Center of Excellence, Marine Manufacturing & Technology
Skagit Valley College
South Seattle Community College
National STEM Consortium
DACUM Workshop Report
Composite Repair Technician
Facilitation: Cunningham Enterprises; davidg.cunningham@comcast.net
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
Lunch
1:15PM
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.
2.
3.
4.
5.
6.
7.
Bart Bauer, The Boeing Company
Jim Roebuck, Clover Park Technical College
Matthew Weaver, Fiberglass Supply
Michael Swietzer, Skagit Valley College
Lou Dorworth, ABARIS
Brian Nasralla, Industrial Engineering, The Boeing Company
Dave Cunningham, - DACUM Facilitator, Cunningham Enterprises
Introductions:
Facilitation: Cunningham Enterprises; davidg.cunningham@comcast.net
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
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
Has both an analytical
and a creative
approach to problem
solving
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.
Facilitation: Cunningham Enterprises; davidg.cunningham@comcast.net
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
Common Repair Practices
Disassemble and
reassemble
equipment
B
Manage thermal
effects during the
curing process
B1
Use range of power
tools safely and
effectively
B6
Complete common
finishing tasks
A2
Demonstrate proper
use of slings and
rigging
B2
Do Vacuum bagging
according to standard
B7
Create a Ply template
A3
Conduct routine
service on rigging
equipment
B3
Perform all layup
tasks for a typical
repair
A4
B4
B8
Scarf the damaged
area
Remove damage and
properly prepare a
scarf joint.
Damage Repair
and Inspection
C
Identify damaged
plies
Identify the different
types of commonly
found composite
damage
C1
Conduct a
comprehensive visual
inspection of all
damaged parts
C2
Perform a visual and
a tap test successfully
D1
Identify SRM Repair
Procedures
C3
Operate N.D.I.
equipment safely and
effectively
D3
Demonstrate how to
choose the best
repair option for a
particular project
D4
C4
B9
Handle all materials
safely and
B3
appropriately
B10
Program the Hot
Check all set-ups and
Bonder machine
follow-through on all
repairs
B4
B11
Control the curing
Observe ergonomic
process
guidelines
B5
B12
Make precision measurements using standard
devices
B13
Measure Resin ratios
Note:
1. Numbers and letters are for ease of reference only. They do not denote priority.
Facilitation: Cunningham Enterprises; davidg.cunningham@comcast.net
Approved DATA
Interpretation
D
D2
Read and
comprehend
technical manuals
Interpret SRM
allowable damage
limits
D5
Interpret composite
drawings
D6
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.
Facilitation: Cunningham Enterprises; davidg.cunningham@comcast.net
The Recommended Knowledge Base for : Composite Technologies Repair Technician (letters
and numbers for ease of reference only)
= Most important elements
Repair Specifications
A
Safety
B
Know waste disposal
regulations for all composite
chemicals and materials
A1
The format for documenting
all repair work
Knowledge of all hazards
associated with different
repair tools
B1
Knowledge of all
hazardous energy sources
Appropriate N.D.I. methods
Proper Q.A. Procedures
and standards
C1
Composite repair vocabulary
D1
Standard repair
procedures
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
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
B5
How and when to employ
Lock-out and Tag out
procedures
B5
Common procedures for
FOD control
C5
Tooling certification and its
importance
D5
A4
Composite drawings
convention
A5
How to choose the best
repair options
A4
The level of specifications
expected for standard repair
documentations
A5
B6
Materials and
Processes
C
Work Planning
D
C6
Environmental constraints
and requirements when
working with composites
C7
Composite material
identification
C8
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.
Facilitation: Cunningham Enterprises; davidg.cunningham@comcast.net
The Work Profile of the typical Composite Technologies Repair Technician
Main Duties
Occupational
Safety
A
Performing
Repairs
B
Damage
Assessment &
Preparation
C
Quality
Assurance
D
Maintaining
Facilities
E
Primary Tasks (Purple = most challenging: Green = most commonly performed tasks: Tan = both common and
challenging)
Using PPE
according to SOPs
Using only certified
tools
Observing chemical
and MSDS safety
Preparing rigging
and staging
Implementing lockout and tag-out
procedures
Checking on high
pressure equipment
throughout a repair
A1
Operating all tools
safely
A3
Maintaining
certifications
A5
Conducting cleanup as per SOPs
A9
Monitoring curing
equipment
A11
Training on all
equipment
A2
Following
appropriate repair
procedures (SRMs)
A4
Cleaning the
bonding area
A6
Assembling vacuum
bags
A7
Observing standard
ergonomic
procedures
A8
Impregnating
Fabric
A12
Creating, applying
and locating
templates
B1
B3
B5
B7
A10
Preparing for bond
scarf ratios
Remove damage
and properly
prepare a scarf joint.
Removing damaged
parts
Managing cure
cycles
Mixing Resin
Cutting and laying
down fabric
B2
Performing N.D.I.
B4
Interpreting
Structural Repair
manual (SRM)
B6
Programming cure
cycle repair
parameters
B8
Reading and
interpreting
drawings
C1
Documenting
Compliance
Approval
C2
Following all
performance
directions
C3
Assessing the
damage
C4
Dis-assembling
mechanical systems
C6
Collecting repair
materials
C4
Identifying
inspection points
C5
Conducting Q.A.
inspections during
and after repairs
C7
Confirming
customer
satisfaction
D1
Following storage
procedures
D2
Maintaining
environmental
control at all times
D3
Performing plant
safety checks
D4
Maintaining all
tooling
Ready for use
E1
E2
E3
E4
Facilitation: Cunningham Enterprises; davidg.cunningham@comcast.net
B11
B9
Drying scarfed area
Bolting repairs
B10
B12
Locating damage
Determining if
damage is within
allowable limits
C8
C9
Obtaining
regulatory Approval
D5
Disposing,
removing and
storing hazardous
materials
A13
Watching for
human factor
safety risks
A14
Facilitation: Cunningham Enterprises; davidg.cunningham@comcast.net