Aircraft assembler

Aircraft assemblers use hand tools, power tools and other equipment such as CNC machines or robots to construct, fit and install prefabricated parts to manufacture fixed or rotary wing aircrafts and aircraft subassemblies such as flight controls, aircraft skins, rigging and other mechanical systems etc. They read and interpret blueprints. They operate control systems to determine functional performance of the assemblies and adjust accordingly.

Includes people working in benches or on aircraft structures.

The duties of an aircraft assembler include, but are not limited to:

• Install and fit parts for aerial vehicles.
• Assemble, fit, fasten, and install parts of airplanes, space vehicles, or missiles, including tails and wings, landing gear, and heating and ventilation systems.
• Consult with manufacturers and designers.
• Perform precision assembling.
• Adjust timing devices.
• Build prototypes.
• Test products and parts.
• Read and interpret engineering specifications from text and drawings.
• Utilize computer-aided drafting systems.
• Redesign parts for easier install.
• Use precision-measuring instruments.
• Attach brackets, hinges, or clips to secure parts.
• Cut, trim, and smooth parts.
• Verify sizes and adjust if necessary.
• Repair parts.
• Test for malfunctions.
• Position and align subassemblies in jigs.
• Fit and fasten sheet metal coverings to surface areas.
• Cut and fit cables and tubing.
• Set, align, adjust, or synchronize aircraft armament.
• Operate machines to crimp, saw, flare, or straighten tubing.
• Form loops or splice cables using clamps.

Aircraft assemblers work in manufacturing plants, and working conditions vary by plant and by industry. Many physically difficult tasks, such as tightening massive bolts or moving heavy parts into position, have been automated or made easier through the use of power tools. Assembly work, however, may still involve long periods of standing, sitting, or working on ladders.

Some aircraft assemblers come into contact with potentially dangerous chemicals or fumes, but ventilation systems usually minimize any harmful effects. Other assemblers come into contact with oil and grease, and their work areas may be noisy. Fiberglass laminators and fabricators are exposed to fiberglass, which may irritate the skin; these workers must wear protective gear, such as gloves and long sleeves, and must use respirators for safety.

Most aircraft assemblers work full time. Some assemblers work in shifts, which may require evening, weekend, and night work.

The following job titles also refer to aircraft assembler:

aircraft sub-assembly installer
aeroplane assembler
aircraft rigging assembler
aircraft mechanical systems installer
aircraft structure assembler
aircraft fitter
helicopter assembler
plane assembler
flight control installer
military aircraft assembler
aircraft wing assembler
fixed wing aircraft
jet aircraft assembler
flight control assembler
aircraft fuselage assembler

A high school diploma is typically required to work as an aircraft assembler. Employers usually provide on-the-job training.

ISCO skill level is defined as a function of the complexity and range of tasks and duties to be performed in an occupation. It is measured on a scale from 1 to 4, with 1 the lowest level and 4 the highest, by considering:

• the nature of the work performed in an occupation in relation to the characteristic tasks and duties
• the level of formal education required for competent performance of the tasks and duties involved and
• the amount of informal on-the-job training and/or previous experience in a related occupation required for competent performance of these tasks and duties.

Aircraft assembler is a Skill level 2 occupation.

These occupations, although different, require a lot of knowledge and skills similar to aircraft assembler.

aircraft de-icer installer
motor vehicle body assembler
motor vehicle parts assembler
aircraft gas turbine engine overhaul technician
aircraft engine assembler

These occupations require some skills and knowledge of aircraft assembler. They also require other skills and knowledge, but at a higher ISCO skill level, meaning these occupations are accessible from a position of aircraft assembler with a significant experience and/or extensive training.

aircraft engine tester
aircraft assembly supervisor
rolling stock engine tester
avionics inspector
aircraft engine inspector

This knowledge should be acquired through learning to fulfill the role of aircraft assembler.

• Electromechanics: The engineering processes that combine electrical and mechanical engineering in the application of electromechanics in devices that need electricity to create mechanical movement or devices that create electricity by mechanical movement.
• Aircraft mechanics: Technicalities over mechanics in aircrafts and related topics in order to perform a wide range of repairs in aircrafts.
• Quality standards: The national and international requirements, specifications and guidelines to ensure that products, services and processes are of good quality and fit for purpose.
• Common aviation safety regulations: The body of legislation and regulations that apply to the field of civil aviation at regional, national, European and International levels. Understand that regulations aimed at protecting citizens at all times in civil aviation; ensure that operators, citizens, and organisations comply with these rules.
• Mechanics: Theoretical and practical applications of the science studying the action of displacements and forces on physical bodies to the development of machinery and mechanical devices.

These skills are necessary for the role of aircraft assembler.

