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2 Revised April 2012 Copyright Skills LLC All Rights Reserved This document and its content is copyright of 180 Skills LLC All rights reserved. Any redistribution or reproduction of part or all of the contents without express permission of 180 Skills LLC is prohibited. You may not, except with our express written permission, distribute or commercially exploit the content. Nor may you transmit it or store it in any other website or other form of electronic retrieval system.

3 Index Index Aviation and Aerospace Technician Competencies Weeks to Employment Program Details Certificate Program Courses Aerospace Manufacturing Core Certificate Aerospace Assembly Mechanic Certificate Aerospace Electrical Assembler Certificate Aerospace Composite Repair Certificate Aerospace Quality Assurance Certificate Aerospace CNC Certificate Aerospace Tooling Certificate of 31

4 1.0 Aviation and Aerospace Technician Competencies Based on input from numerous employers and industry associations across the nation, 180 Skills has developed curricula that serves as the Body of Knowledge for the Aviation and Aerospace Technician Certification (AATC). We have mapped these Competencies to the current SCS credentials and identified the additional skills that could be codified under a nationally-portable, third-party-validated, AATC. The AATC consists of seven stackable technical certificates that can be combined to create an ATA degree in Manufacturing and Material Technology (92 credits) or an AAS-T degree in Material Science Technology (90 credits). These technical certificates build skills in the areas of Aircraft Assembly, Electrical Assembler, Composite Repair, CNC, Tool Making and Quality Assurance. The duration of each certificate program ranges from 4 to 8 weeks. Upon completion students are fully prepared for entry level jobs in the aerospace industry. The Aerospace Certificate Program is delivered as blended learning with asynchronous, selfpaced online courses followed by instructor lead, hands-on classroom sessions. The use of asynchronous online content allows advanced learners to speed through or bypass instruction that is redundant. Novices can slow their own progress through the content, eliminating frustration with themselves, their fellow learners, and the course. In these ways, e- learning reaches a maximum number of participants with a maximum range of learning styles, preferences, and needs. 4 of 31

5 Weeks to Employment The AATC program design enables the students (displaced workers, workers retooling their skills) to attain the skills required for a living wage job in 12 weeks. The minimum educational requirement to qualify for a job interview in the aerospace manufacturing industry is two technical certificates. The minimum requirement for the program is a high school diploma or a GED equivalent. All students must enroll with the respective academic institution in their region. All exams and lab work are performed on-site at the academic institution. The 12 week program of study is as follows: Four weeks of online, asynchronous study in the Core Skills program. o Final proctored exam score of 90%. Four weeks of online asynchronous study in one of the six technical areas. o Final proctored exam score of 90%. Four weeks full-time of on-site lab work. 5 of 31

6 3.0 Program Details The AATC program is delivered by our academic partners as seven unique technical certificates. All students are required to complete or test out of the Aerospace Manufacturing Core certificate. The remaining certificates are chosen based upon the industry demands. Each of the certificates is completed in 4 to 8 weeks. The breakdown for each certificate is shown below. Certificate Name Credits Contact Hours Online / Lab Duration 1 Aerospace Manufacturing Core % / 0% 4 weeks 2 Aerospace Assembly Mechanic % / 50% 8 weeks 3 Aerospace Electrical Assembler % / 50% 8 weeks 4 Aerospace Composite Repair % / 50% 3 weeks 5 Aerospace Quality Assurance % / 50% 8 weeks 6 Aerospace Tooling % / 50% 8 weeks 7 Aerospace CNC % / 50% 8 weeks 6 of 31

7 4.0 Certificate Program Courses Aerospace Manufacturing Core Certificate Course # Course Title Credits MST155-1 Aircraft Familiarization 0.5 MST155-2 Sealing & Safety 1.0 MST155-3 Manufacturing Paperwork 0.5 MST155-4 Engineering Processes 0.5 MST155-5A Precision Measurement Tools and 1.5 Techniques MST155-5B Hand Tools 1.5 MST155-6 Blueprint Reading 1.0 MST155-7 Bonding & Grounding 0.5 MST159 Introduction to Composites 1.0 MST155 Capstone Assessment 1.0 Aerospace Manufacturing Assembly Certificate Course # Course Title Credits Course # Course Title Credits MST155-8 Assembly Mechanic Orientation 0.5 MST155-9 Power Island 1.0 MST Basic Drilling & Riveting 1.0 MST Advanced Fasteners 1.5 MST Countersinking & Flush Riveting 1.0 MST º Drilling & Reaming 1.5 MST Wing Structure 1.5 MST Fuselage Skin Assembly 2.0 MST Drilling Titanium 1.0 MST Drilling Composites 1.0 MST Sealant Application Processes 1.5 MST Electrical Bonding & Grounding 1.0 MST169 Composite Manufacturing 2.0 MST155 Capstone Assessment of 31

8 Aerospace Electrical Assembly Certificate Course # Course Title Credits MST Electrical Assembly Mechanic Orientation 0.5 MST Electrical Hand Tools 2.0 MST Basic Drilling & Riveting 1.0 MST Wire Bundle Basics 2.0 MST Wire Installation Drawings 1.0 MST Wire Bundle Installation 2.0 MST Electrical Ground Jumpers 0.5 MST Electrical Ground Studs & Wire Grounding 1.0 MST Crimping Terminals & Splices 1.5 MST Assembly of Coaxial Connectors 1.5 MST Fiber Optics for Aerospace 2.0 MST155 Capstone Assessment 1.0 Aerospace Composite Certificate Course # Course Title Credits MST159 Composite Materials 1.0 MST169 Composite Manufacturing 2.0 MST189-A Composite Repair I.75 MST189-B Composite Repair II.75 Aerospace Quality Assurance Certificate Course # Course Title Credits Introduction to Quality Assurance 2.0 Basic Roles and Responsibilities 3.0 Conflict Resolution Statistical Process Control (SPC) 3.0 Engineering Drawing Interpretation 3.0 Aircraft Familiarization Part 2 General Dimensioning and Tolerancing 2.0 (GD&T) Technical Writing Precision Measurement Tools and 2.0 Techniques Complete in June of 31

9 Aerospace Tooling Certificate Course # Course Title Credits Manufacturing Teams 1.0 Introduction to Tooling 1.0 Hand Tools 1.0 Power Hand Tools 2.0 Hole Quality & Tap and Die Review 2.0 Floor Mounted Power Tools 2.0 Torque 2.0 Precision Measurement Tools and 2.0 Techniques General Dimensioning and Tolerancing 2.0 (GD&T) Complete in July 2012 Aerospace CNC Certificate Course # Course Title Credits Manufacturing Teams 1.0 Manufacturing Paperwork 0.5 Engineering Processes 0.5 Safety 0.5 Precision Measurement Tools and 2.0 Techniques General Dimensioning & Tolerances (GD&T) 2.0 Blueprint Reading 1.0 Statistical Process Control 3.0 Materials 1.5 Job Planning, Benchwork and Layout 2.0 Introduction to CNC 1.0 CNC Turning Level I 2.0 CNC Milling Level II 2.0 This certificate will be developed in of 31

10 5.0 Aerospace Manufacturing Core Certificate 9 credits 4 weeks online Program Outcomes Demonstrate an understanding of the opportunities and culture of aerospace manufacturing. Identify basic aircraft types, manufacturers and models. Demonstrate a basic knowledge of sealing principles in aerospace manufacturing. Demonstrate a basic knowledge of aerospace manufacturing paperwork and procedures. Develop self-strategies for the use of product databases and online resources. Understand the use of engineering process requirements in aerospace manufacturing. Demonstrate a working knowledge of precision measuring tools. Demonstrate a working knowledge of hand held power tools and associated safety procedures. Demonstrate a working knowledge of aerospace fasteners Understand the use of blueprints and picture sheets used in the aerospace manufacturing. Understanding of electrical bonding and grounding theory, required tools and procedures. Understand the common materials used in composites, their safety considerations and general properties. Course Descriptions 1. Aircraft Familiarization This course provides an introduction for potential aerospace industry technicians, providing an overview of the industry, its culture and common aircraft types. 2. Sealing & Safety This course provides an introduction on basic sealing principles; from finding and using tools, sealant selection, cleaning methods and application processes. 10 of 31

11 3. Manufacturing Paperwork This course provides an overview of various manufacturing documentation and database processes and procedures. 4. Engineering Processes This course provides an overview of Lean manufacturing concepts and procedures as well as an introduction to the process requirements in aerospace manufacturing. 5. Precision Instruments This course provides an introduction to the various precision measuring instruments and their correct, proper and safe use, in aerospace manufacturing. 6. Hand Tools and Fasteners This course provides an introduction to the various hand tools used in the aerospace industry. This course also introduced the student to a several aerospace fasteners including temporary fasteners, bolts and lock bolts, Hi-Loks and rivets. 7. Blueprints & Picture Sheets This course provides an introduction to the types, interpretation and scaling of blueprints and picture sheets used in the manufacturing process. 8. Bonding & Grounding This course provides an overview of electrical bonding and grounding theory, required tools and procedures and final quality control. 9. Intro to Composites This course provides an introduction to a variety of common materials used in fiber / matrix composites, their safety considerations and general properties which can be achieved with different manufacturing and orientation procedures. 10. Capstone Assessment 11 of 31

12 6.0 Aerospace Assembly Mechanic Certificate 18.5 credits 4 weeks online 4 weeks in lab Program Outcomes Demonstrate an understanding of the opportunities and principles of aerospace assembly. Demonstrate practical knowledge of power island equipment and associated safety practices. Demonstrate practical knowledge of drilling, countersinking and riveting in different types of materials in aerospace assembly. Demonstrate practical knowledge of safety and quality control in drilling, installing fasteners and inspecting installations in aerospace assembly. Understand the terminology and documentation skills required of an assembly mechanic. Demonstrate practical knowledge of preparing and applying sealants. Demonstrate practical knowledge of preparing electrical bonding and grounding locations. Demonstrate practical knowledge of methods used to fabricate and manufacture fiber reinforced composites. Course Descriptions 1. Assembly Mechanic Orientation This course provides an overview of the technical and manufacturing knowledge and skills necessary to qualify for employment in the aerospace industry as an assembly mechanic. 2. Power Island Equipment This course provides specific technical and manufacturing knowledge and skills necessary to operate power island equipment in the aerospace industry as an assembly mechanic. 3. Basic Drilling & Riveting This course provides specific technical and manufacturing knowledge and skills necessary to safely drill and countersink quality holes and to properly install rivets in the aerospace industry as an assembly mechanic. 12 of 31

13 4. Advanced Fasteners This course provides specific technical and manufacturing knowledge and skills necessary to correctly torque, lock wire and install advanced fasteners properly in the aerospace industry as an assembly mechanic. 5. Countersinking & Flush Riveting This course provides specific technical and manufacturing knowledge and skills necessary to properly countersink and install flush rivets in the aerospace industry as an assembly mechanic Degree Drilling, Reaming & Permanent Fasteners This course provides specific technical and manufacturing knowledge and skills necessary to perform 90 degree drilling and reaming operations for fastener installation in the aerospace industry as an assembly mechanic. 7. Wing Structure Project This course provides specific technical and manufacturing knowledge and skills necessary to assemble skin assemblies in the aerospace industry as an assembly mechanic. 8. Fuselage Skin Assembly This course provides specific technical and manufacturing knowledge and skills necessary to assemble fuselage and related skin assemblies in the aerospace industry as an assembly mechanic. 9. Drilling Titanium Materials This course provides specific technical and manufacturing knowledge and skills necessary to safely and correctly drill holes in titanium based materials in the aerospace industry as an assembly mechanic. 10. Drilling Composite Materials This course provides specific technical and manufacturing knowledge and skills necessary to safely and correctly drill holes in composite materials in the aerospace industry as an assembly mechanic. 11. Sealant Application Processes Mechanical This course provides specific technical and manufacturing knowledge and skills necessary to safely and properly prepare and apply sealants to various surfaces in the aerospace industry as an assembly mechanic. 13 of 31

14 12. Electrical Bond and Ground Mechanical This course provides specific technical and manufacturing knowledge and skills necessary to prepare electrical bonding and grounding locations in the aerospace industry as an assembly mechanic. 13. Fiber Reinforced Composites Manufacturing This course provides technical knowledge of fiber optic cables and components. The student will learn terminology, fiber optic transmission principles, optic fiber / cable manufacturing process and common fiber optic assemblies as well as defects and safety hazards associated with fiber optics. 14. Capstone Assessment 14 of 31

15 7.0 Aerospace Electrical Assembler Certificate 15 credits 4 weeks online 4 weeks in lab Program Outcomes Demonstrate an understanding of the opportunities and culture of aerospace electrical assemblers. Identify basic aircraft electrical hand held tools and hardware and associated safety.procedures used by an aerospace electrical assembler. Understand the use of production illustrations by an aerospace electrical assembler. Demonstrate a working knowledge of wire bundling, crimping terminals and splicing. Demonstrate a working knowledge of coaxial cable and connector assembly. Course Descriptions 1. Electrical Assembly- Orientation This course provides an overview of the electrical knowledge and skills necessary to qualify for employment in the aerospace industry as an electrical assembler. 2. Hand & Power Tools This course provides an introduction to the various types of hand tools and their correct and safe use for an aerospace electrical assembler. 3. Basic Drilling & Riveting This course provides specific technical and manufacturing knowledge and skills necessary to safely drill and countersink quality holes in the aerospace industry as an electrical assembler. 4. Wire Bundle Basics This course provides technical knowledge and skills in electrical wire identification and preparation, CAU processes, wire attachment and tying wire bundles for an electrical assembler in the aerospace industry. 15 of 31

16 5. Wire Installation Drawings This course provides knowledge to identify the concept of airplane specific configuration table, module parts list, distinguish between a production illustration and an assembly and installation drawing and enable an interpretation of electrical production illustration drawing sheets. 6. Wire Bundle Installation This course provides technical knowledge of the components of acceptable wire bundle installation and the skills necessary to complete a wire bundle installation as an electrical assembler. 7. Electrical Ground Jumpers This course provides technical knowledge of electrical ground jumpers and the skills necessary to complete ground jumper installation as an electrical assembler. 8. Electrical Ground Studs & Wire Grounding This course provides technical knowledge of how to correctly install a standard preinstalled ground stud per specifications such that the installation meets all electrical resistance and inspection requirements. 9. Crimping Terminals & Splices This course provides instruction and practice in the assembly of aircraft electrical terminations. Topics include preparation of wires, crimping terminals & splices, selection and adjustment of tools, and safety procedures. 10. Assembly of Electrical Coaxial Connectors This course provides instruction and practice in the assembly and inspection of coaxial connectors. Topics include preparation of coaxial cable, connector assembly, hardware and associated tools and the safe use of these tools and hardware. 11. Fiber Optics for Aerospace This course provides technical knowledge of fiber optic cables and components. The student will learn terminology, fiber optic transmission principles, optic fiber / cable manufacturing process and common fiber optic assemblies as well as defects and safety hazards associated with fiber optics. 12. Capstone Assessment 16 of 31

17 8.0 Aerospace Composite Repair Certificate 4.5 credits 1.5 weeks online 1.5 weeks in lab Program Outcomes Understanding of the advantages and disadvantages of composites. Identify differences working with metals versus composites. Identify and describe where composites are used in aerospace and other industries. Describe the processes of hand lay-up with pre-pregs, vacuum bagging, ply cutting, and curing using autoclaves. Identify health hazards associated with working with composites. Understanding of co-curing and co-bonding with composites. Describe the processes of resin transfer molding and vacuum assisted resin transfer molding. Describe the processes of filament winding and automated tape lay-up. Describe the processes of compression molding and pultrusion. Demonstrate a working knowledge of composite manufacturing safety practices. Identify the NDI processes available to determine a damaged part condition. Demonstrate a basic composite repair. Course Descriptions 1. Introduction to Composites This course provides technical knowledge of the advantages and disadvantages of composites, the differences of working with metals versus composites and where composites are used in aerospace and other industries. 17 of 31

