Assessor Resource

MEA363B
Inspect, repair and maintain structures and related components of non-pressurised small aircraft

Assessment tool

Version 1.0
Issue Date: May 2024


This unit requires application of procedures and techniques associated with the inspection and maintenance of aircraft structures, and with the performance of a limited range of metal and composite repairs. Also required is an application of procedures and techniques associated with the removal and installation of related structural and non-structural components.

Applications include the performance of structural maintenance activities and component removal and installation on non-pressurised fixed or rotary wing aircraft on the flight line or in the hangar.

This unit of competency is part of the Mechanical Certificate IV (Aircraft Maintenance Stream) training pathway. It covers the competencies required to inspect, repair and maintain small aircraft structure and the removal and installation of related non-structural components such as internal trim, seats and emergency equipment.

The competency Elements and Performance Criteria also cover a significant portion of those required for units MEA304C Remove and install non-pressurised aircraft structural and non-structural components, MEA311D Inspect and repair/modify aircraft structures and MEA339C Inspect, repair and maintain aircraft structures.

Where a CASA licensing outcome is sought this unit forms part of the CASA requirement for the granting of the chosen maintenance certification licence under CASR Part 66, in accordance with the licensing provisions in Section 3, Assessment Guidelines.

You may want to include more information here about the target group and the purpose of the assessments (eg formative, summative, recognition)

Prerequisites

MEA101B

Interpret occupational health and safety practices in aviation maintenance

MEA103B

Plan and organise aviation maintenance work activity

MEA105C

Apply quality standards applicable to aviation maintenance processes

MEA107B

Interpret and use aviation maintenance industry manuals and specifications

MEA108B

Complete aviation maintenance industry documentation

MEA109B

Perform basic hand skills, standard trade practices and fundamentals in aviation maintenance


Employability Skills

This unit contains employability skills.




Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment

A person who demonstrates competency in this unit must be able to inspect and maintain aircraft structure, perform a range of metal and composite structural repair tasks and remove and install structural and non-structural components that are representative of the scope of the listed variables in accordance with relevant maintenance documentation while applying all relevant OHS procedures and standard processes.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

The underlying skills inherent in this unit should be transferable across a range of inspection, testing and repair applications associated with aircraft maintenance. It is essential that the procedures take into account all aircraft and personal safety precautions relating to aircraft structure.

Evidence of transferability of skills and knowledge related to inspection, testing and repair of aircraft structure is essential. This may be demonstrated through application across a number of aircraft systems or aircraft types. Ability to interpret inspection and repair procedures and specifications and apply them in practice is critical. The application of the procedures should also clearly indicate knowledge of structural flight loads and aerodynamic requirements.

A person cannot be assessed as competent until it can be demonstrated to the satisfaction of the workplace assessor that the relevant elements of the unit of competency are being achieved under routine supervision across the variables in the Range Statement as follows:

inspection and/or testing of at least one item from each of Groups 1 to 8

recognition of each type of damage in Groups 9 to 12

one repair task from each of Groups 13 to 20

one removal and installation task from each of Groups 21 to 25.

This shall be established via the records in the Log of Industrial Experience and Achievement.

Context of and specific resources for assessment

Competency should be assessed in the work environment or simulated work environment using tools and equipment specified in maintenance documentation. It is also expected that general purpose tools and test equipment found in most routine situations would be used where appropriate.

Method of assessment

Guidance information for assessment


Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assingnment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)


Assessment Tasks

Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.

