MY LAND TRAINING & SERVICES SDN BHD

DT 3649 PT 3105 (TINGKAT BAWAH & ATAS),

JALAN ANGKASA NURI 21, TAMAN ANGKASA NURI,
76100 DURIAN TUNGGAL,
MELAKA.

KERTAS PENERANGAN
(INFORMATION SHEET)
KOD NAMA DAN
PROGRAM / PROGRAM MT-011-2 COMPOSITE PRODUCTION
CODE AND NAME
TAHAP / LEVEL LEVEL 2

NO DAN TAJUK MODUL/

C01 - COMPOSITE MATERIAL PREPARATION
MODULE NO AND TITLE

01.01 Check composite materials preparation requirements

NO DAN PERNYATAAN 01.02 Prepare composite materials preparation work requirements

TUGASAN / TASK(S) NO 01.03 Carry out composite materials cutting
AND STATEMENT 01.04 Carry out composite materials kitting
01.05 Organise prepared materials and work area

OBJEKTIF PENCAPAIAN OBTAIN RAW MATERIAL FROM STORAGE USING MATERIAL

AKHIRAN / TERMINAL REQUISITION DOCUMENT, ETC. SO THAT RAW MATERIAL
PERFORMANCE REQUISITION AND RECEIVED IN ACCORDANCE WITH
OBJECTIVE MATERIAL DOCUMENT.

NO KOD / CODE NO MT-011-2:2014/C01/P(1/2) Muka : 1 Drp: 7

TAJUK : COMPOSITE MATERIAL PREPARATION

TUJUAN : TO UNDERSTAND AND APPLY MATERIALS FROM STORAGE.

IDENTIFY TYPE OF MATERIALS AND FOLLOW THE STANDARD
PROCEDURES.
NO KOD / CODE NO MT-011-2:2014/C01/P(1/2) Muka: 2 Drp: 7

PENERANGAN / INFORMATION:

Composite Material Preparation is the preliminary process in composite product

fabrication/production. The composite material sometimes called raw/semi-finished materials
obtained from the storage area (warehouse/freezer) and make ready for lay-up or fabricated
process in accordance with Material Safety Data Sheet company requirements, Standard
Operating Procedure (SOP), Company Approved Procedure (CAP), Quality Procedure
Manual (QPM), Technical Notification (TN) and Health, Safety and Environmental (HSE)
Acts.

General Process Flow

RECEIVING WAREHOUSE KITTING LAY UP

MOULD
PREPARATION

N.D.T TRIMMING DEMOULD CURING

MECHANICAL PAINTING FINAL STAGING/PACKING

ASSEMBLY INSPECTION

SHIPPING

Picture 1: General Process Flow for Composite Manufacturing

NO KOD / CODE NO MT-011-2:2014/C01/P(1/2) Muka: 3 Drp: 7

Kitting Related Reference Requirements

1) Quality Procedure Manual

a. Q.P.M 08-01 Identification and Traceability
b. Q.P.M 09-01 Process Control
c. Q.P.M 10-01 Inspection
d. Q.P.M 13-01 Control of Non Conformance Product
e. Q.P.M 16-01 Quality Record Management
f. Q.P.M 17-01 Internal Audit

2) Company Approved Procedure

a. C.A.P 01-001 Accumark and Gerber Cutter Machine
b. C.A.P 01-003 Freezer Operating Manual
c. C.A.P 01-009 Work Instruction
d. C.A.P 03-002 Kitting Material Preparation
e. C.A.P 03-003 Freezer Operation
f. C.A.P 04-001 CCA and EMA

Kitting Room Environmental Requirements

1) This procedure is applied to Control Contamination Area (CCA) where the working
environment is controlled:

Humidity: Maximum 70% RH

Temperature: 18.3 °C – 25.0°C
Dust particles: 1 micron not larger than 72,000 particles
5 micron not larger 2,200 particles
Air Pressure: Slightly Positive.

2) Example Project Requirement:

1) Airbus Specification:
Humidity: 75% RH
Temperature: 16.0°C ~ 26.0°C
Reference: ACT/AB TECH 0005

2) Boeing Specification:
Humidity: 70% RH
Temperature: 16.0°C ~ 25.0°C
Reference: BAC 5317

3) UTAS Specification:
Humidity: 70% RH
Temperature: 18.3°C ~ 32.22°C
Reference: RPS 17.34 (Rev F)
NO KOD / CODE NO MT-011-2:2014/C01/P(1/2) Muka: 4 Drp: 7

For daily monitoring on temperature, humidity using thermo hygrograph and

positive air pressure using ribbon. The Dust particles monitor once a week.

Thermo Environmental Specification and Monitoring

hygrograph Sheet

Picture 2: Monitoring Environmental Equipment and Sheet

Material Process and Control Flow Chart

Raw Material 1) Raise Material Requisition Note (MRN) and record in log book.
from Warehouse 2) Issuance to Warehouse (Minimum 3 days prior to Cutting
schedule).

