful behaviour at all times Take opportunities to enhance the level of assistance offered to colleagues Meet all reasonable requests for assistance within acceptable workplace timeframes Complete allocated tasks as assigned Seek assistance when difficulties arise Use questioning techniques to clarify instructions or responsibilities, Identify and display a nondiscriminatory attitude in all contacts with customers and other staff members Observe appropriate dress code and presentation as required by the workplace, job role and level of customer contact Follow personal hygiene procedures according to organisational policy Interpret, confirm and act on workplace information, instructions and procedures relevant to the particular task Interpret, confirm and act on legal requirements with regards to anti- White/Black board/ Chart paper, Markers/Computer and projector, trainer s guide, student handbook Aerospace Avionics Technician 6

10 Sr. No. Total Duration Theory Duration 232:00 Practical Duration 344:00 Module Key Learning Outcomes Equipment Required discrimination, sexual harassment and bullying Ask questions to seek and clarify workplace information Plan and organise daily work routine within the scope of the job role Prioritise and complete tasks according to required timeframes Identify work and personal priorities and achieve a balance between competing priorities Unique equipment used; Precision Tool kit Multimeter Soldering kit SMT Repair/ Assembly kit Standard Tool kit Oscilloscope Antistatic tool kit Wattmeter Functional Generator Crimping tool kit Decade Resistance Box Micro-controller software loading kits ESD Worktable IC Trainer kit Grand Total Course Duration: 576 Hours, 0 Minutes (This syllabus/ curriculum has been approved by Aerospace and Aviation Sector Skill Council) Aerospace Avionics Technician 7

11 Trainer Prerequisites for Job role: Aerospace Avionics Technician mapped to Qualification Pack: AAS/Q1603 Sl. No. Area 1 Description 2 Personal Attributes 3 4a 4b Minimum Educational Qualifications Domain Certification Platform Certification Details 5 Experience 05 years To deliver accredited training service, mapping to the curriculum detailed above, in accordance with the Qualification Pack AAS/Q1603. Aptitude for conducting training, and pre/post work to ensure competent, employable candidates at the end of the training. Strong communication skills, interpersonal skills, ability to work as part of a team; a passion for quality and for developing others; well organised and focused, eager to learn and keep oneself updated with the latest in the mentioned field. Diploma in Mechanical trade Statutory Certificate from Aerospace and Aviation Sector Skill Council (AASSC) for Job Role: Aerospace Avionics Technician mapped to QP: AAS/Q1603. Minimum accepted score for domain certification will be 80%. Recommended that the Trainer is certified for the job role Trainer mapped to the Qualification Pack : MEP/Q Minimum accepted percentage as per respective SSC guidelines is 80%. Aerospace Avionics Technician 8

12 Annexure : Assessment Criteria Job Role: Aerospace Avionics Technician Qualification Pack: AAS / Q1603 Sector Skill Council: Aerospace and Aviation Sector Skill Council 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 centre (as per assessment criteria below). 5. Individual assessment agencies will create unique evaluations for skill practical for every student at each examination/training centre 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. Compulsory NOS Total Marks: 100 Marks Allocation Assessment outcomes Assessment Criteria for outcomes Total Marks Out of Theory Skills Practical 1. AAS/ N1603 Perform avionics assembly and manually assemble PCB PC 1. Interpret the avionics component layout and ascertain the required tools and equipment to carry out assembly is available. PC 2. Inspect visually to ensure that the avionics components are defect free PC 3. Undertake equipping and testing of the components using circuit testers/ oscilloscopes/ voltmeters or any other testing tool/ equipment as per organisation procedures PC 4. Install avionics components, assemblies and systems in the aircraft/rig using hand tools, power tools or soldering irons PC 5. Assemble components such as sensors, diodes, electrical controls, junction boxes etc. Using relevant tools as per organisation assembly procedures PC 6. Connect components to assemblies such as communication systems, instruments, magnetos, inverters, and inflight refuelling systems, using hand tools and soldering irons PC 7. Set up and operate ground support and test equipment to perform functional flight tests of avionics systems Aerospace Avionics Technician 9

