course development: maintenance of composite aircraft structures€¦ · f1: understand the basics...

Course Development: Maintenance of Composite Aircraft Structures

Process, Progress and Results

Charles Seaton – Principal Investigator, Edmonds Community College

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 conceptsIs not intended to provide training that qualifies students as composite repair practitioners

Primary DeliverablesTerminal Course Objectives (TCO)+ Course Abstract

ModulesSafety Messages

TCOs, Content, AssessmentsProgress – Focus on process

FAA guidelines (precursor to policy) on training needs:Critical Composite Maintenance & Repair Issues

Curriculum Development: Composite Materials Maintenance and Repair

Edmonds Community CollegeDefine Framework for Course

CurriculumOutcome: Terminal Course Objectives (TCOs)

Chicago Workshop

September 2005

Contract Award

Public Domain: 12/31/05 Availability

August 2004

Workshop November 2004

(Seattle)

50+ World Experts

Global Teleconference

April 2005

Course Enhancements•Testimonials

•Videos

•Lab Instructions

60+ World Experts Consider:

•Consistency between Content and TCOs

•Proper Emphasis

•Modified Curriculum

‘Populate’ TCOs with written

content

Develop Content

April – Sept 2005

Framework, Content and Enhancements

Expanded Scope as a result of industry input

Chicago

Develop Terminal Course Objectives

(TCOs)

Cooperative Agreement Begins

Curriculum DevelopmentCritical Elements

Framework defined by Terminal Course Objectives (TCOs)Content to populate TCOsAssessment

Deliverables: Publish TCOs, Content and curriculum enhancements by EOY 2005 –Phase IDeliverables (2006): Develop course and assessments – Phase II

Curriculum DevelopmentCollaboration of Industry & Academia & Government

Workshops during curriculum developmentFAA/Industry/Academia Workshop in Seattle, WA (November/December2004) Establish course framework by identifying terminal course objectives (TCOs)Tele-conference (April 2005) - ~10 participantsFAA Workshop (Chicago - Sept 2005) Evaluate content relative to course framework as defined by TCOs

Results2004 workshop – 450 skills identified; 60+ TCOs; 11 major areas (‘modules’)Workshop report posted on AMTAS web-site for review: Jan 05Workshop attendees invited to evaluate progress and provide suggestions via teleconference: April 28, 2005Increase in scope, resulting in prerequisite course plus additional content detail and toolsMajor Achievement: Consensus on course expectations2005 workshop – Considerable feedback on content and TCOs currently being integrated into curriculum

Original Statement of Work

Organize Course Modules

WorkshopFeedback

Jan to Apr ‘05

Revised Statement of Work

Lab - Regional

Content – Web Based

2006

Repair Course Development

Apr to Dec ‘05Lecture/PowerPointStreaming VideoTestimonialsSafety Messages‘Black Board’ or equivalent.

Curriculum Development2005 Chicago Workshop

Modules: Grouped into Key Subject areas and provided to small teams for preliminary assessment before workshop

Published on website for participant viewingFocus: Define issues based on content

Objective: 2005/2006: Publish course content and other teaching tools in ‘public domain’

Terminal Course Objectives (TCOs), categorized by modulesWritten content, corresponding to TCOsTestimonials and VideosLaboratory instructions

Modules

TCO A Module - Understand Basics of Composite Materials TechnologyTCO B Module - Understand the Basics of Composite Materials Maintenance and

RepairTCO J Module - Understand other Critical Elements of Composite Maintenance and

RepairTCO C Module – Understand Roles and ResponsibilitiesTCO D Module – Recognize Composite Damage Types and SourcesTCO E Module – Identify and Describe Information Contained in DocumentationTCO F Module – Describe Composite Laminate Fabrication and Bonded Repair

MethodsTCO G Module – Perform a Bonded Composite RepairTCO 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

Elements of CurriculumRelationship to Course Design

Target audience characteristics

Videos

Teaching formatTestimonials

Modified mix of elements

STORY BOARD

Flight Safety Messages

Learning techniques

TCOs & Content

Custom Curriculum

TechniqueElements (published)

TuesdayMorning

8:00 to 9:50

Primary Mode[s]:Lecture

Supplemental Mode[s]:

P. Pt Presentation

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 documentsE3: Identify & demonstrate use of regulatory documentsE4: Understand the requirements and engineering

approvals necessary for valid sources of technical information & maintenance instructions

Total Time: 1hr 50minMorning

9:10 to 10:10 Intermission Total Time: 20 min

Morning

10:10 to 12:00

Primary Mode[s]:Lecture

Supplemental Mode[s]:

P. Pt Presentation

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 repairF3: 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.

