DACUM Workshop Report Composite Repair Technician

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1 Center of Excellence, Marine Manufacturing & Technology Skagit Valley College South Seattle Community College National STEM Consortium DACUM Workshop Report Composite Repair Technician

2 South Seattle Community College Georgetown Campus November 8, 2012 Agenda: Focus Questions: What is the expected work profile of a typical Composite Technologies Repair Technician and what knowledge skills and abilities will be required to do this work? 8:30AM Welcome from Ann Avary, Director of the Marine Manufacturing & Technology Center of Excellence, Skagit Valley CC Overview of Composite Repair training at State Community and Technical colleges Ann Avary 9:00AM Introduction of the panel members panel members Introduction to the DACUM process and the agenda - Dave Cunningham Workshop I Mapping out the initial profile of the Composite Technologies Repair Technician Break Finalizing the work profile Noon 1:15PM Lunch Refinement of the Work profile and the component tasks Identification of priorities Break Workshop II Mapping out the necessary Knowledge Skills and Abilities required of Composites Technology Repair Technician (KSAs) Break Finalizing the KSAs Wrap-up discussion 4:30PM Adjourn Participants: 1. Bart Bauer, The Boeing Company 2. Jim Roebuck, Clover Park Technical College 3. Matthew Weaver, Fiberglass Supply 4. Michael Swietzer, Skagit Valley College 5. Lou Dorworth, ABARIS 6. Brian Nasralla, Industrial Engineering, The Boeing Company 7. Dave Cunningham, - DACUM Facilitator, Cunningham Enterprises Introductions:

3 Ann Avary, Director of the Marine Manufacturing & Technology Center of Excellence at Skagit Valley College gave a brief overview of the whole project and the various Composite Technology degree and certificate programs that are currently going on in the state. Represented on the DACUM panel were representatives from several industries including aviation, marine and education. Other industries where composite technology is gaining a growing footprint in the state include medical prosthetics, wind energy, sporting equipment and automotive. After a brief discussion, the facilitator, Dave Cunningham, introduced the group to the DACUM process and the agenda for the rest of the day. Following this, the workshop got underway with the creation of the work profile of the Composite Technologies Repair Technician. This process went through the afternoon and ended at 4:30PM. The preferred Attributes (Abilities) required of the Composite Technologies Repair Technician: Key Attributes for making quality repairs to composite structures Physical capability to work in a challenging industrial setting Can work standing or moving for x hours Has a mechanical aptitude and comfort around power tools and material handling equipment. Interested in learning and personal professional development Is knowledgeable about and interested in IT technologies Has both an analytical and a creative approach to problem solving Willing to assume responsibility And work in a high stress environment Is adaptable and teachable Has a passion for polymer products Has a strong work ethic that includes showing up on time, every day. Values personal hygiene and appearance. Is able to work collaboratively in a team and also to work independently. Communicates effectively with others Enjoys fixing things Can be an independent thinker when necessary Can work to check points Has a sense of urgency and time Notes: 1. Text in blue denotes most important aptitudes for the repair technician.

4 2. In comparing the attributes preferred for a technician working on the production side of composites, the repair technician should be more of an independent thinker, a person who likes fixing things and one who frequently finds innovative solutions to problems. The other attributes all apply. The Preferred Demonstrated Skill Sets required of the Composite Technologies Technician Most critical and challenging skills Structural Staging A Perform proper jacking and shoring of equipment and parts according to S.O.P.s A1 Operate a Fork Lift and bucket according to required standards A2 Demonstrate proper use of slings and rigging Common Repair Practices Disassemble and reassemble equipment B1 Use range of power tools safely and effectively B2 Do Vacuum bagging according to standard B Manage thermal effects during the curing process B6 Complete common finishing tasks B7 Create a Ply template Damage Repair and Inspection C Identify damaged plies C1 Conduct a comprehensive visual inspection of all damaged parts C2 Perform a visual and a tap test successfully Approved DATA Interpretation D Identify the different types of commonly found composite damage D1 Identify SRM Repair Procedures D2 Read and comprehend technical manuals A3 Conduct routine service on rigging equipment A4 B3 Perform all layup tasks for a typical repair B4 B8 Scarf the damaged area Remove damage and properly prepare a scarf joint. C3 Operate N.D.I. equipment safely and effectively C4 D3 Demonstrate how to choose the best repair option for a particular project D4 Measure Resin ratios B3 Program the Hot Bonder machine B9 Handle all materials safely and appropriately B10 Check all set-ups and follow-through on all repairs B11 Observe ergonomic guidelines B12 B4 Control the curing process B5 Make precision measurements using standard devices B13 Interpret SRM allowable damage limits D5 Interpret composite drawings D6 Note: 1. Numbers and letters are for ease of reference only. They do not denote priority.