13 PC 8. Ensure the ESD protection and contamination prevention standards PC 9. Take anti-static precautions before work and wear ESD wrist straps or aprons PC 10. Read the PCB loading kit list PC 11. Check the component before insertion, after receiving from bonded store PC 12. Ensure the leads performed are correct fit PC 13. Make sure insertion location is correct according to process layout instructions PC 14. Insert the components in the prescribed order, with smaller components inserted first PC 15. Check the placement and that inserted components are straight PC 16. Cut the component leads extending through the holes PC 17. Use standard operating instructions to apply adhesive to glue the components after insertion PC 18. Mount the components on the board using hand tools as per circuit diagram PC 19. Ensure that the component is firmly placed and does not fall during movement PC 20. Solder the components in the circuit boards using soldering station PC 21. Ensure proper wetting of the solder PC 22. Ensure work-bench does not have other loose components PC 23. Hand over the assembled boards to testing technician PC 24. Cross check against process layout (PL) and components received prior to assembly PC 25. Visually check assembled PCB for missing or wrong components against PL/ simple PCB PC 26. Route electrical, avionics, mission & weapon looms on aircraft as per wire harness drawings. PC 27. Perform loom integration of various looms as per wiring drawings PC 28. Carry out continuity and Megger checks after integration of looms as per inspection schedules to ensure correctness & conformance of work instructions/ loom drawings. Rectify if any snag noticed. Record the data. PC 29. Finalise connectors as per wiring drawings by crimping/ soldering using proper stripping & crimping tools. Check proper stripping, crimping & locking of pins, insert dummy pins & finalise back shells of connectors. Aerospace Avionics Technician 10

14 PC 30. Finalise relays, connector brackets, earth modules and junction modules, tie looms with p-clamps, tyraps for proper harnessing with aircraft structure PC 31. Check electrical LRU's to be installed have correct part numbers, modification status, hardware & software version, serviceability and shelf life. PC 32. Install LRU as per applicable maintenance manual by ensuring appropriate adjustment and alignment with mechanical interface PC 33. Use proper tools as prescribed in equipping manuals. Ensure use of calibrated tools, testers and torque wrenches. Proper torqueing of fasteners as per specification manual/ drawing PC 34. Achieve specified bonding values for each LRU by using bonding tester PC 35. Put identification labels near each LRU s PC 36. Inspect proper installation of LRU and offer the installation to quality PC 37. Ensure components are placed with 100% accuracy as per latest documents/ drawing/ PL PC 38. Ensure the components are damage free PC 39. Ensure good quality of solder joints PC 40. Deliver in time to the next process PC 41. Ensure zero defects in mounting Total Compulsory NOS Total Marks: 100 Marks Allocation Assessment outcomes Assessment Criteria for outcomes Total Marks Out of Theory Skills Practical 2. AAS/N1001 Follow organisation safety and security procedures PC 1. Comply with the organisation s safety and security policies and procedures PC 2. Comply with the regulatory guidelines on safe conduct of operations and maintenance of conditions to thwart any acts of unlawful interference PC 3. Report any identified breaches of safety and security policies and procedures to the designated person PC 4. Report any theft of organisation property according to the organisation policy PC 5. Coordinate with other resources at the workplace (within and outside the organisation) to achieve a safe and secure environment PC 6. Identify and mitigate any safety and security hazards like illness, accidents, 100 Aerospace Avionics Technician 11

