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I have just a quick question on AS91620 Implement complex procedures to integrate parts using resistant materials to make a specified product. (Level 3)

When using wood/plastics what sorts of procedures are classed as "complex"?What is meant by "integrate parts"?

Your help will be much appreciated. Many thanks.

AnswerComplex procedures require the student to select and use a variety of techniques for the precise integration of parts. The product the student makes needs to provide opportunity for this to occur. The resource called A Power Tower is a good starting point and provides an example in wood.

As per Explanatory Note 2 of the standard, implementing complex procedures to integrate parts for products such as a ladder or sprinkler could include:

preparation of parts for integration (preparing all parts of the ladder or sprinkler to tolerance before it is put together)

preparation of the integration environment (making a jig to ensure the ladder is perfectly square and straight; preparing a clean assembly environment with the equipment needed to accurately assemble the product)

integrating parts to ensure product meets specifications (putting it together) ongoing testing against reference points to reduce error in the integration of parts

(using the jig and checking for tolerances at each stage of assembly).

Radio controlled boats could also provide a platform for this standard in plastics. The expectation would be coverage of a range of techniques in the discipline of plastics forming, for example:

vacuum forming, including material properties affecting form and making plugs to suit assembly tolerances

heat strip bending, including allowances for distortion, wall thickness, temp settings

protocols relating to adhesives, including initial tack and setting times (adhesive selection and application should take into account the performance required of the adhesive in the outcome, for example, load, exposure to high temperature, water)

mechanical fixings, including material properties relating to drilling/cutting that affect alignment and relationship of parts.

Radio Control would include many things to be integrated and require students to find such things as reference lines, centrelines, and datums or start positions for assembly alignment. Each part would need to be taken into account when assembling.

It is likely that any plastics outcome would include materials other than just plastics. 

A sailing yacht without radio control may also offer the complexity required for this standard. 

Additional products and possible associated examples are suggested below.

Standard Criteria Power tower Boat Aquarium table Lectern Complex procedures

require the student to select and use a variety of techniques for the precise integration of parts.

The integration of an inner revolving shelf unit, an electrical multi-plug, and an outer free-standing cabinet

Shaped and manufactured cleats to internal carcass to provide shaped exterior

Machine materials for the legs and rails and drawer construction

Accurately mark out and machine joints

Prepare plan for tank(glass cutting outsourced)

Rebating front panels into uprights

Marking out joints for the column

The preparation of an integration environment

Jigs and shaping blocks to accurately shape and fashion components

Prepare a cradle to hold the boat carcass together so that the other components could be attached to this.

Preparing the carcass (as this will be used as a jig for the glass tank, the shelf cut out determines the size of the rebate to support the corner of the tank)

Preparing the lower plinth (as this will be used as the framework for the drawer construction)

Templates made for base so that accuracy and symmetry achieved

Jig for drilling holes for the tops of the columns, which have to align with the holes in the lectern top

On-going testing against reference points to reduce error in the integration of parts

Testing parts against central axis points when pattern shaping

Testing during assembly to ensure the inner cabinet revolves smoothly

Testing for symmetry of construction along central axis points through the length of the boat to ensure balance

Testing to ensure the jointing method is accurate and allows the tank and the drawer to fit accurately

Measuring the cavity for the drawer and the tank to check they will fit

Testing to ensure the holes line up with the top of the lectern

The width of the internal columns have to be accurate to coincide with the holes in the base and the top (use a fixed jig for the top and reference back to this)

Preparation of parts for integration

Preparing the slats, the outer cabinet boards, and the shelves and testing against specifications for size

Machining interior and exterior components to fit carcass and testing against specifications for size

Preparation of framework, drawer, drawer runners, and glass panels and glass surface and testing against specifications for size

Preparation of the lectern base, lectern top , upright columns, and their fixing components to other components testing against specifications for size and stability