Look for evidence that confirms knowledge of:

applicable OHS procedures, including the use of PPE and MSDS

construction methods and materials used in:

fuselage sections

wing sections

engine nacelles and mounts

windows and window frames

doors, locks and access panels

definition of structural terms, i.e. safe life, damage tolerant, failsafe, stress, strain, shear and cycles

inspection requirements for metal and composite structure, including:

ageing aircraft inspection requirements

safe life structure

damage tolerant structure

fail safe structure

potential causes of structural failure

NDT methods and application of the various techniques

construction methods of, and assessing common defects in, aircraft plastic transparencies

basic constructional features of, and assessing common defects in, glass windscreens

the various forms of structural corrosion, stating the causes and structural effects of corrosion on aircraft

the terms associated with composite materials and types of composite materials

requirements for handling and storing aircraft metals and composite materials, including sealing agents, to industry standards

means of identifying aircraft structural assembly fasteners (metal and composite) by interpretation of markings, numbering systems, size, shape and colour

structural and non-structural component methods of attachment, faying surface treatment and fuel tank sealing

non-pressurised fuselage aircraft doors, related seals and window and transparent panel attachment methods and sealing

aircraft interior fittings (trim, linings, seats and floor panels) construction and attachment methods

the location and attachment or stowage methods for emergency equipment

assessment of structural damage:

types and classes of mechanical damage

types of corrosion and determining the extent of damage

relevant documentation and manuals

damage limits and repair schemes for metallic and non-metallic structure

procedures for the fabrication and fitment of metal repairs:

scab patch

flush patch

splice

lap

formed section

corrosion removal and passivation

procedures for performing composite repairs:

external patch

scarf patch

stepped repairs

bolted repairs

repair of integral fuel tanks and sealing of faying surfaces, including specific OHS and PPE requirements

surface finishes and methods of restoration, including specific OHS and PPE requirements

how to obtain MSDS

relevant maintenance and structural repair manuals

relevant regulatory requirements and standard procedures

Look for evidence that confirms skills in:

applying all relevant OHS procedures, including the selection and use of MSDS and applicable items of PPE

demonstrating appropriate cleaning procedures to enable structure inspection

demonstrating correct inspection procedures in accordance with aircraft and procedures manuals

identifying damage to aircraft metallic (ferrous and non-ferrous) structures and/or components by way of impact, fatigue or the various types of corrosion

inspecting damage and assessing composite components/structures

identifying various aircraft metals and their basic properties

identifying composite materials used in aircraft construction, associated safety precautions and hazards

correctly interpreting repair scheme drawings, including third angle projection, isometric, sectional formats and hand sketches

using appropriate hand tools and machines, including riveting equipment, drilling equipment, aligning tools and material fasteners (grip pins)

applying correct removal, installation and repair techniques for:

a range of rivets (blind and solid) using hand, squeeze and pneumatic situations

a range of close tolerance fasteners (standard and oversize – hillocks and taper locks), including hole preparation

threaded devices, including internal and external thread cutting, Helicoil inserts and damaged stud replacement

hardware assembled by close tolerance fits using heat, cooling and force methods, including bearings, bushes and inserts

performing a range of metal structure and composite material repair techniques, including:

metal scab patch, flush, splice, lap and formed section repair

composite external patch, scarf, stepped and bolted repairs

metal to metal and metal to composite bonding

applying structural corrosion removal/treatment techniques

restoring aircraft structure sealing and surface finishes

using relevant maintenance documentation and aircraft manuals to:

remove and install structural and non-structural components

remove and install aircraft interior fittings

remove and install doors, door seals, windows and transparent panels

checking and adjusting all doors and access panels, including locking mechanisms

removing and installing emergency equipment

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Note

Range statements listed below are numbered to facilitate specification of the assessment requirements included in the Evidence Guide

Inspection and repair of aircraft structure and removable components of structure

Inspection of aircraft structure includes:

Non-ferrous and ferrous alloys and composite (FRP) materials used in aircraft construction

Structural fastening and attachment hardware and/or devices

Seals and sealants

Glass and moulded plastics

Application of NDT techniques

Doors, hinges and locking mechanisms for damage/misalignment

Inspections applicable to each of safe life, damage tolerant and fail safe structure relevant to enterprise

Ageing aircraft inspection programs

Damage or defects

Damage or defects may include:

9. Impact damage

10. Fatigue cracking

11. Corrosion

12. Delamination of composites and bonded structures

Structural repairs

Structural repairs may include the following:

13. Remove corrosion by chemical and mechanical methods

14. Restore protective coatings

15. Apply sealants and jointing compounds

16. Freehand precision hole generation

17. Remove and install structural hardware and fastening devices

18. Remove and replace bushes, bearings and bearing surfaces

19. Metal scab patch, flush, splice, lap and formed section repair

20. Composite external patch, scarf, stepped and bolted repairs

Removable components

Removable components of structure:

are those that are installed using bolts and/or screws. Where component removal and installation requires the removal and installation of rivets the applicable unit is MEA311D Inspect and repair/modify aircraft structures

Components

Components may include:

21. Removable components of wings, tail booms, pylons, empennage, skids, fairings and nacelles

22. Removable components or sections of non-pressurised fuselages

23. Non-pressurised fuselage entry, cargo, access doors and associated seals (including checking and adjustment of all doors and access panels and associated locking mechanisms)

24. Non-pressurised fuselage windows and transparent panels

25. Floor panels

Specialist advice

Specialist advice is obtained from:

supervisors

specialist structures personnel

Documentation

Relevant maintenance documentation includes:

servicing schedules

maintenance manuals

Application

Application of this unit may relate to:

scheduled or unscheduled maintenance, including special inspections required after events, such as heavy landings, overstress or flight through heavy turbulence

individual or team-related activities

Procedures and requirements

Refer to industry standard procedures specified by manufacturers, regulatory authorities or the enterprise

Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.

Observation Checklist

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Relevant maintenance documentation is used to identify specific inspection requirements 
Appropriate preparation and access to the aircraft structure is undertaken to allow for proper inspection in accordance with maintenance documentation 
Aircraft structure is visually or physically checked for signs of deformation defects or damage in accordance with maintenance documentation and approved procedures 
Damage or defects are assessed against damage or wear limits specified by structural repair manual or other approved data to determine if repair or replacement is required 
Maintenance documentation is completed and processed in accordance with standard enterprise procedures 
Extent of damage is correctly assessed to assist in determining repair procedure 
Appropriate repair scheme is identified in accordance with structural repair manual and/or approved data 
Specialist advice is obtained in establishing an approved repair scheme where a standard repair scheme cannot be identified or damage is out of limits 
All materials and equipment required are organised 
Structural repairs are performed, in accordance with approved repair scheme, ensuring that aircraft standard practices are used and process requirements are carried out 
Preventative maintenance techniques are employed to preserve the integrity of aircraft structure 
Work area is cleaned of all waste material or contaminants 
Required maintenance documentation is completed and processed in accordance with standard enterprise procedures 
Structure is supported and prepared in accordance with the applicable maintenance manual to ensure personnel safety and freedom from damage to aircraft or component during component removal 
Component removal is carried out in accordance with the applicable maintenance manual 
Required maintenance documentation is completed and processed in accordance with standard enterprise procedures 
Where applicable, removed components are tagged and prepared for transport in accordance with specified procedures 
Structural and/or non-structural components to be installed are checked to confirm correct part numbers, serviceability and modification status 
Component installation is carried out in accordance with the applicable maintenance manual 
Support/safety equipment is removed at an appropriate time to ensure personnel safety and freedom from structural damage 
Required maintenance documentation is completed and processed in accordance with standard enterprise procedures 

Forms

Assessment Cover Sheet

MEA363B - Inspect, repair and maintain structures and related components of non-pressurised small aircraft
Assessment task 1: [title]

Student name:

Student ID:

I declare that the assessment tasks submitted for this unit are my own work.

Student signature:

Result: Competent Not yet competent

Feedback to student

 

 

 

 

 

 

 

 

Assessor name:

Signature:

Date:


Assessment Record Sheet

MEA363B - Inspect, repair and maintain structures and related components of non-pressurised small aircraft

Student name:

Student ID:

Assessment task 1: [title] Result: Competent Not yet competent

(add lines for each task)

Feedback to student:

 

 

 

 

 

 

 

 

Overall assessment result: Competent Not yet competent

Assessor name:

Signature:

Date:

Student signature:

Date: