Mechanical Fitting and Assembly Apprenticeship Unit

Enrol Now

Mechanical Fitting and Assembly Apprenticeship Unit

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Home| Engineering| EP34

Mechanical Fitting and Assembly Apprenticeship Unit

Enrol Now

Mechanical Fitting and Assembly Apprenticeship Unit

FIND A COURSE

Home| Engineering| EP34

Course Introduction

The mechanical fitting and assembly apprenticeship unit (AU0003) is a funded, high-impact upskilling programme designed to rapidly build core workshop competence. Tailored specifically for learners working with Preformed Line Products (PLP) high-performance infrastructure hardware, this course bridges the gap between engineering theory and the precise hands-on skills required to assemble tension ties, suspension units, conductor fittings, and splices safely and accurately.

This unit is a focused, flexible training solution for existing engineering operatives and technicians aged 19+, providing fast upskilling without the time commitment of a full multi-year apprenticeship.

Course Content

Week 1

Objective: Establish core safety habits, emergency protocols, and baseline mechanical principles on the customer site.

Topics Covered:

HSE Principles: HASaWA, CoSHH (cutting fluids/solvents), Manual Handling, PPE requirements, safety signage, and emergency stops.
Machine Isolation: Lockout/Tagout (LOTO) on primary workshop machines.
Back to Basics: Basic hand tools (spanners, wrenches, files, soft hammers), screw thread care, and machine hygiene.
Practical Machine Activity: Perform LOTO on machinery; conduct a pre-use machine visual inspection

Week 2

Objective: Interpret technical drawings into accurate layout work on material stock.

Topics Covered:

Drawing Interpretation: Orthographic projections, title blocks, revisions, surface finishes, and notes.
Material Identification: Selecting correct stock (steel, aluminium, alloys) and recognising material properties.
Marking Out: Scribers, engineers' squares, height gauges, surface plates, center punches, and marking out fluid.
Practical Machine Activity: Interpret an onsite technical drawing and mark out material ready for cutting and drilling.

Week 3

Objective: Practice manual measurement techniques to verify part dimensions before, during, and after operations.
Topics Covered:

Vernier Calipers: Imperial and metric scales, measuring internal/external/depth.
Micrometers: External micrometers, ratchet stop usage, barrel reading, parallax error avoidance.
Dial Test Indicators (DTIs): measuring runout, flatness, and parallelism.
Practical Machine Activity: Measure a series of master gauge blocks and live components using calipers, micrometers, and DTIs.

Week 4

Objective: Understand how dimensional tolerances dictate component interchangeability and assembly fit.

Topics Covered:

Tolerances: Absolute values, upper/lower limits, geometric dimensioning and tolerancing (GD&T) basics.
Fits: Clearance fits (sliding/running), transition fits, and interference fits (press fit).
Inspection: Calculating allowable variance and logging dimensional quality checks.
Practical Machine Activity: Inspect machined shafts and bores to classify the resulting engineering fit.

Week 5

Objective: Identify unknown thread types confidently and apply correct assembly techniques to ensure joint integrity.

Topics Covered:

Thread Forms: Pitch, thread angle, major/minor diameters across Metric (Coarse/Fine), UNC, UNF, Whitworth (BSW), and BSP.
Identification Tools: Pitch gauges, thread identification charts, and micrometer thread checking.
Fasteners, torque settings, thread-locking compounds, and preventing cross-threading.
Practical Machine Activity: Use pitch gauges and calipers to identify 10 mixed fasteners from the customer’s inventory.

Week 6

Objective: Safely operate the customer's bandsaw, execute blade changes, and optimise cutting parameters.

Topics Covered:

Bandsaw Safety: Guards, emergency stops, coolant systems, and swarf management.
Blade Selection: Tooth pitch (TPI) selection based on material section and thickness.
Blade Changing Procedure: Isolation (LOTO), dangers of stored energy, tension release, guide alignment, tracking adjustment, tensioning, and test runs.
Practical Machine Activity: Perform a full hands-on blade change on the customer bandsaw, followed by cut quality verification.

Week 7

Objective: Perform safe linishing/belt-sanding operations for deburring, sizing, and surface finishing.

Topics Covered:

Linishing Safety: Abrasive wheel/belt safety, dust extraction, sparking hazards, and eye protection.
Machine Setup: tracking alignment, work rest adjustment, and tensioning.
Finishing Techniques: Deburring edges, holding flat profiles, avoiding over-grinding, and verifying finished dimensions.
Practical Machine Activity: Replace and align a linishing belt on site, then deburr and finish components to drawing spec.

Week 8

Objective: Master fixture setup, rigid workholding without part distortion, and preventative maintenance/cleaning.

Topics Covered:

Clamping Principles: Points of support, clamping forces, avoiding component deflection, and datum alignment.
Jig & Fixture Setup: Setting up customer-specific jigs, dialling in alignment with DTIs, and secure mounting.
Cleaning & Maintenance: Swarf/chip cleaning procedures, mating surface maintenance, and corrosion protection.
Fault Identification: Identifying fixture wear, out-of-square clamping, or component misalignment.
Practical Machine Activity: Dismantle, thoroughly clean, reassemble, and align a customer jig using a DTI; clamp and verify a test workpiece.

Week 9 - Week 10 Assessment weeks

Entry Requirement

Entry requirements agreed between BCoT and the employer PLP

Assessment

The assessment consists of a mandatory provider skills test where learners complete a practical mechanical assembly task alongside a brief theory test. To successfully pass the unit, the employer must formally validate the results, confirming the employee has demonstrated the required workplace competence.

How to Enrol

Upon agreement with BCoT and PLP please enrol online. Any queries, please contact Shane Munford at shane.munford@bcot.ac.uk