Process, Progress and Results

Transcription

1 Course Development: Maintenance of Composite Aircraft Structures Process, Progress and Results Charles Seaton Principal Investigator, Edmonds Community College

2 General Comments Course Caveats This course Provides an overview of the issues involved in composites maintenance and repair, beginning with a common level of knowledge of composite materials terminologies and concepts Is not intended to provide training that qualifies students as composite repair practitioners

3 Primary Deliverables Terminal Course Objectives (TCO) + Course Abstract Modules Safety Messages TCOs, Content, Assessments Progress Focus on process FAA guidelines (precursor to policy) on training needs: Critical Composite Maintenance & Repair Issues

4 Cooperative Agreement Begins Contract Award August 2004 Curriculum Development: Composite Materials Maintenance and Repair Edmonds Community College Define Develop Framework Terminal for Course Course Curriculum Objectives Workshop Outcome: Terminal Course Objectives (TCOs) November 2004 (Seattle) 50+ World Experts (TCOs) Global Teleconference April 2005 Expanded Scope as a result of industry input Populate TCOs with written content Develop Content April Sept 2005 Course Enhancements Testimonials Videos Lab Instructions Chicago Chicago Workshop September World Experts Consider: Consistency between Content and TCOs Public Domain: 12/31/05 Availability Framework, Content and Enhancements Proper Emphasis Modified Curriculum

5 Curriculum Development Critical Elements Framework defined by Terminal Course Objectives (TCOs) Content to populate TCOs Assessment Deliverables: Publish TCOs, Content and curriculum enhancements by EOY 2005 Phase I Deliverables (2006): Develop course and assessments Phase II

6 Curriculum Development Collaboration of Industry & Academia & Government Workshops during curriculum development Results FAA/Industry/Academia Workshop in Seattle, WA (November/December 2004) Establish course framework by identifying terminal course objectives (TCOs) Tele-conference (April 2005) - ~10 participants FAA Workshop (Chicago - Sept 2005) Evaluate content relative to course framework as defined by TCOs 2004 workshop 450 skills identified; 60+ TCOs; 11 major areas ( modules ) Workshop report posted on AMTAS web-site for review: Jan 05 Workshop attendees invited to evaluate progress and provide suggestions via teleconference: April 28, 2005 Increase in scope, resulting in prerequisite course plus additional content detail and tools Major Achievement: Consensus on course expectations 2005 workshop Considerable feedback on content and TCOs currently being integrated into curriculum

7 Original Statement of Work Workshop Feedback Organize Course Modules Jan to Apr 05

8 Revised Statement of Work Lab - Regional Repair Course Development Apr to Dec 05 Lecture/PowerPoint Streaming Video Testimonials Safety Messages Black Board or equivalent. Content Web Based 2006

9 Curriculum Development 2005 Chicago Workshop Modules: Grouped into Key Subject areas and provided to small teams for preliminary assessment before workshop Published on website for participant viewing Focus: Define issues based on content Objective: 2005/2006: Publish course content and other teaching tools in public domain Terminal Course Objectives (TCOs), categorized by modules Written content, corresponding to TCOs Testimonials and Videos Laboratory instructions

10 Modules TCO A Module - Understand Basics of Composite Materials Technology TCO B Module - Understand the Basics of Composite Materials Maintenance and Repair TCO J Module - Understand other Critical Elements of Composite Maintenance and Repair TCO C Module Understand Roles and Responsibilities TCO D Module Recognize Composite Damage Types and Sources TCO E Module Identify and Describe Information Contained in Documentation TCO F Module Describe Composite Laminate Fabrication and Bonded Repair Methods TCO G Module Perform a Bonded Composite Repair TCO H Module Describe Composite Damage and Repair Inspection Procedures TCO I Module Describe Composite Laminate Bolted Assembly and Repair Methods, and Perform and Inspect a Bolted Composite Repair TCO K Module Case Team Studies

11 Elements of Curriculum Relationship to Course Design Elements (published) TCOs & Content Flight Safety Messages Testimonials Videos Technique STORY BOARD Custom Curriculum Learning techniques Modified mix of elements Teaching format Target audience characteristics

12 Tuesday Intro to Composite Maintenance & Repair Timeline Morning 8:00 to 9:50 Morning 9:10 to 10:10 Morning 10:10 to 12:00 Afternoon 12:00 to 1:00 Primary Mode[s]: Lecture Supplemental Mode[s]: P. Pt Presentation Testimonial from Practitioner Intermission Primary Mode[s]: Lecture Supplemental Mode[s]: P. Pt Presentation Video Testimonial from Practitioner Lunch Topics: TCO [E] Identify & describe information contained in documentations E1: Describe requirements in material & process specifications and structural repair manuals E2: Demonstrate use of source documents E3: Identify & demonstrate use of regulatory documents E4: Understand the requirements and engineering approvals necessary for valid sources of technical information & maintenance instructions Fight Safety Message #3 Total Time: 1hr 50min Total Time: 20 min Topics: TCO [F] Describe composite laminate fabrication & bonded repair methods F1: Understand the basics of composite laminate fabrication F2: Understand the basics of composite bonded repair F3: Describe the detailed processing steps necessary for laminate fabrication [factory], bonded repair [field], and Material Review Board (OEM) F4: Describe key characteristics and processing parameters for laminate fabrication F5: Identify typical processing defects which occur in composite laminate fabrication & bonded repair. Fight Safety Message #4 Total Time: 1hr 50min Total Time: 1 hr

13 Safety Messages 1: Interlinked aspects of composite repair 2: Repair disposition 3: Repair documentation 4: Correct processing 5: In-service inspections 6: Procedures and post-repair of bonded repairs 7: Post-repair inspections 8: Bolted repairs 9: Importance of teamwork

14 Chicago Workshop Pre- Workshop Issues Feedback and Discussion Review/Discussion Session Session 3 Panel of Experts Panel Leader Panel Discussion Interactive Session Session 4 Participants Reaction Moderator & Scribe Recap Session Session 5 Moderator Reviews Feedback from Sessions 3 & 4 FAA/Edmonds Community College Workshop,Chicago

15 How Session 4 Worked How Session 4 Worked Break-out Group (15-25 participants) Break-out Group (15-25 participants) Feedback Collec tion She et P le as e I nd ic at e A p pl ic ab l e Mo du le s K Cas e Te am Stud ie s [ La b] P er f or m a Bo lt ed C omp osi t es R epa ir Method s B B as ics o f C ompo si te s Ma in te na nce a nd R epa ir A Basics of Composite Materials Technology P le as e I nd ic at e A p pl ic ab l e Mo du le s K Cas e Te am Stud ie s [ La b] P er f or m a Bo lt ed C omp osi t es R epa ir Method s B B as ics o f C ompo si te s Ma in te na nce a nd R epa ir A Basics of Composite Materials Technology Recommendation, Issue or Concern: Sug g est ed Reso ur ce s t o En ha nce Co nt ent : Pleaseuse theback side of this sheet for additionalcomments Feedback Collec tion She et P le as e I nd ic at e A p pl ic ab l e Mo du le s K Cas e Te am Stud ie s Maintenance and Repair [ La b] P er f or m a Bo lt ed C omp osi t es R epa ir Met hod s B B as icso f C ompo si te sma in te na nce a nd R epa ir P le as e I nd ic at e A p pl ic ab l e Mo du le s K Cas e Te am Stud ie s Maintenance and Repair [ La b] P er f or m a Bo lt ed C omp osi t es R epa ir Met hod s B B as icso f C ompo si te sma in te na nce a nd R epa ir Rec ommen da tio n, Issu e o r Con ce rn : Sug g est ed Reso ur ce s t o En ha nce Co nt ent : Pleas euse theback side of this sheet for additionalcomments Feedback Collection Sheet Pleas e IndicateApplicable Modules K Cas e Te am Stud ie s [ La b]p er f or m a Bo lt edc omp osi t es R epa ir Method s B B as icso f C ompo si te sma in te na nce a nd R epa ir A Basics of Composite Materials Technology Pleas e IndicateApplicable Modules K Cas e Te am Stud ie s [ La b]p er f or m a Bo lt edc omp osi t es R epa ir Method s B B as icso f C ompo si te sma in te na nce a nd R epa ir A Basics of Composite Materials Technology Rec ommen da tio n, Issu e o r Con ce rn : Sug g est ed Reso ur ce s t o En ha nce Co nt ent : Pleas euse theback side of this sheet for additionalcomments Feedback Collec tion She et Please IndicateApplicable Modules K C as e Te am St ud ie s [ La b]p er f or m a Bo lt edc omp osi t es R epa ir G [L ab ] Pe r fo rm ab on dedc omp osi t e Repair Met hod s B B as ics o f C ompo si te s Ma in te na nce a nd R epa ir Please IndicateApplicable Modules K C as e Te am St ud ie s [ La b]p er f or m a Bo lt edc omp osi t es R epa ir G [L ab ] Pe r fo rm ab on dedc omp osi t e Repair Met hod s B B as ics o f C ompo si te s Ma in te na nce a nd R epa ir Recommendation, Issue or Concern: Sug g est ed Reso ur ce s t o En ha nce Co nt ent : Pleas euse theback side of this sheet for additionalcomments Feedbac k Collection Sheet P l ea se I n di ca te Ap p li ca bl e Mo du le s K Case Team Stu dies J Othe rc r it ic al E le ment s of Co mposi t e Mai nt en anc e and R ep ai r I [L ab] Pe rf or m a B olt e d Co mposi t es R epa ir H C ompo sit e D et ec ti on a nd I nspe ct io n Pr oc edu res G [ La b] P er f or m a Bo nde d Co mpos it e R epa ir F Lam i na te F ab ri cat i on an d Bo nde d R epa ir Metho ds E I nf or mat io n Co nt ai ned i n D ocu ment at i on D C ompo sit ed ama ge Ty pesa nd S our ce s C R ol es an d Re spo nsi bi li ti es B B asi cs of C omp osi t es Mai nt ena nce a nd R ep air A B asi cs of C omp osi t e Mat eria ls Te chn ol ogy P l ea se I n di ca te Ap p li ca bl e Mo du le s K Case Team Stu dies J Othe rc r it ic al E le ment s of Co mposi t e Mai nt en anc e and R ep ai r I [L ab] Pe rf or m a B olt e d Co mposi t es R epa ir H C ompo sit e D et ec ti on a nd I nspe ct io n Pr oc edu res G [ La b] P er f or m a Bo nde d Co mpos it e R epa ir F Lam i na te F ab ri cat i on an d Bo nde d R epa ir Metho ds E I nf or mat io n Co nt ai ned i n D ocu ment at i on D C ompo sit ed ama ge Ty pesa nd S our ce s C R ol es an d Re spo nsi bi li ti es B B asi cs of C omp osi t es Mai nt ena nce a nd R ep air A B asi cs of C omp osi t e Mat eria ls Te chn ol ogy Rec ommend at ion, Is su e o r Co nc ern: Sug ge ste d Re so ur ces to Enh an ce Co nt en t: Please use the back sideof this sheet for additional comments Feedback Collec tion She et P le as e I nd ic at e A p pl ic ab l e Mo du le s K C as e Te am St ud ie s [ La b]p er f or m a Bo lt edc omp osi t es R epa ir Method s B Basics ofcomposites Maintenance and Repair P le as e I nd ic at e A p pl ic ab l e Mo du le s K C as e Te am St ud ie s [ La b]p er f or m a Bo lt edc omp osi t es R epa ir Method s B Basics ofcomposites Maintenance and Repair Rec ommen da tio n, Issu e o r Con ce rn : Sug g est ed Reso ur ce s t o En ha nce Co nt ent : Pleas euse theback side of this sheet for additionalcomments Feedbac k Collection Sheet Please Indicate Applicable Modules K C aset eam S tu di es J Othe rc r it ic al E le ment s of Co mposi t e Mai nt en anc e and R ep ai r I [L ab] Pe rf or m a B olt e d Co mposi t es R epa ir H CompositeDetection and InspectionProcedures G [ La b] P er f or m a Bo nde d Co mpos it e R epa ir F Lam i na te F ab ri cat i on an d Bo nde d R epa ir Metho ds E I nf or mat io n Co nt ai ned i n D ocu ment at i on D C ompo sit ed ama ge Ty pesa nd S our ce s C R ol es an d Re spo nsi bi li ti es B B asi cs of C omp osi t es Mai nt ena nce a nd R ep air A B asi cs of C omp osi t e Mat eria ls Te chn ol ogy Please Indicate Applicable Modules K C aset eam S tu di es J Othe rc r it ic al E le ment s of Co mposi t e Mai nt en anc e and R ep ai r I [L ab] Pe rf or m a B olt e d Co mposi t es R epa ir H CompositeDetection and InspectionProcedures G [ La b] P er f or m a Bo nde d Co mpos it e R epa ir F Lam i na te F ab ri cat i on an d Bo nde d R epa ir Metho ds E I nf or mat io n Co nt ai ned i n D ocu ment at i on D C ompo sit ed ama ge Ty pesa nd S our ce s C R ol es an d Re spo nsi bi li ti es B B asi cs of C omp osi t es Mai nt ena nce a nd R ep air A B asi cs of C omp osi t e Mat eria ls Te chn ol ogy Rec ommend at ion, Is su e o r Co nc ern: Sug ge ste d Re so ur ces to Enh an ce Co nt en t: Please use the back sideof this sheet for additional comments Feedback Collec tion She et P le as e I nd ic at e A p pl ic ab l e Mo du le s K C as e Te am St ud ie s J Other Cr i ti cal El eme nt s of C omp osi t e [ La b]p er f or m a Bo lt edc omp osi t es R epa ir G [L ab ] Pe r fo rm ab on dedc omp osi t e Repair Method s E I nf or ma ti on C on ta in ed i n Do cume nt at io n B B as ics o f C ompo si te s Ma in te na nce a nd R epa ir P le as e I nd ic at e A p pl ic ab l e Mo du le s K C as e Te am St ud ie s J Other Cr i ti cal El eme nt s of C omp osi t e [ La b]p er f or m a Bo lt edc omp osi t es R epa ir G [L ab ] Pe r fo rm ab on dedc omp osi t e Repair Method s E I nf or ma ti on C on ta in ed i n Do cume nt at io n B B as ics o f C ompo si te s Ma in te na nce a nd R epa ir Rec ommen da tio n, Issu e o r Con ce rn : Sug g est ed Reso ur ce s t o En ha nce Co nt ent : Pleas euse theback side of this sheet for additionalcomments Feedback Collection Sheet Please Indic ateapplicable Modules K Cas e Te am Stud ie s [ La b] P er f or m a Bo lt ed C omp osi t es R epa ir Met hod s B B as ics o f C ompo si te s Ma in te na nce a nd R epa ir Please Indic ateapplicable Modules K Cas e Te am Stud ie s [ La b] P er f or m a Bo lt ed C omp osi t es R epa ir Met hod s B B as ics o f C ompo si te s Ma in te na nce a nd R epa ir Recommendation, Issue or Concern: Sug g est ed Reso ur ce s t o En ha nce Co nt ent : Pleaseuse theback side of this sheet for additionalcomments Feedbac k Collection Sheet P l ea se I n di ca te Applicable Modules K Case Team Stu dies J Othe rc r it ic al E le ment s of Co mposi t e Mai nt en anc e and R ep ai r I [L ab] Pe rf or m a B olt e d Co mposi t es R epa ir H C ompo sit e D et ec ti on a nd I nspe ct io n Pr oc edu res G [Lab] Perform a Bonded Co mpos it e R epa ir F Laminate Fabri cat i on an d Bo nde d R epa ir Metho ds E I nf or mat io n Co nt ai ned i n D ocu ment at i on D C ompo sit ed ama ge Ty pesa nd S our ce s C R ol es an d Re spo nsi bi li ti es B B asi cs of C omp osi t es Mai nt ena nce a nd R ep air A B asi cs of C omp osi t e Mat eria ls Te chn ol ogy P l ea se I n di ca te Applicable Modules K Case Team Stu dies J Othe rc r it ic al E le ment s of Co mposi t e Mai nt en anc e and R ep ai r I [L ab] Pe rf or m a B olt e d Co mposi t es R epa ir H C ompo sit e D et ec ti on a nd I nspe ct io n Pr oc edu res G [Lab] Perform a Bonded Co mpos it e R epa ir F Laminate Fabri cat i on an d Bo nde d R epa ir Metho ds E I nf or mat io n Co nt ai ned i n D ocu ment at i on D C ompo sit ed ama ge Ty pesa nd S our ce s C R ol es an d Re spo nsi bi li ti es B B asi cs of C omp osi t es Mai nt ena nce a nd R ep air A B asi cs of C omp osi t e Mat eria ls Te chn ol ogy Rec ommend at ion, Is su e o r Co nc ern: Sug ge ste d Re so ur ces to Enh an ce Co nt en t: Please use the back sideof this sheet for additional comments Feedback Collec tion She et Pleas e Indic ateapplic able Modules K Cas e Te am Stud ie s [ La b]p er f or m a Bo lt edc omp osi t es R epa ir Met hod s B B as ics o f C ompo si te s Ma in te na nce a nd R epa ir Pleas e Indic ateapplic able Modules K Cas e Te am Stud ie s [ La b]p er f or m a Bo lt edc omp osi t es R epa ir Met hod s B B as ics o f C ompo