Assessor Resource

PMBPROD259
Operate granulating equipment

Assessment tool

Version 1.0
Issue Date: March 2024


This unit of competency covers the skills and knowledge required to operate granulating equipment and ancillary equipment that is integral to the process. Granulating equipment is typically used in the plastics and rubber sectors to process virgin or recycled material into granules for further production.

This unit of competency applies to operators who are required to check materials and measurements, monitor operations and adjust equipment, maintain feed and recognise routine and non-routine problems and take appropriate action.

This unit of competency applies to an individual working alone or as part of a team or group and working in liaison with other shift team members, team leader and supervisor, as appropriate.

No licensing, legislative or certification requirements apply to this unit at the time of publication.

You may want to include more information here about the target group and the purpose of the assessments (eg formative, summative, recognition)



Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Check work requirements

1.1

Identify work requirements from production plan or request

1.2

Check product, materials and equipment meet requirements for job

1.3

Recognise requirements which may not be in accordance with usual practice

1.4

Ask questions of appropriate person to confirm unusual practice

1.5

Identify hazards associated with the job and take appropriate action

1.6

Perform other pre-operational checks in accordance with procedures

2

Start up granulator to procedures

2.1

Conduct pre-start checks

2.2

Start up granulator

3

Operate equipment to procedures

3.1

Check process is operating within required limits

3.2

Check materials are in specification and to required quality standard

3.3

Ensure materials are consistently ready for next operation

3.4

Maintain supply of materials as required

3.5

Complete logs and records as required

3.6

Collect and segregate scrap, trim and other materials as required

3.7

Keep equipment and work area clean

3.8

Pause machine cycle and perform emergency stop, as required

4

Respond to routine problems in accordance with procedures

4.1

Recognise known faults that occur during the operation

4.2

Identify and take action on causes of routine faults

4.3

Log problems as required

4.4

Identify non-routine process and quality problems and take appropriate action

Evidence required to demonstrate competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria and demonstrate the ability to:

read and interpret procedures, job specifications, basic machine control panels, material labels and safety data sheets (SDS)

select and use materials, procedures, tools and equipment to meet job specifications

monitor granulating and ancillary equipment using measured/indicated data and smell, sight, sound and feel as appropriate

monitor and interpret key variables, including:

speeds

temperature

output rate

product integrity and general conformance to specification/sample

operate and adjust the equipment to meet product quality and production output specifications

pause the equipment or shut down equipment in normal and abnormal circumstances

identify hazards and apply relevant hazard controls

apply safety procedures

apply housekeeping procedures

apply waste management procedures

recognise early warning signs of equipment/processes needing attention or with potential problems

recognise routine and non-routine problems

identify when the operator is able to rectify faults, when assistance is required and who is the appropriate source for assistance

take action to resolve faults or report faults to appropriate personnel

distinguish between possible causes of routine faults, including:

raw material variations/contamination

process abnormalities

procedural errors

mechanical abnormalities

communicate effectively with team/work group and supervisors

complete workplace records

do basic arithmetical manipulations, including additions, subtractions, divisions, fractions and percentages.


Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assingnment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)


Assessment Tasks

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.

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Check work requirements

1.1

Identify work requirements from production plan or request

1.2

Check product, materials and equipment meet requirements for job

1.3

Recognise requirements which may not be in accordance with usual practice

1.4

Ask questions of appropriate person to confirm unusual practice

1.5

Identify hazards associated with the job and take appropriate action

1.6

Perform other pre-operational checks in accordance with procedures

2

Start up granulator to procedures

2.1

Conduct pre-start checks

2.2

Start up granulator

3

Operate equipment to procedures

3.1

Check process is operating within required limits

3.2

Check materials are in specification and to required quality standard

3.3

Ensure materials are consistently ready for next operation

3.4

Maintain supply of materials as required

3.5

Complete logs and records as required

3.6

Collect and segregate scrap, trim and other materials as required

3.7

Keep equipment and work area clean

3.8

Pause machine cycle and perform emergency stop, as required

4

Respond to routine problems in accordance with procedures

4.1

Recognise known faults that occur during the operation

4.2

Identify and take action on causes of routine faults

4.3

Log problems as required

4.4

Identify non-routine process and quality problems and take appropriate action

This field allows for different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.

Regulatory framework

The latest version of all legislation, regulations, industry codes of practice and Australian/international standards, or the version specified by the local regulatory authority, must be used.

Applicable legislation, regulations, standards and codes of practice include:

health, safety and environmental (HSE) legislation, regulations and codes of practice relevant to the workplace, equipment and production processes and hazardous materials

Australian/international standards relevant to the materials being used and products being made

any relevant licence and certification requirements.