Total Time: 1hr 50min

Intro to Composite Maintenance & Repair Timeline

Video

Afternoon12:00 to 1:00 Lunch Total Time: 1 hr

Fight Safety Message #3

Fight Safety Message #4Testimonial from Practitioner

Testimonial from Practitioner

Safety Messages1: Interlinked aspects of composite repair2: Repair disposition3: Repair documentation4: Correct processing5: In-service inspections6: Procedures and post-repair of bonded repairs7: Post-repair inspections8: Bolted repairs9: Importance of teamwork

FAA/Edmonds Community College Workshop,Chicago

Chicago Workshop

Issues Feedback and Discussion

Panel of Experts

Panel Leader

Panel Discussion

Moderator & Scribe Moderator

Reviews Feedback

from Sessions

3 & 4

Participants’Reaction

“Review/Discussion Session” Session 3

“Interactive Session” Session 4 “RecapSession”Session 5

Pre-Workshop

How Session 4 WorkedHow Session 4 Worked

Break-out Group(15-25 participants)

Break-out Group(15-25 participants)

Feedback Collection SheetPle as e Ind ic ate Ap pl ic ab le Mo du le s

K Cas e Te am Stud ie s

J Other Cri ti cal El eme nts of Comp osi t e Main tena nce a nd Rep air

I [ La b] P erf orm a Bo lt ed Comp osi t es Repa irH Co mpos it e Detect io n an d In spe ct ion P roce dure sG [L ab ] Pe rfo rm a B on ded Comp osi t e Re pa ir

F L ami nate Fa bri cat io n and B o nde d Re pai r Method s

E Informa ti on Con ta in ed i n Do cume ntat io nD Co mpos it e Damag e Typ es an d S ource sC Ro le s and Res pon sib il it i esB B as ics o f Compo si te s Ma in te na nce a nd Repa irA B as ics o f Compo si te Ma te ri al s Te chn olo gy

Ple as e Ind ic ate Ap pl ic ab le Mo du le s






Rec ommenda tion, Issue or Conce rn:

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Suggest ed Resource s t o Enha nce Cont ent :

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Feedback Collection SheetPl ea se In di ca te Ap p li ca bl e Mo du le s

K Case T eam S tu di es

J Ot he r Crit ic al E le ment s of Co mposi t e Mai nt en anc e and Rep ai r

I [L ab] Pe rf orm a B olt e d Co mposi t es Repa irH Compo sit e Det ec ti on a nd I nspe ct io n Proc edu re sG [ La b] P erf orm a Bo nde d Co mpos it e Repa ir

F Lami na te F ab ri cat i on an d Bo nde d Repa ir Met ho ds

E I nf ormat io n Co nt ai ned i n Docu ment at i onD Compo sit e Dama ge Ty pes a nd S ource sC Rol es an d Re spo nsi bi li ti esB B asi cs of Comp osi t es Mai nt ena nce a nd Rep airA B asi cs of Comp osi t e Mat eria ls Te chn ol ogy

Pl ea se In di ca te Ap p li ca bl e Mo du le s






Rec ommendat ion, Is sue or Conc ern:

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Sugge ste d Re sources to Enhance Cont ent:

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______________________________Com pany

______________________________Phone


Feedback Collec tion SheetPle as e Ind ic ate Ap pl ic ab l e Mo du le s

K Cas e Te am St ud ie s

J Ot her Cri ti cal El eme nt s of Comp osi t e Main t ena nce a nd Rep air

I [ La b] P erf orm a Bo lt ed Comp osi t es Repa irH Co mpos it e Det ect io n an d In spe ct ion P roce dure sG [L ab ] Pe rfo rm a B on ded Comp osi t e Re pa ir

F L ami nat e Fa bri cat io n and B o nde d Re pai r Met hod s

E I nf orma ti on Con ta in ed i n Do cume nt at io nD Co mpos it e Damag e Typ es an d S ource sC Ro le s and Res pon sib il it i esB B as ics o f Compo si te s Ma in te na nce a nd Repa irA B as ics o f Compo si te Ma te ri al s Te chn olo gy

Ple as e Ind ic ate Ap pl ic ab l e Mo du le s

K Cas e Te am St ud ie s

J Ot her Cri ti cal El eme nt s of Comp osi t e Main t ena nce a nd Rep air

I [ La b] P erf orm a Bo lt ed Comp osi t es Repa irH Co mpos it e Det ect io n an d In spe ct ion P roce dure sG [L ab ] Pe rfo rm a B on ded Comp osi t e Re pa ir

F L ami nat e Fa bri cat io n and B o nde d Re pai r Met hod s

E I nf orma ti on Con ta in ed i n Do cume nt at io nD Co mpos it e Damag e Typ es an d S ource sC Ro le s and Res pon sib il it i esB B as ics o f Compo si te s Ma in te na nce a nd Repa irA B as ics o f Compo si te Ma te ri al s Te chn olo gy


