Assessor Resource

MEA423A
Aircraft structure major disassembly and reassembly

Assessment tool

Version 1.0
Issue Date: May 2024


This unit requires application of hand skills and use of maintenance publications, drawings, and appropriate jigs, fixtures and tools to disassemble and reassemble aircraft structure. Structural repair/modification is covered by MEA422A Repair/modify aircraft metal structure or MEA405B Repair/modify aircraft composite material structure/components. Where fabrication of replacement components is required the applicable units are MEA420A Fabricate basic structural components for aircraft and MEA421A Fabricate advanced structural components for aircraft.

Applications include fixed and rotary wing aircraft.

This unit of competency is part of the Aeroskills Structures Maintenance Certificate IV training pathway. It covers the competencies required for major disassembly and reassembly of aircraft structure for the purposes, such as major repair or modification. The unit is used in workplaces that operate under the airworthiness regulatory systems of the ADF and CASA.

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

Prerequisites

MEA401C

Inspect aircraft structure

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 apply hand skills and use maintenance publications, drawings and specifications and appropriate jigs, fixtures and tools to disassemble and reassemble aircraft structure while applying all relevant safety precautions.

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

The underlying skills inherent in this unit should be transferable into other areas that require similar techniques. It is essential that procedures take into account all safety precautions and quality requirements, standards and practices, and processes associated with assembly.

Evidence of knowledge about repair techniques and the use of the standard repair manual in a range of different repair situations will be necessary to supplement evidence of ability to plan and undertake structure and component repair.

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 on elements from each of Groups 1 to 3 listed in the Range Statement. This shall be established via the records in the Log of Industrial Experience and Achievement or, where appropriate, an equivalent Industry Evidence Guide.

Context of and specific resources for assessment

Competency should be assessed in the work environment, using tools and equipment specified by aircraft maintenance manuals. It is also expected that general purpose tools and ground support 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:

aircraft construction principles, including the causes of structural fatigue and corrosion

describing the basic construction methods used to assemble:

fuselage (pressure and non-pressurised)

wings, vertical and horizontal stabilisers, rotary wing tail cones and pylons

engine nacelles/pylons

doors and windows, including seals, sealants and locking mechanisms

material specifications for aluminium alloys and steel alloys used in aircraft structure

composite cloths, matrix materials and adhesives

structural material identification by markings and numbering systems

material identification by chemical, electrical and mechanical methods

material storage requirements

hardware types and specifications

composite bonding methods

identification of hardware

sealants used in aircraft structure and their application and handling

chemical surface treatments

electroplating

paints and finishes

OHS precautions associated with repair of aircraft structure, including the safe handling of heavy components

MSDS

PPE

Look for evidence that confirms skills in:

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

the use of approved maintenance documentation and aircraft publications relating to aircraft structural disassembly and assembly

correctly supporting the aircraft structure by jacking, trestling, bracing and/or jigging methods

safely handling heavy components during removal and assembly

identifying various aircraft metals/composite materials and their basic metallurgy properties by interpretation of markings, numbering systems or visual, chemical or mechanical means

handling and storing aircraft metal and composite components to industry standards

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

using appropriate hand tools and machines to remove and assemble aircraft structural components, parts, sections and skin, including riveting equipment, drilling equipment, aligning tools, reamers and material fasteners (grip pins)

applying correct removal and installation techniques for general and close tolerance fasteners (rivets, standard and oversize – hilocks), including hole preparation and location techniques

performing aircraft alignment and mensuration checks

applying sealants and restoring aircraft structure surface finishes

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

The Range Statements below are numbered to facilitate specification of the assessment requirements included in the Evidence Guide.

Scope

The competency applies to:

1. Assembly of aircraft sub-assemblies or end items from detailed parts using jigs and fixtures

2. Disassembly and reassembly of aircraft structure, such as wings, tailplanes or fuselage sections, using trestling, jigs and fixtures

3. Replacement of major structural load carrying members, for example, skins, longerons, spars, frames and bulkheads

Assembly procedures

Assembly procedures will include:

drilling, reaming and counter-sinking

fitting of fasteners and rivets

application of adhesives and sealants

fitting of hardware

application of corrosion inhibitors and protective coatings

Assembly stress defects can refer to:

oil canning, buckling, contour misalignment and stress raisers

Application

Application of this unit may relate to:

scheduled or unscheduled maintenance

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
The procedure for assembly/disassembly of structure is determined in order to plan equipment use 
Appropriate jigs, fixtures or bracing methods are selected to ensure maintenance of contour/structural integrity during disassembly/assembly operations 
All components and equipment are organised 
Structure is supported with appropriate jigs, fixtures or bracing, as required 
Structural components are removed, as required, to provide access 
Aircraft standard practices are applied in the removal of structural hardware and fasteners 
Disassembled components are tagged, as required, to facilitate correct reassembly 
Jigs and fixtures are set up to ensure accuracy of component assembly 
Replacement component alignment is checked for conformance to specifications prior to fastener hole generation 
Hole location/relocation is carried out in accordance with specification procedures and standard practices 
Standard practices in hole generation sequencing are followed to ensure that assembly stress defects are not built in 
Components are disassembled, cleaned, deburred and surface treatments applied prior to final assembly 
Sealants and/or adhesives are selected and applied in accordance with assembly specifications or applicable documentation 
Components are positioned and secured with appropriate temporary fastening devices for accurate assembly 
Fasteners are selected and installed in accordance with assembly specifications or applicable manuals 
Assembled components are inspected to confirm dimensional accuracy and specifications are met 
Checking or testing equipment is used, where appropriate, to ensure requirements are met 
Aircraft mensuration is checked for compliance with applicable maintenance manuals, where necessary 
Required documentation is completed and processed in accordance with standard enterprise procedures 

Forms

Assessment Cover Sheet

MEA423A - Aircraft structure major disassembly and reassembly
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

MEA423A - Aircraft structure major disassembly and reassembly

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: