1、_SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising theref
2、rom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions.Copyright 2013 SAE International All rights reserved. No part of this pub
3、lication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-4970
4、(outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/ARP6240AEROSPACERECOMMENDED PRACTICEARP6240Issued 2013-10 Training for Quality Contr
5、ol of Overhaul Chemical Process Operators (Parts Cleaners) RATIONALEThere is a close relationship between part cleaning and most non-destructive inspection techniques. The FAA requested SAE Committee J to develop and issue a training guideline for chemical process operators in the parts cleaning are
6、a as this is generally considered unskilled labor and in the past, little or no training had been provided or recommended. Since overhaul cleaning is a critical process step prior to visual and fluorescent penetrant inspection processes, consideration must be given to minimum levels of training for
7、these process operators. The FAA plans to refer to this document in future shop audits of the parts cleaning areas. TABLE OF CONTENTS 1. SCOPE 2 1.1 Purpose . 2 2. REFERENCES 2 3. GUIDELINES FOR TRAINING CHEMICAL PROCESS OPERATORS . 2 4. NOTES 5 APPENDIX A 6FIGURE 1 WATER-BREAK TEST 3 SAE INTERNATIO
8、NAL ARP6240 Page 2 of 6 1. SCOPE The task of chemical process operator in the parts cleaning area is generally considered unskilled labor and in the past, little or no training had been provided or recommended. Since overhaul cleaning is a critical process step prior to visual and fluorescent penetr
9、ant inspection processes, consideration must be given to minimum levels of training for these process operators. It is the responsibility of the department supervisor to ensure that all personnel within the department are trained to acceptable level in all general aspects of health and safety and ba
10、sic operating procedures. This document is intended to augment the local quality control system which will control the application and frequency of the guidelines stated within. 1.1 Purpose To provide an outline for training chemical process operators to insure an acceptable level of understanding a
11、nd proficiency within the existing production process system. 2. REFERENCES There are no referenced publications specified herein. 3. GUIDELINES FOR TRAINING CHEMICAL PROCESS OPERATORS 3.1 Basic Operator Requirements 3.1.1 Physically fit enough to carry out any component handling requirements. 3.1.2
12、 Literate enough to read, and understand, any relevant process specifications and accompanying flow charts. 3.1.2.1 The operator shall be able to demonstrate his/her understanding of the planning/router by reading and then following the instructions on an example of a typical chemical process line r
13、outer. 3.1.3 Numerate enough to read, and understand, any relevant process specification and accompanying flow charts. 3.1.3.1 The operator shall be able to demonstrate his/her understanding of the planning/router by reading and then following the instructions on an example of a temporary/marked-up
14、process router that is an example of an exception to the normal chemical processing document. 3.1.4 Operator shall be capable of adequately distinguishing and differentiating colors used in the process. 3.1.5 Operator shall understand the differences between acids and alkalis and their effects on pa
15、rts. 3.2 Qualification Requirements for Operators 3.2.1 Initial qualification of operators shall determine the level of introduction training for each job assignment. 3.2.1.1 Test shall be conducted to qualify operator for tank cleaning operations in initial qualification period. 3.2.1.2 The operato
16、r shall be qualified to perform processes for which he/she successfully completed the test. 3.2.2 Operators shall be re-qualified at least once every 12 months and when new cleaning process has been introduced or current process significantly changed. 3.2.2.1 Operator failing the re-qualification te
17、st shall be allowed a second test in the same process within 3 week period.3.2.2.2 An operator that fails a second test shall undergo further training and shall only be permitted to perform process operations under supervision until successfully re-qualified. 3.2.2.3 Remedial training shall be desig
18、ned to rectify an employees demonstrated lack of knowledge or skill. SAE INTERNATIONAL ARP6240 Page 3 of 6 3.2.2.4 Operator shall be entitled to complete re-qualification test upon submitting evidence of completing remedial training.3.2.3 Training records are generated and maintained showing all tra
19、ining and qualification documents for each operator performing cleaning processes. 3.3 Basic training course requirements may be met through classroom training (approximately 4 to 5 hours) and/or a structured on-the-job training program that meets these requirements: 3.3.1 Importance of cleanliness
20、with respect to follow-on inspections or operations (NDT, bonding, painting, etc.) (30 minutes). 3.3.1.1 The operator shall be able to demonstrate his/her understanding of the importance of the cleaning process by describing the effects of improperly cleaned parts on several downstream processes. 3.
21、3.2 Importance of maintaining correct bath concentration, temperature, and component immersion times. Explain effects of incorrect concentrations, temperature, and component immersion times including the process to recall parts if necessary. Importance of flow charts showing proper sequencing of ope
22、rations. Importance of proper fixturing of parts for cleaning (30 minutes). 3.3.2.1 The operator shall be able to demonstrate his/her understanding of the importance of the cleaning processes concentration and temperature by describing potential effects of improperly maintained chemical cleaning tan
23、ks. 3.3.2.2 The operator shall be able to demonstrate his/her understanding of the importance of the cleaning process by describing the effects of leaving parts in the chemical bath for unspecified times. 3.3.2.3 The operator shall be able to demonstrate his/her understanding of the importance of th
24、e cleaning process by describing the possible effects of re-sequencing the steps in the cleaning process. This training shall include the definition of “waterbreak” and how to observe for it and that recleaning is necessary if found. FIGURE 1 - WATER-BREAK TEST SAE INTERNATIONAL ARP6240 Page 4 of 6
25、3.3.2.4 The operator shall be able to identify and use the proper fixturing and lifting devices used for the parts specified on a typical router. 3.3.3 Importance of efficient rinsing and maintenance of rinse tanks (30 minutes). 3.3.3.1 The operator shall be able to demonstrate his/her understanding
26、 of the importance the rinsing process by describing the effects of improperly rinsed parts on downstream processes. 3.3.3.2 The operator shall be able to describe the various methods used for rinsing and demonstrate the proper rinsing techniques.3.3.3.3 The operator shall be able to demonstrate his
27、/her understanding of proper part orientation to avoid air entrapment.3.3.3.4 The operator shall be able to describe the difference in adequately processed surfaces. 3.3.3.5 The operator shall be able to demonstrate his/her understanding of the importance rinse tank maintenance by describing how to
28、recognize when a rinse tank is not properly maintained and the process of bringing it back into full service. 3.3.4 Solvent cleaning versus light duty aqueous cleaning (30 minutes). 3.3.4.1 The operator shall be able to demonstrate his/her understanding of solvent cleaning and aqueous cleaning by de
29、scribing examples of each as they are used in the chemical cleaning operation. 3.3.5 Proper techniques to prevent handling damage and what problems can result from damage (10 minutes). 3.3.5.1 The operator shall be able to demonstrate his/her understanding of the importance the proper part handling
30、by describing the potential effects of improperly handled parts on downstream processes. 3.3.5.2 The operator shall be able to identify and demonstrate the use of proper material handling devices used for the parts specified on a typical router in the cleaning process. 3.3.6 Post cleaning protection
31、 processes. 3.3.6.1 The operator shall be able to describe the effects of corrosion on metals. 3.3.6.2 The operator shall be able to identify the corrosion protection materials. 3.3.6.3 The operator shall be able to demonstrate his/her understanding when use of corrosion protection materials is nece
32、ssary.3.3.7 Environmental requirements including minimizing water usage, effluent and waste disposal (30 minutes). 3.3.7.1 The operator shall be able to demonstrate his/her understanding of consequences for not following the local environmental requirements in the chemical processing line by describ
33、ing the potential health, environmental, and civil penalty. 3.3.7.2 The operator shall be able to demonstrate understanding of responsibility to report EH&S incidents to his/her supervisor.3.3.8 Health and safety, including: identification and proper use of Personal Protective Equipment (PPE), handl
34、ing hazardous materials, local procedure for handling spills, basic first aid, how to read and understand local Material Safety Data Sheets (MSDS) (90 minutes). 3.3.8.1 The operator shall be able to identify and use the appropriate PPE for the tasks assigned. SAE INTERNATIONAL ARP6240 Page 5 of 6 3.
35、3.8.2 The operator shall be able to identify hazardous materials and demonstrate proper handling according to local regulations.3.3.8.3 The operator shall be aware of procedures to follow in the event of a spill and be able to demonstrate his/her ability to properly document and secure a spill. 3.3.
36、8.4 The operator shall be familiar with relevant first aid and shall be able to demonstrate what to do in the event of an accident involving an injury. 3.3.8.5 The operator shall be able to locate the MSDS information for any of the chemical tank processes in the chemical cleaning line. 3.3.8.6 The
37、operator shall be able to demonstrate his/her understanding of the MSDS by describing the recommended personal protective equipment from a sample MSDS. 3.3.8.7 The operator shall be able to demonstrate his/her understanding of the MSDS describing the potential health hazards and recommended first ai
38、d for exposure from a sample MSDS. 3.3.9 Training according to OEM practices and standards (40 minutes). 3.3.9.1 The operator shall be able to demonstrate his/her understanding of the chemical cleaning process by citing examples of chemical cleaning best practices. 3.3.9.2 The operator shall be able
39、 to describe his/her understanding of the human factors. 3.3.10 Evaluation using an appropriate tool such as multi-choice question and answer system (15 minutes). 3.3.10.1 The operator shall be able to demonstrate his/her understanding of the chemical cleaning process by successfully completing an o
40、verview of the material presented in this training module. 4. NOTES 4.1 A change bar (l) located in the left margin is for the convenience of the user in locating areas where technical revisions, not editorial changes, have been made to the previous issue of this document. An (R) symbol to the left
41、of the document title indicates a complete revision of the document, including technical revisions. Change bars and (R) are not used in original publications, nor in documents that contain editorial changes only. PREPARED BY AMS COMMITTEE “J“ SAE INTERNATIONAL ARP6240 Page 6 of 6 APPENDIX A A.1 Brea
42、ks shall be scheduled as needed within the context of the training sequence. A.2 At all times it must be emphasized that “when in doubt, ask“ and if a part is dipped in the wrong tank, the supervisor must be notified immediately. A.3 Attendees successfully completing the evaluation shall be awarded a “Certificate of Competence“ and be given a pocket sized handbook for use as a reference/reminder.