si te s Ma in te na nce a nd R epa ir Rec ommen da tio n, Issu e o r Con ce rn : Sug g est ed Reso ur ce s t o En ha nce Co nt ent : Pleaseuse theback side of this sheet for additionalcomments Feedbac k Collection Sheet P l ea se I n di ca te Applicable Modules K C aset eam S tu di es J Othe rc r it ic al E le ment s of Co mposi t e Mai nt en anc e and R ep ai r I [L ab] Pe rform a Bolted Co mposi t es R epa ir H C ompo sit e D et ec ti on a nd I nspe ct io n Pr oc edu res G [ La b] P er f or m a Bo nde d Co mpos it e R epa ir F Laminate Fabri cat i on an d Bo nde d R epa ir Metho ds E I nf or mat io n Co nt ai ned i n D ocu ment at i on D C ompo sit ed ama ge Ty pesa nd S our ce s C R ol es an d Re spo nsi bi li ti es B B asi cs of C omp osi t es Mai nt ena nce a nd R ep air A B asi cs of C omp osi t e Mat eria ls Te chn ol ogy P l ea se I n di ca te Applicable Modules K C aset eam S tu di es J Othe rc r it ic al E le ment s of Co mposi t e Mai nt en anc e and R ep ai r I [L ab] Pe rform a Bolted Co mposi t es R epa ir H C ompo sit e D et ec ti on a nd I nspe ct io n Pr oc edu res G [ La b] P er f or m a Bo nde d Co mpos it e R epa ir F Laminate Fabri cat i on an d Bo nde d R epa ir Metho ds E I nf or mat io n Co nt ai ned i n D ocu ment at i on D C ompo sit ed ama ge Ty pesa nd S our ce s C R ol es an d Re spo nsi bi li ti es B B asi cs of C omp osi t es Mai nt ena nce a nd R ep air A B asi cs of C omp osi t e Mat eria ls Te chn ol ogy Rec ommend at ion, Is su e o r Co nc ern: Sug ge ste d Re so ur ces to Enh an ce Co nt en t: Please use the back sideof this sheet for additional comments Feedbac k Collection Sheet P l ea se I n di ca te Applicable Modules K C aset eam S tu di es J Othe rc r it ic al E le ment s of Co mposi t e Mai nt en anc e and R ep ai r I [L ab] Pe rf or m a B olt e d Co mposi t es R epa ir H C ompo sit e D et ec ti on a nd I nspe ct io n Pr oc edu res G [ La b] P er f or m a Bo nde d Co mpos it e R epa ir F Lam i na te F ab ri cat i on an d Bo nde d R epa ir Metho ds E I nf or mat io n Co nt ai ned i n D ocu ment at i on D C ompo sit ed ama ge Ty pesa nd S our ce s C R ol es an d Re spo nsi bi li ti es B B asi cs of C omp osi t es Mai nt ena nce a nd R ep air A B asi cs of C omp osi t e Mat er ia ls Te chn ol ogy P l ea se I n di ca te Applicable Modules K C aset eam S tu di es J Othe rc r it ic al E le ment s of Co mposi t e Mai nt en anc e and R ep ai r I [L ab] Pe rf or m a B olt e d Co mposi t es R epa ir H C ompo sit e D et ec ti on a nd I nspe ct io n Pr oc edu res G [ La b] P er f or m a Bo nde d Co mpos it e R epa ir F Lam i na te F ab ri cat i on an d Bo nde d R epa ir Metho ds E I nf or mat io n Co nt ai ned i n D ocu ment at i on D C ompo sit ed ama ge Ty pesa nd S our ce s C R ol es an d Re spo nsi bi li ti es B B asi cs of C omp osi t es Mai nt ena nce a nd R ep air A B asi cs of C omp osi t e Mat er ia ls Te chn ol ogy Rec om m end at ion, Is su e o r Co nc er n: Sug ge ste d Re so ur ces to Enh an ce Co nt en t: Please use the back sideof this sheet for additional comments Participants Post Ideas throughout Conference Participants Post Ideas throughout Conference Scribe Scribe Captures Verbal Ideas on Screen Captures Verbal Ideas on Screen 45 minutes per session 45 minutes per session Convey Verbal Ideas and Post Written Feedback Convey Verbal Ideas and Post Written Feedback Moderator Moderator Facilitates Conversation and Feedback Facilitates Conversation and Feedback Feedback Collection Sheet Please Indicate Applicable Modules K Case Team Studies J Other Critical Elements of Composite Maintenance and Repair [Lab] Perform a Bolted Composites Repair H Composite Detection and Inspection Procedures G [Lab] Perform a Bonded Composite Repair F Laminate Fabrication and Bonded Repair Methods D Composite Damage Types and Sources C Roles and Responsibilities B Basics of Composites Maintenance and Repair A Basics of Composite Materials Technology Please Indicate Applicable Modules K Case Team Studies J Other Critical Elements of Composite Maintenance and Repair [Lab] Perform a Bolted Composites Repair H Composite Detection and Inspection Procedures G [Lab] Perform a Bonded Composite Repair F Laminate Fabrication and Bonded Repair Methods D Composite Damage Types and Sources C Roles and Responsibilities B Basics of Composites Maintenance and Repair A Basics of Composite Materials Technology Recommendation, Issue or Concern: Suggested Resources to Enhance Content: Name Company Please use the back side of this sheet for additional comments Feedback Slips Feedback Slips Verbal Ideas Verbal Ideas Module Content Module Content