Thawing 1) Material receives from Warehouse. Receiving operator and QC to

ensure Serviceable Tag, Material Identification Tag (MIT) and
Material Log are attached to all incoming boxes of roll material.
2) Receiving operator/QC to check all incoming roll of material are
supported at both ends and stack to its designated racks.
3) Receiving operator to paste color code sticker on all incoming
boxes of roll material.
4) All operator are to apply and practice First in First out (FIFO)
system or use material with least hours first when consuming
material.
5) Thawing operator is to review daily all thawed material shelf life
and out life time hours are controlled.
6) Raw material to be thawed at least 12 hours or such that no
condensation on the outside of the bag when wipe prior cutting.
7) Area Leader, Team Leader and QC to monitor this procedure are
Cutting
complying daily.
1) All operators are to review daily on all material usage for their
Shelf Life or Out Life time is within specification.
2) Place roll of material to be cut on cutting bed or “A” frame rack.
3) Remove Serviceable Tag, MIT and material Log on box and
attach it together with material to be cut.
4) Transfer all data or information from Serviceable Tag and MIT to
Stacking Work Order.
1) Sort, stack and form ply into kit set
2) Generate Kit Identification and attach to kit.
3) Inspect kit to Ply Check List.
4) Label kit with KSN Number.
1) If the Kit not for immediate use, shall be place in a seal
Packing bag with at least one desiccant.
NO KOD / CODE NO MT-011-2:2014/C01/P(1/2) Muka: 5 Drp: 7

1) Freezer
1. Capability:
 Minimum temperature control: -18°C
 Approximately Size: 36ft x 36ft x 10ft
 Temperature Chart Recorder
 Automatic re-start – zero interruption generator back up
 Alarm system – when temperature drop at below setting temperature
2. Material:
 Glass Pre-preg
 Carbon Pre-preg
 Uni-carbon Pre-preg
 Lightning-Mesh (Al) Pre-preg
 Film Adhesive
 Core Splice

2) Thawing
3. Purpose:
 A process that the material is to warm up to the room temperature
(Temperature 18.3°C - 25.0°C, Humidity Maximum 70%RH).
 In thawing room for 8 hours (minimum) to 12 hours (maximum).
 Shelf life - length of time of material can be stored, under specified
environment condition without failure to meet specification.
 Out Time – the time that the material retains its physical and mechanical
properties when exposed to a temperature higher than allowed by specification
4. Material Pre-preg from Warehouse Freezer:
 Kitting personnel shall carried out receiving inspection and ensure the
materials is
accompanied with Serviceable Tag, Material Log & Identification Tag (MIT).
 To ensure the box is physically in good condition and material inside the box is
supported at both ends.
NO KOD / CODE NO MT-011-2:2014/C01/P(1/2) Muka: 6 Drp: 7

 Box of incoming material are to be arrange neatly on rack after receiving

inspection.
5. Material Pre-preg from Kitting Freezer:
 Kitting personnel to deduct the out-life time on Material Log/Tag.
 To consume/issue roll/kits material is based on FIFO practice.
6. Action To Be Taken for Any Non-Compliant of Environmental Condition
 If any non-compliant occurred due to humidity and temperature exceeded the
specification, Contaminated Controlled Area (CCA) and Freezer personnel
must take immediate action as per below details:
 Raise the Service Request Form to facility department to fix the
problem.
 All the materials that are not being laid up shall be put into the sealed
plastic bag together with desiccant.
 All the materials that are still in the laid up process shall be
immediately vacuumed until the humidity and temperature is fixed.
 If the humidity and temperature problem cannot be fixed back to the
Specification within 12 hours, all the affected materials shall be
transferred to the other CCA or Freezer which is complying with the
specification.
 All materials out life will be deducted accordingly to the total time of out
of specification happen. The balance remaining out time will be
recorded in the material identification Tag (MIT) and Work Order
Routing.
7. Inspection Method:
 Ensure serviceable, MIT and Material Log attached incoming boxes of
material.
 Good condition per physical container, plastic cover & material condition.
 Ensure backers cover all material resin.
 Ensure no defects such as wrong orientation, dryness, wrinkle, spot,
different backers and etc.
 Incoming rolls materials are supported at both ends and stack to its
designated racks.
 Ensure no condensation outside bag area.

8. Personal Protective Equipment (PPE):

NO KOD / CODE NO MT-011-2:2014/C01/P(1/2) Muka: 7 Drp: 7

SOALAN / QUESTION:

1. List 3 procedures of Company Approved Procedure where use in Kitting?

a. _________________________________________________________________
b. _________________________________________________________________
c. _________________________________________________________________

2. Special room for placing composite material (pre-preg) before thawing process?

____________________________________________________________________

3. What is the minimum hour’s composite material (pre-preg) need to be thaw before
cutting process?
____________________________________________________________________

4. What is the equipment use for monitoring the temperature and humidity?
____________________________________________________________________

RUJUKAN / REFERENCES:

CTRM ACTC Syllabus (C01-Composite Material Preparation), date 16 December 2018

Cindy Foreman, Jeppesen 2002, Advanced Composite Book, ISBN-13 9780884873167
http://www.safety.com.my, safety management, date 16 December 2018