All operations to which this unit applies are subject to stringent HSE requirements, which may be imposed through state/territory or federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between performance criteria and such requirements the legislative requirements take precedence.

Procedures

All operations must be performed in accordance with relevant procedures.

Procedures are written, verbal, visual, computer-based or in some other form, and include one or any combination of:

emergency procedures

work instructions

standard operating procedures (SOPs)

safe work method statements (SWMS)

formulas/recipes

batch sheets

temporary instructions

any similar instructions provided for the smooth running of the plant.

Tools and equipment

Tools and equipment include:

granulator equipment

ancillary equipment that is integral to the process, such as regrind evacuation systems, conveyors, hoppers and de-humidifiers.

Additional tools and equipment will be selected as required from:

magnets

screens

dust collection systems tools (such as verniers and gauges)

hoists/lifting equipment not requiring any special permits or licences

manual handling aids, such as hand carts and trolleys

relevant personal protective equipment (PPE).

Hazards

Hazards must be identified and controlled. Identifying hazards requires consideration of:

weight, shape, volume of materials to be handled

hazardous products and materials

knives, blades and cutting tools

sharp edges, protrusions or obstructions

slippery surfaces, spills or leaks

rotational equipment or vibration

high temperatures

smoke, dust, vapours or other atmospheric hazards

electricity

gas

gases and liquids under pressure

structural hazards

equipment failures

machinery, equipment and product mass

other hazards that might arise.

Routine problems

Routine problems must be resolved by applying known solutions.

Routine problems are predictable and include one or more of:

equipment malfunction

variations in cycle time, temperature, pressure and speed

variations in materials or contamination of materials

poor maintenance of blades, screens

inconsistency in granulation

incorrect product size

incorrect weight

poor mixing of additive and raw material

surface moisture.

Known solutions are drawn from one or more of:

procedures

training

remembered experience.

Non-routine problems must be reported according to according to relevant procedures.

Evidence required to demonstrate competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria and demonstrate the ability to:

read and interpret procedures, job specifications, basic machine control panels, material labels and safety data sheets (SDS)

select and use materials, procedures, tools and equipment to meet job specifications

monitor granulating and ancillary equipment using measured/indicated data and smell, sight, sound and feel as appropriate

monitor and interpret key variables, including:

speeds

temperature

output rate

product integrity and general conformance to specification/sample

operate and adjust the equipment to meet product quality and production output specifications

pause the equipment or shut down equipment in normal and abnormal circumstances

identify hazards and apply relevant hazard controls

apply safety procedures

apply housekeeping procedures

apply waste management procedures

recognise early warning signs of equipment/processes needing attention or with potential problems

recognise routine and non-routine problems

identify when the operator is able to rectify faults, when assistance is required and who is the appropriate source for assistance

take action to resolve faults or report faults to appropriate personnel

distinguish between possible causes of routine faults, including:

raw material variations/contamination

process abnormalities

procedural errors

mechanical abnormalities

communicate effectively with team/work group and supervisors

complete workplace records

do basic arithmetical manipulations, including additions, subtractions, divisions, fractions and percentages.

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

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Identify work requirements from production plan or request 
Check product, materials and equipment meet requirements for job 
Recognise requirements which may not be in accordance with usual practice 
Ask questions of appropriate person to confirm unusual practice 
Identify hazards associated with the job and take appropriate action 
Perform other pre-operational checks in accordance with procedures 
Conduct pre-start checks 
Start up granulator 
Check process is operating within required limits 
Check materials are in specification and to required quality standard 
Ensure materials are consistently ready for next operation 
Maintain supply of materials as required 
Complete logs and records as required 
Collect and segregate scrap, trim and other materials as required 
Keep equipment and work area clean 
Pause machine cycle and perform emergency stop, as required 
Recognise known faults that occur during the operation 
Identify and take action on causes of routine faults 
Log problems as required 
Identify non-routine process and quality problems and take appropriate action 

Forms

Assessment Cover Sheet

PMBPROD259 - Operate granulating equipment
Assessment task 1: [title]

Student name:

Student ID:

I declare that the assessment tasks submitted for this unit are my own work.

Student signature:

Result: Competent Not yet competent

Feedback to student

 

 

 

 

 

 

 

 

Assessor name:

Signature:

Date:


Assessment Record Sheet

PMBPROD259 - Operate granulating equipment

Student name:

Student ID:

Assessment task 1: [title] Result: Competent Not yet competent

(add lines for each task)

Feedback to student:

 

 

 

 

 

 

 

 

Overall assessment result: Competent Not yet competent

Assessor name:

Signature:

Date:

Student signature:

Date: