Module 7.

Workshop Practices
 Care of Tools
• Important that an aircraft engineers look after
their tools.
• Both personal tools and the companies special
tools.
• Tools should be kept in good condition and not
mistreated to achieve maximum performance.
• Precision tools have their own dedicated box.
• Tools should be well maintained.
• Pre-use zero checks on precision instruments.
• Light oiling to prevent onset of corrosion.
• Corks on scriber ends to prevent blunting.
 Control of Tools
• Shadow board system can help to account for
tools being used.
• Used in conjunction with tool tags.
• Racking in personal tool boxes can help to
account for tools.
• Tools must be accounted for at the end of
each shift, task and maintenance check.
• Lost tools can cause:
a. Foreign Object Damage (FOD)
b. Expense
c. Loss of life!
 Tool Tag/Shadow Board

Hammer Hammer
Shaped on top of Mobile Tool Kit
Shadow with Shadow
Tag in Place
 Calibration Standards
• Calibration of Test Equipment is a legislative
requirement - JAR/BCAR.
• Calibration done iaw National and International
standards - BS/ISO/DIN.
• Standard usually determined by equipment
manufacturer or design organisation.
• When no standard is recommended, British
Standard EN 30012-1: Quality Assurance
Requirements for Measuring Equipment is
used in the UK.
 Calibration Systems
• Company normally runs its own internal
Measurement and Calibration System.
• Sub contracting an outside Appliance Calibration
Service may be done by small companies or
Approved/Licensed Engineers.
• Calibrated equipment require a ‘Next Inspection’
label, showing date and (if req.) place of next test.
• Calibration dates of similar test equipment is
usually staggered to ensure continuous
availability.
• When small numbers of test equipment are held
contract loan of equipment is permitted.
 Calibration Intervals
• Calibration intervals depends on:
a. Nature of the equipment
b. Conditions under which it is used
c. Consequences of incorrect results
• Calibration frequency initially decided by the
manufacturer, unless the user can show a
different interval is warranted.
• Normally requires a system of continuous
calibration results to support the variation in
the recommended calibration interval.
 Calibration Records
• Records of calibration must be kept to ensure
traceability.
• These records will be audited by QA and CAA at
least annually.
• Records must be kept in the Calibration Bay for
previous 3 years, and archived for 20 years.
• The end user of the test equipment is
responsible for maintaining the records of
calibration.
• Calibrating equipment should be at least ten
times more accurate than the instrument being
calibrated.
calibrated
 Calibration Trends
• Records will show wear trends as the
instrument age through normal wear and tear.
• If trend shows a drift away from the limits
major overhaul or replacement can be
planned.
• Calibration intervals may also need re
assessing.
• Suspect equipment must be removed from
service and clearly labelled as ‘unserviceable’.
• When repaired it should be re-calibrated, if at
all possible, before being used again.
 Calibration Certificates
• Calibration Certificates should contain the
following minimum information:
1. Identification of equipment
2. Limits of permissible error
3. Standard used
4. Authority under which the document was
issued
5. Results obtained
6. Any limitation of use of equipment
7. Uncertainty of measurement
8. Date when each calibration was conducted
9. Assigned calibration interval
 Calibration Environment

• Measurements can be affected by

environmental changes.

• To ensure valid and repeatable test results,

facilities for calibration must have a controlled
environment.

• A ‘Clean Room’ in which the environment can

be controlled is normally used.
 Control of Clean Room
• Clean Room parameters to control:

1. Temperature
2. Humidity
3. Vibration
4. Dust
5. Cleanliness
6. Electromagnetic interference
7. Lighting
 Workshop Materials
• Consumable materials used in a workshop
require controlling for:

a. Safety

b. Management

c. Economy

Continued..
.
• Safety issues will involve risks to personnel
who come into contact with these materials
such as COSHH assessments.

• Management is the storage, use and correct

handling of these solid, liquid and gaseous
materials.

• Economy would be the issue of the correct

number or quantity of the material and the use
of materials in date order to avoid expiry of
shelf life.

End
 Control of Workshop
Materials
• Certain consumable materials require little
control, items such as:
a. Cleaning Cloths
b. Emery Paper
c. Hacksaw and ‘Stanley’ Knife blades

• Some materials need to be stored outdoors in

special metal lockers, these include:
a. Oils and Greases
b. Paints, Adhesives and Resins
c. Alocrom and Cleaning Fluids
Continued..
.
• Other materials require special precautions
with regard to personal protection.

• The PPE may be to protect:

a. Skin - Barrier Cream and Gloves

b. Respiratory - Face Masks
c. Eye - Safety Glasses or Goggles
d. Feet - Safety Shoes/Boots

End
 Workshop Materials -
General
• Location of outside metal lockers should be on
the Northern Side of a building.
• This reduces the amount of time the sun is on
the locker during the summer months.
• Certain materials requires specialist assistance
when disposing of them.
• Liquids should not be poured down drains,
thrown on grassed areas or stored in
unidentified containers.
• Certain solid materials that have been
contaminated during use require special
disposal.
 Standards of Workmanship
• Standard of workmanship with hand-worked
items depends on the craftsperson and his
tools.
• When machines are used to manufacture
items standard of workmanship depends on
allowances and the type of machine tool used.
• Various tools produce different finishes and
the correct tool for the task depends on how
important the finish on the item needs to be.
• We don’t spend time and money on producing
a smooth finish just because it looks good.
 Typical Written Question

• Describe how a JAR-145 approved

company would control its store of
Tools, Equipment and Precision
Measuring Instruments.

• Include the process of calibration

and its recording.
Any Questions?

End