Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.
This describes the essential skills and knowledge and their level required for this unit.
Application of an operational knowledge of the materials, equipment and process sufficient to recognise out of specification products, process problems and materials faults. For example, clamp frames are commonly used to hold heated sheet in place around the perimeter of each individual mould cavity creatingTherefore, clamp pressure should be monitored so that uniform parts are created and variation between cavities is reduced.
Knowledge of organisation procedures and relevant regulatory requirements along with the ability to implement them within appropriate time constraints and work standards. For example, when monitoring process conditions, action should be taken when there is more than 10% shrinkage of the sheet during heating.
Application of the knowledge of managing risks using the hierarchy of controls applied to the thermoforming process. Application of approved hazard control and safety procedures and the use of PPE in relation to handling materials, equipment operation and cleanup.
Knowledge of, and skills in the operation of, thermoforming equipment and main components sufficient for consistent production of quality products, including:
production workflow sequences and materials demand
reasons for checking process control panels and reporting readings which are outside of normal range of process variability
accurately monitoring equipment operation and product quality
the potential effects of variations in raw materials and equipment operation in relation to quality of product
processing behaviour of polymers and the role of additives
waste management and importance of reusing non-conforming products wherever possible
explain the effect of unauthorised or emergency shutdown in relation to safety and production requirements
correct selection and use of equipment, materials, processes and procedures
identify factors which may affect product quality or production output and appropriate remedies.
Competence also includes the ability to:
plan own work, including predicting consequences and identifying improvements
identify when the operator is able to rectify faults, when assistance is required and who is the appropriate source for assistance
identify and describe own role and role of others involved directly in the thermoforming process.
Language, literacy and numeracy requirements
This unit requires the ability to read and interpret typical product specifications, job sheets, procedures, material labels and safety information as provided to operators.
Writing is required to the level of completing workplace forms.
Basic numeracy is required, eg to read and interpret temperature and pressure gauges, add weights and interpret graphs.
The Range Statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Add any essential operating conditions that may be present with training and assessment depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts.
Where reference is made to industry codes of practice, and/or Australian/international standards, the latest version must be used.
Context
This competency applies to all thermoforming operations within the plastics and rubber sectors. It includes the operation of all relevant additional equipment where that equipment is integral to the thermoforming process.
Procedures
All operations are performed in accordance with procedures.
Procedures include all relevant workplace procedures, work instructions, temporary instructions and relevant industry and government codes and standards.
Tools and equipment
This competency includes use of equipment and tools such as:
heaters
mould
stacker
winder
granulator
conveyors and chutes
hand tools used in the thermoforming process
relevant personal protective equipment.
Hazards
Typical hazards include:
spills
dusts/vapours
slip and fall (such as due to leaks)
temperature (such as from ovens)
hazardous substances
moving equipment (such as opening the tool/mould cavity)
manual handling hazards.
Problems
'Respond to routine problems' means 'apply known solutions to a limited range of predictable problems'. Typical process problems may include:
equipment malfunction
variations in temperature (such as uneven oven temperatures)
pressure
speed (such as cycle times)
variations in sheet or contamination of sheet
product tool damage
machine malfunction
mould/tooling problems
variations in materials and/or contamination of materials.
Typical product problems may include routine thermoforming faults such as:
wall thinning
pin holes
poor surface finish
poor colour dispersion
stacking damage
colour contamination
black spots
scorching
shrinkage
uneven stretching.
Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.
Observation Checklist