15 fires or acts of unlawful interference if it falls within the limits of the individual s authority PC 7. Report any hazards outside the individual s authority to the relevant person in line with organisational procedures and regulatory guidelines PC 8. Follow the organisation s emergency procedures for accidents, fires or acts of unlawful interference PC 9. Identify and recommend opportunities for improving health, safety, and security to the designated person PC 10. Ensure that all health and safety records are updated and procedures are well defined Total Compulsory NOS Total Marks: 100 Marks Allocation Assessment outcomes 3. ASC/N0021 Maintain 5S at the work premises Assessment Criteria for outcomes PC 1. Follow the sorting process and check that the tools, fixtures & jigs that are lying on workstations are the ones in use and unnecessary items are not cluttering the workbenches or work surfaces PC 2. Ensure segregation of waste into hazardous/ non-hazardous waste as per the sorting work instructions PC 3. Follow the technique of waste disposal and waste storage in the proper bins as per sop PC 4. Segregate the items which are labeled as red tag items for the process area and keep them in the correct places PC 5. Sort the tools/ equipment/ fasteners/ spare parts as per specifications/ utility into proper trays, cabinets, lockers as mentioned in the 5S guidelines/ work instructions PC 6. Ensure that material storage areas are not overflowing PC 7. 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 PC 8. Return extra material and tools to the designated sections and make sure that no additional material/ tool is lying near the work area PC 9. Follow the floor markings/ area markings used for demarcating the various sections in the plant as per the prescribed instructions and standards Total Marks Out of Theory Skills Practical Aerospace Avionics Technician 12

16 PC 10. Follow the proper labeling mechanism of instruments/ boxes/ containers and maintain reference files/ documents with the codes and the lists PC 11. Check that the items in the respective areas have been identified as broken or damaged PC 12. 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. PC 13. Make sure that all material and tools are stored in the designated places and in the manner indicated in the 5S instructions PC 14. Check whether safety glasses are clean and in good condition PC 15. Keep all outside surfaces of recycling containers clean PC 16. Ensure that the area has clean floors, clean machinery and is generally clean. While cleaning is in progress, ensure that proper displays are maintained on the floor which indicate potential safety hazards PC 17. Check whether all hoses, cabling & wires are clean, in good condition and clamped to avoid any mishap or mix up PC 18. Ensure that workbenches and work surfaces are clean and in good condition PC 19. Follow the cleaning schedule for the lighting system to ensure proper illumination PC 20. Store cleaning material and equipment in the correct location and in good condition PC 21. Ensure self-cleanliness - clean uniform, clean shoes, clean gloves, clean helmets, and personal hygiene PC 22. Follow the daily cleaning standards and schedule to create a clean working environment PC 23. Attend all training programs for employees on 5S PC 24. Support the team during the audit of 5S PC 25. Participate actively in employee work groups on 5S and encourage team members for active participation PC 26. 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 Total Aerospace Avionics Technician 13

17 Assessment outcomes 4. AAS/N0503 Work effectively in a team Compulsory NOS Total Marks: 100 Assessment Criteria for outcomes PC 1. Display courteous and helpful behaviour at all times PC 2. Take opportunities to enhance the level of assistance offered to colleagues PC 3. Meet all reasonable requests for assistance within acceptable workplace timeframes Total Marks Out of Theory Marks Allocation Skills Practical PC 4. Complete allocated tasks as required PC 5. Seek assistance when difficulties arise PC 6. Use questioning techniques to clarify instructions or responsibilities PC 7. Identify and display a nondiscriminatory attitude in all contacts with customers and other staff members PC 8. Observe appropriate dress code and presentation as required by the workplace, job role and level of customer contact PC 9. Follow personal hygiene procedures according to organisational policy and relevant legislation PC 10. Interpret, confirm and act on workplace information, instructions and procedures relevant to the particular task PC 11. Interpret, confirm and act on legal requirements in regard to antidiscrimination, sexual harassment and bullying PC 12. Ask questions to seek and clarify workplace information PC 13. Plan and organise daily work routine within the scope of the job role PC 14. Prioritise and complete tasks according to required timeframes PC 15. Identify work and personal priorities and achieve a balance between competing priorities Total Aerospace Avionics Technician 14