• Assemble metal parts: Align and arrange steel and metal parts in order to assemble complete products; use the appropriate hand tools and gauges.
• Apply preliminary treatment to workpieces: Apply preparatory treatment, through mechanical or chemical processes, to the workpiece preceding the main operation.
• Troubleshoot: Identify operating problems, decide what to do about it and report accordingly.
• Align components: Align and lay out components in order to put them together correctly according to blueprints and technical plans.
• Use power tools: Operate power driven pumps. Use hand tools or power tools. Use vehicle repair tools or safety equipment.
• Wear appropriate protective gear: Wear relevant and necessary protective gear, such as protective goggles or other eye protection, hard hats, safety gloves.
• Read standard blueprints: Read and comprehend standard blueprints, machine, and process drawings.
• Ensure equipment availability: Ensure that the necessary equipment is provided, ready and available for use before start of procedures.
• Operate drill press: Operate a semi-automated, semi-manual drill press to drill holes in a work piece, safely and according to regulations.
• Read engineering drawings: Read the technical drawings of a product made by the engineer in order to suggest improvements, make models of the product or operate it.
• Fasten components: Fasten components together according to blueprints and technical plans in order to create subassemblies or finished products.
• Use technical documentation: Understand and use technical documentation in the overall technical process.
• Apply health and safety standards: Adhere to standards of hygiene and safety established by respective authorities.

This knowledge is sometimes, but not always, required for the role of aircraft assembler. However, mastering this knowledge allows you to have more opportunities for career development.

• Engineering principles: The engineering elements like functionality, replicability, and costs in relation to the design and how they are applied in the completion of engineering projects.
• Engineering processes: The systematic approach to the development and maintenance of engineering systems.
• Defense system: The various weapons and weapon systems used to protect citizens and to harm or shield incoming enemies and enemy weapons.
• Rivet types: The various types of rivets used in manufacturing, such as solid head rivets, blind rivets, drive rivets, semi-tubular rivets, oscar rivets, flush rivets, and others.

These skills and competences are sometimes, but not always, required for the role of aircraft assembler. However, mastering these skills and competences allows you to have more opportunities for career development.

• Inspect quality of products: Use various techniques to ensure the product quality is respecting the quality standards and specifications. Oversee defects, packaging and sendbacks of products to different production departments.
• Use welding equipment: Operate welding equipment in a safe manner; use welding techniques such as shielded metal arc welding or flux-cored arc welding.
• Record test data: Record data which has been identified specifically during preceding tests in order to verify that outputs of the test produce specific results or to review the reaction of the subject under exceptional or unusual input.
• Tend CNC milling machine: Tend a computer numerical controlled (CNC) milling machine designed for cutting manufacturing processes on metal, wooden, plastic materials and others, monitor and operate it, according to regulations.
• Tend CNC metal punch press: Monitor and operate a computer numerical controlled (CNC) metal punch press according to regulations.
• Archive documentation related to the work: Select relevant documentation related to the ongoing or complete work and take steps to archive it in a way that ensures its future accessibility.
• Tend CNC grinding machine: Tend a computer numerical controlled (CNC) grinding machine designed for manufacturing processes on metal, wooden, plastic materials and others, monitor and operate it, according to regulations.
• Operate handheld riveting equipment: Operate various kinds of tools and equipment used in riveting processes, such a pin hammer and a rivet set, handheld squeezers, a hammer and bucking bar, a pneumatic hammer, a rivet gun, and others.
• Use testing equipment: Use equipment to test performance and operation of machinery.
• Use CAM software: Use computer-aided manufacturing (CAM) programmes to control machinery and machine tools in the creation, modification, analysis, or optimisation as part of the manufacturing processes of workpieces.
• Tend CNC drilling machine: Tend a computer numerical controlled (CNC) drilling machine designed for cutting manufacturing processes on metal, wooden, plastic materials and others, monitor and operate it, according to regulations.
• Cut metal products: Operate cutting and measuring instruments in order to cut/shape pieces of metal into given dimensions.
• Tend CNC laser cutting machine: Monitor and operate a computer numerical controlled (CNC) laser cutting machine according to regulations.
• Conduct performance tests: Conduct experimental, environmental and operational tests on models, prototypes or on the systems and equipment itself in order to test their strength and capabilities under normal and extreme conditions.
• Program a CNC controller: Set up the desired product design in the CNC controller of the CNC machine for product manufacturing.
• Operate lifting equipment: Transport heavy objects using lifting equipment such as cranes, forklifts etc.
• Tend computer numerical control lathe machine: Tend a computer numerical controlled (CNC) lathe and turn machine designed for cutting manufacturing processes on metal, wooden, plastic materials and others, monitor and operate it, according to regulations.
• Liaise with engineers: Collaborate with engineers to ensure common understanding and discuss product design, development and improvement.
• Keep records of work progress: Maintain records of the progress of the work including time, defects, malfunctions, etc.
• Tend riveting machine: Tend a metalworking machine designed to join metal pieces by automatically shooting mechanical fasteners, rivets, into them, monitor and operate it according to regulations.
• Perform aircraft maintenance: Carry out inspection and maintenance on aircraft parts according to the maintenance procedures and documentation, and perform repair work to remedy functional and deterioration problems.
• Set up automotive robot: Set up and programme an automotive robot working on machine processes and substituting or collaboratively supporting human labour, such as the six-axis automotive robot.
• Follow safety procedures when working at heights: Take necessary precautions and follow a set of measures that assess, prevent and tackle risks when working at a high distance from the ground. Prevent endangering people working under these structures and avoid falls from ladders, mobile scaffolding, fixed working bridges, single person lifts etc. since they may cause fatalities or major injuries.

8211 – Mechanical machinery assemblers

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References

1. ESCO
2. U.S. Bureau of Labor Statistics
3. Aircraft Rigging Assembler Job Description – LocalJobNetwork.com
4. Featured image: By DearEdward from New York, NY, USA – A321 final assembly, CC BY 2.0