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Feedback Collection SheetPl ea se In di ca te Ap p li ca bl e Mo du le s






Pl ea se In di ca te Ap p li ca bl e Mo du le s







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______________________________Company

______________________________Phone


Feedback Collection SheetPlea se In di ca te Ap p li ca ble Mo du le s


J Othe r Crit ic al E le ments of Co mposi t e Mai nten anc e and Rep ai r

I [L ab] Pe rf orm a B olt e d Co mposi t es Repa irH Compo sit e Detec ti on a nd I nspe ct io n Proc edu re sG [La b] P erf orm a Bo nde d Co mpos it e Repa ir

F Lami na te F ab ri cat i on an d Bo nde d Repa ir Metho ds

E Informat io n Co ntai ned i n Docu mentat i onD Compo sit e Dama ge Ty pes a nd S ource sC Rol es an d Re spo nsi bi li ti esB B asi cs of Comp osi t es Mai ntena nce a nd Rep airA B asi cs of Comp osi t e Materia ls Te chn ol ogy

Plea se In di ca te Ap p li ca ble Mo du le s







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Feedback Collection SheetPlea se In di ca te Ap p li ca ble Mo du le s













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Please use the back side of this sheet for additional commentsFeedback Collection Sheet














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Participants Post Ideas throughout Conference

Participants Post Ideas throughout Conference

ScribeScribeCaptures Verbal Ideas

on ScreenCaptures Verbal Ideas

on Screen

45 minutes per session45 minutes per session

Convey Verbal Ideas and Post Written Feedback

Convey Verbal Ideas and Post Written Feedback

ModeratorModerator

Facilitates Conversation and Feedback

Facilitates Conversation and Feedback

Feedback Collection SheetPlease Indicate Applicable Modules

K Case Team Studies

J Other Critical Elements of Composite Maintenance and Repair

I [Lab] Perform a Bolted Composites RepairH Composite Detection and Inspection ProceduresG [Lab] Perform a Bonded Composite Repair

F Laminate Fabrication and Bonded Repair Methods

E Information Contained in DocumentationD Composite Damage Types and SourcesC Roles and ResponsibilitiesB Basics of Composites Maintenance and RepairA Basics of Composite Materials Technology

Please Indicate Applicable Modules

K Case Team Studies

J Other Critical Elements of Composite Maintenance and Repair

I [Lab] Perform a Bolted Composites RepairH Composite Detection and Inspection ProceduresG [Lab] Perform a Bonded Composite Repair

F Laminate Fabrication and Bonded Repair Methods

E Information Contained in DocumentationD Composite Damage Types and SourcesC Roles and ResponsibilitiesB Basics of Composites Maintenance and RepairA Basics of Composite Materials Technology

Recommendation, Issue or Concern:

_________________________________________________

_________________________________________________

_________________________________________________

_________________________________________________

Suggested Resources to Enhance Content:

_________________________________________________

______________________________Name

______________________________Company

______________________________Phone


FeedbackSlips

FeedbackSlips

VerbalIdeas

VerbalIdeas

ModuleContentModuleContent

FAA/Edmonds Community College Workshop,Chicago

Issues Feedback: Workshop

Session 5 (Thursday Morning): Scribe Reviewed Section 3 & 4 Inputs

Issues

ThemesTCO/Content ConsistencyContent BalancePrimary Emphasis on Issues of Safety ConcernPath to Complete Review and Update the Course Standard

Workshop Results

Building curriculum framework: TCOsRefined descriptions to better reflect intentPrerequisite course contrasted with repair course – clarified in small group discussions

Providing content to support TCOs‘Tightened up’ content

Next Steps

Integrate feedback into TCOs and ContentPublish outcomes on websites

PresentationsTCO and Content Revisions

Compliance Approval

Next Steps: Posting & Links of Workshop Results

Detail of Workshop: www.mpdc.biz

Overview: depts.washington.edu/amtas/

Links: www.niar.twsu.edu/newniar/

Click on this Link

Next Steps: Compliance Approval

Purpose – Validation of Trainer process to the TCOs, content and assessment of courseOne Scenario

Trainer documents curriculumIndependent organization assesses compliance (similar to ISO 9000, for example)

TCOs – Documented by CACRC

Organization Roles (One Scenario)

Modules/Safety Messages – FAA Technical Center Report

Assessments – Documented by CACRC

Independent Organization assesses

Compliance/Certification

Training Organization

develops procedures

Next Steps: Curriculum Development

Deliverables: Publish TCOs, Content and curriculum enhancements by EOY 2005 – Phase IDeliverables (2006): Develop course and assessments – Phase II

course development: maintenance of composite aircraft structures€¦ · f1: understand the basics...

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