5 2. Compared to the skill sets required of a production technician, the repair technician should be comfortable figuring out a work plan based on making creative assessments of the repair task. Communications and professionalism remain equally important.

6 The Recommended Knowledge Base for : Composite Technologies Repair Technician (letters and numbers for ease of reference only) = Most important elements Repair Specifications A Know waste disposal regulations for all composite chemicals and materials A1 The format for documenting all repair work Safety B Knowledge of all hazards associated with different repair tools B1 Knowledge of all hazardous energy sources Materials and Processes C Appropriate N.D.I. methods C1 Composite repair vocabulary Work Planning D Proper Q.A. Procedures and standards D1 Standard repair A2 MSDS format B2 The potential effects of polymers on health C2 How to interpret the effects of composite damage D2 How to plan and organize a major repair project A3 Standard record keeping practices A4 Composite drawings convention B3 How to use standard personal protective equipment (PPE) B4 S.O.P.s for movement and work in restricted areas C3 General knowledge of materials science as it applies to composites C4 The cure cycle for composites D3 Where and how to locate tools and parts during a repair project D4 Standard tooling set-up A5 How to choose the best repair options A4 The level of specifications expected for standard repair documentations A5 B5 How and when to employ Lock-out and Tag out B5 Common for FOD control B6 C5 Tooling certification and its importance C6 Environmental constraints and requirements when working with composites C7 Composite material identification C8 D5 Notes: In comparison to the knowledge base for production technicians, the repair technician will be less concerned with LEAN principles and practices. Otherwise there is much overlap.

7 The Work Profile of the typical Composite Technologies Repair Technician Main Duties Primary Tasks (Purple = most challenging: Green = most commonly performed tasks: Tan = both common and challenging) Occupational Safety A Performing Repairs Using PPE according to SOPs A1 Operating all tools safely A2 Following appropriate repair (SRMs) B1 Using only certified tools A3 Maintaining certifications A4 Cleaning the bonding area B3 Observing chemical and MSDS safety A5 Conducting cleanup as per SOPs A6 Assembling vacuum bags B5 Preparing rigging and staging A7 Observing standard ergonomic A8 Impregnating Fabric B7 Implementing lockout and tag-out A9 Monitoring curing equipment A10 Preparing for bond scarf ratios Remove damage and properly prepare a scarf joint. Checking on high pressure equipment throughout a repair A11 Training on all equipment A12 Creating, applying and locating templates B11 Disposing, removing and storing hazardous materials A13 Watching for human factor safety risks A14 B Removing damaged parts Managing cure cycles Mixing Resin Cutting and laying down fabric B9 Drying scarfed area Bolting repairs Damage Assessment & Preparation C Quality Assurance D Maintaining Facilities E B2 Performing N.D.I. C1 Documenting Compliance Approval C2 Following all performance directions D1 Following storage E1 B4 Interpreting Structural Repair manual (SRM) C3 Assessing the damage C4 Identifying inspection points D2 Maintaining environmental control at all times E2 B6 Programming cure cycle repair parameters C4 Dis-assembling mechanical systems C5 Conducting Q.A. inspections during and after repairs D3 Performing plant safety checks E3 B8 Reading and interpreting drawings C6 Collecting repair materials C7 Confirming customer satisfaction D4 Maintaining all tooling Ready for use E4 B10 Locating damage C8 Obtaining regulatory Approval D5 B12 Determining if damage is within allowable limits C9

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