16 Issues Feedback: Workshop Session 5 (Thursday Morning): Scribe Reviewed Section 3 & 4 Inputs Issues Themes TCO/Content Consistency Content Balance Primary Emphasis on Issues of Safety Concern Path to Complete Review and Update the Course Standard FAA/Edmonds Community College Workshop,Chicago

17 Workshop Results Building curriculum framework: TCOs Refined descriptions to better reflect intent Prerequisite course contrasted with repair course clarified in small group discussions Providing content to support TCOs Tightened up content

18 Next Steps Integrate feedback into TCOs and Content Publish outcomes on websites Presentations TCO and Content Revisions Compliance Approval

19 Next Steps: Posting & Links of Workshop Results Detail of Workshop: Overview: depts.washington.edu/amtas/ Links:

20 Click on this Link

21 Next Steps: Compliance Approval Purpose Validation of Trainer process to the TCOs, content and assessment of course One Scenario Trainer documents curriculum ndependent organization assesses compliance (similar to ISO 9000, for example)

22 Organization Roles (One Scenario) Independent Organization assesses Compliance/Certification TCOs Documented by CACRC Modules/Safety Messages FAA Technical Center Report Training Organization develops procedures Assessments Documented by CACRC

23 Next Steps: Curriculum Development Deliverables: Publish TCOs, Content and curriculum enhancements by EOY 2005 Phase I Deliverables (2006): Develop course and assessments Phase II