18 2. Composites Manufacturing I and II This course provides specific technical knowledge of the different processes and procedures of manufacturing composites. Topics include hand lay-up, vacuum bagging, curing, resin transfer molding, filament winding, automated tape lay-up, compression molding and pultrusion. This course also provides specific knowledge about the unique health hazards and required safety practices associated with these procedures. 3. Composite Repair This course provides specific technical knowledge and skills necessary to understand and be able to demonstrate the processes and procedures to repair composites such as surface, potted, taper sanded and bolted repairs. Other topics include NDI processes, quality inspection, roles and responsibilities of the engineer, inspector and technician, identifying sources of damage, different repair techniques, and FOD sources. 4. Capstone Assessment 18 of 31

19 9.0 Aerospace Quality Assurance Certificate 15 credits 4 weeks online 4 weeks in lab Program Outcomes Understand the role of the quality assurance department. Define the role of the quality assurance associate. Explain products based upon an engineering drawing. Evaluate product conformance to specifications. Apply statistical analysis tools in the workplace. Explain complex product features using geometric dimensioning and tolerancing. Select the proper communication tools required to resolve conflict. Explain how to use precision measurement tools. Course Descriptions 1. Introduction to Quality Assurance This course provides specific technical knowledge and skills necessary to understand QA s role within the production system. This includes terms, quality assurance systems such as TQM, lean manufacturing and SPC. 2. Basic Roles and Responsibilities This course prepares the student for their role as a quality assurance associate. 3. Statistical Process Control This course provides the specific technical knowledge and skills necessary to utilize the tools of SPC to evaluate manufacturing processes. This includes the collection and analysis of production data to assess process abilities. 4. Engineering Drawing Interpretation This course provides an introduction to the types, interpretation and scaling of blueprints and picture sheets used in the manufacturing process. 19 of 31

20 5. Geometric Dimensioning and Tolerancing This course provides specific knowledge and skills necessary to interpret and apply the principles of geometric dimensioning and tolerancing as they apply to the manufacture of products. 6. Precision Measurement Tools This course provides an introduction to the various precision measuring instruments and their correct, proper and safe use, in aerospace manufacturing. 7. Conflict Resolution This course provide the skills required to understand conflict in the workplace and presents the student with best practices for handling conflict when it does occur. 8. Technical Writing This courses prepares the student to be able to communicate clearly and precisely in written reports. This includes consistent use of proper terms, names and defect description as well as document structure and format. 9. Capstone Assessment 20 of 31

21 10.0 Aerospace CNC Certificate 19.0 credits 4 weeks online 4 weeks in lab Program Outcomes TBD Course Topics 1. Manufacturing Teams 2. Manufacturing Paperwork 3. Safety 4. Engineering Processes 5. Precision Measurement Tools & Techniques 6. General Dimensioning & Tolerances (GD&T) 7. Blueprint reading 8. Statistical Process Control 9. Materials 10. Job Planning, Benchwork and Layout 11. Intro to CNC 12. CNC Milling Level CNC Turning Level 2 21 of 31

22 11.0 Aerospace Tooling Certificate 15 credits 4 weeks online 4 weeks in lab Program Outcomes TBD Course Topics 1. Manufacturing Teams 2. Introduction to Tooling 3. Hand Tools 4. Hand Power Tools 5. Hole Quality & Tap and Die Overview 6. Floor Mounted Power Tools 7. Torque 8. Precision Measurement Tools & Techniques 9. General Dimensioning & Tolerances (GD&T) 22 of 31

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24 Aerospace Fiber Optics Course 24 of 31