Assemble, install and test a hydraulic tipping kit

You are a technical operator in the chassis and frame assembly hall.

Simulated workplaceIntermediate missionCAQA Nexus Automotive Manufacturing

What is going on

Tipper body WO-26-0412 for Bellhaven Bulk Haulage is on the assembly line waiting for its front mount hydraulic tipping kit. The first set of hoses was returned to the supplier because the manufacture date was outside the limit, and the replacement hoses arrived this morning. The Assembly Supervisor wants the kit assembled and installed to the drawing, the no load and pressure tests completed to the procedure, and every reading recorded on the work order before he witnesses the final cycle on Thursday. Because the body will be raised during the pressure test, a Job Safety Analysis must be completed and signed on by the crew before the test starts. The build is due on 25 September.

Deshan Perera, Assembly Supervisor
Subject: Hydraulic tipping kit test on WO-26-0412 Thursday

The Bellhaven tipper is ready for its hydraulic kit. The first hoses were returned to the supplier because of the manufacture date, and the replacements arrived this morning. I want you to assemble and install the kit to the drawing, run the no load and pressure tests to the Hydraulic and Pneumatic Kit Assembly and Test Procedure, and record every reading on the work order. Complete a Job Safety Analysis before the pressure test because the body will be raised. I will witness the final cycle.

Your brief

Assemble and install the tipping kit from the drawing and the procedure, complete a Job Safety Analysis for the pressure test, run and record the tests, and present the assembly for the gate inspection with complete records.

Work through it

You do not need to do it all. Doing a few of these will show you what the work is like. Your ticks and notes stay on this device.

Read the Hydraulic and Pneumatic Kit Assembly and Test Procedure and the kit drawing supplied, and list the components, their part numbers and the pressure rating and hose date checks you must make.
Check the Materials and Components Stock register for the tipping kit and hose stock, record the issue against WO-26-0412 and explain what you would do if a hose carried an out of date manufacture marking.
Describe the hose routing, bend radius, securing intervals and torque marking requirements from the procedure and how you will verify them on the installed kit.
Complete a Job Safety Analysis Form for the pressure test with the body raised, listing the steps, hazards, controls, exclusion zone and the body prop, and identify who signs on.
Using the test readings supplied by your assessor, complete the no load and pressure test record, identify any reading outside the specification and state what you must do.
Record the test results and the torque paint confirmation in the build notes of WO-26-0412 and move the stage only if the procedure allows it.
Raise a non-conformance in the register for any test failure or missing torque mark, with the disposition you recommend to the supervisor.

My notes: what did I enjoy, and what surprised me?

What someone in this role would produce

Component and hose check list
Stock issue record
Completed Job Safety Analysis Form
Hydraulic test record with pass or fail decisions
Updated work order and any non-conformance raised

Printing this is a record of what you explored. It is not a certificate or a qualification.