Assessor Resource

PMBPROD290
Operate filament winding equipment

Assessment tool

Version 1.0
Issue Date: March 2024


This unit of competency covers the skills and knowledge required to operate filament winding equipment as used to manufacture filament wound composite products.

This unit of competency applies to operators who are required to take product off the machine, check materials and moulds, operate the equipment, check product quality and conformity to specifications, 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

Conduct pre-operational checks as required

1.1

Check safety equipment is in place and working

1.2

Check moulds, closures and fitting to procedures

1.3

Check moulds for cracks, chips marks and cleanliness

1.4

Check materials, including fibres, resins, additives and release agents are correct

1.5

Undertake other pre-operational checks in accordance with procedures

2

Operate equipment to procedures

2.1

Check process is operating within required limits

2.2

Check product is in specification and to required quality standard

2.3

Collect products and store as required

2.4

Maintain supply of materials as required

2.5

Complete logs and records as required.

2.6

Collect and segregate scrap, waste and other materials as required

2.7

Keep equipment and work are clean

2.8

Pause machine cycle and perform emergency stop as required

3

Respond to routine problems in accordance with procedures

3.1

Recognise known faults that occur during the operation

3.2

Identify and take action on causes of routine faults

3.3

Log problems as required

3.4

Identify non-routine problems and report to designated person

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, tools and equipment to meet job specifications

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

monitor and interpret key variables, including:

operating temperatures

speed

colour

cycle time

output rate

product weight

product integrity and general conformance to specification

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.

Must provide evidence that demonstrates knowledge relevant to their job sufficient to operate under routine only supervision and to solve routine problems, including knowledge of:

function of filament winding equipment, machine components and guides

principles of operation of the equipment

methods of curing of products and the role of wraps, heat and pressure

role of fibres, resins, additives and release agents

the potential effects of variations in raw materials and equipment operation in relation to quality of product

reasons for checking process control panels and reporting readings which are outside of normal range of process variability

production workflow sequences and materials demand

factors which may affect product quality or production output and appropriate remedies

routine problems, their probable causes and relevant corrective actions

organisation procedures relevant to the work environment/job role

hierarchy of control

hazards that may arise in the job/work environment and:

their possible causes

potential consequences

appropriate risk controls.

The unit should be assessed holistically and the judgement of competence shall be based on a holistic assessment of the evidence.

In all plants it may be appropriate to assess this unit concurrently with units such as:

teamwork

communication.

The collection of performance evidence:

should occur over a range of situations which include typical disruptions to normal, smooth operation of an operating plant

will typically include a supervisor/third-party report or other evidence, focusing on consistent performance and problem recognition and solving. A supervisor/third-party report must be prepared by someone who has a direct, relevant, current relationship with the person being assessed and who is in a position to form a judgement on workplace performance relevant to the unit of competency

must include the use of an appropriate industrial item of equipment requiring demonstration of operation, start and stop procedures and responding to problems

may use industry-based simulation for all or part of the unit particularly where safety, lack of opportunity or significant cost is an issue.

Assessment should occur in operational workplace situations. Where this is not possible or where personal safety or environmental damage are limiting factors assessment must occur in a sufficiently rigorous simulated environment that reflects realistic operational workplace conditions. This must cover all aspects of workplace performance, including environment, task skills, task management skills, contingency management skills and job role environment skills.

Assessment in a simulated environment should use evidence collected from demonstration of skills and one or more of:

walk-throughs

pilot plant operation

industry-based case studies/scenarios

‘what ifs’.

Knowledge evidence may be collected concurrently with performance evidence or through an independent process, such as workbooks, written assessments or interviews.

Assessment processes and techniques must be appropriate to the language, literacy and numeracy requirements of the work being performed and the needs of the candidate.

Conditions for assessment must include access to all tools, equipment, materials and documentation required, including relevant workplace procedures, product and manufacturing specifications associated with this unit.

The regulatory framework will be reflected in workplace policies and procedures and is not required to be independently assessed.

Foundation skills are integral to competent performance of the unit and should not be assessed separately.

Assessors must satisfy the assessor competency requirements that are in place at the time of the assessment as set by the VET regulator.

In addition the assessor or anyone acting in subject matter expert role in assessment shall demonstrate both technical competency and currency. If the assessor cannot demonstrate technical competency and currency they shall assess with a subject matter expert who does meet these requirements.

Technical competence can be demonstrated through one or more of:

relevant VET or other qualification/Statement of Attainment

appropriate workplace experience undertaking the type of work being assessed under routine and non-routine conditions

appropriate workplace experience supervising/evaluating the type of work being assessed under routine and non-routine conditions

Currency can be demonstrated through one or more of:

being currently employed undertaking the type of work being assessed

being employed by the organisation undertaking the type of work being assessed and having maintained currency in accordance with that organisation’s policies and procedures

having consulted/had contact with an organisation undertaking the type of work being assessed within the last twelve months, the consultation/contact being related to assessment

conducting on the job training/assessments of the type of work being assessed

being an active member of a relevant professional body and participating in activities relevant to the assessment of this type of work.


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

Conduct pre-operational checks as required

1.1

Check safety equipment is in place and working

1.2

Check moulds, closures and fitting to procedures

1.3

Check moulds for cracks, chips marks and cleanliness

1.4

Check materials, including fibres, resins, additives and release agents are correct

1.5

Undertake other pre-operational checks in accordance with procedures

2

Operate equipment to procedures

2.1

Check process is operating within required limits

2.2

Check product is in specification and to required quality standard

2.3

Collect products and store as required

2.4

Maintain supply of materials as required

2.5

Complete logs and records as required.

2.6

Collect and segregate scrap, waste and other materials as required

2.7

Keep equipment and work are clean

2.8

Pause machine cycle and perform emergency stop as required

3

Respond to routine problems in accordance with procedures

3.1

Recognise known faults that occur during the operation

3.2

Identify and take action on causes of routine faults

3.3

Log problems as required

3.4

Identify non-routine problems and report to designated person

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)

formulae/recipes

batch sheets

temporary instructions

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

Tools and equipment

Tools and equipment include:

filament winding equipment and its major components

programmable logic controllers (PLC) if fitted

ancillary equipment that is integral to the process.

Additional tools and equipment will be selected as required from:

hand tools

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:

hazardous products and materials

sharp edges, swarf and scrap

protrusions or obstructions

slippery surfaces, spills or leaks

rotational equipment or vibration

smoke, dust, vapours or other atmospheric hazards

high temperatures

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 process conditions

variations in materials or contamination of materials

equipment, tool and die damage

machine malfunction

mould/tooling problems

variations in materials and/or contamination of materials

product voids

poor surface finish

colour contamination

release from mandrel damage

routine product faults.

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, tools and equipment to meet job specifications

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

monitor and interpret key variables, including:

operating temperatures

speed

colour

cycle time

output rate

product weight

product integrity and general conformance to specification

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.

Must provide evidence that demonstrates knowledge relevant to their job sufficient to operate under routine only supervision and to solve routine problems, including knowledge of:

function of filament winding equipment, machine components and guides

principles of operation of the equipment

methods of curing of products and the role of wraps, heat and pressure

role of fibres, resins, additives and release agents

the potential effects of variations in raw materials and equipment operation in relation to quality of product

reasons for checking process control panels and reporting readings which are outside of normal range of process variability

production workflow sequences and materials demand

factors which may affect product quality or production output and appropriate remedies

routine problems, their probable causes and relevant corrective actions

organisation procedures relevant to the work environment/job role

hierarchy of control

hazards that may arise in the job/work environment and:

their possible causes

potential consequences

appropriate risk controls.

The unit should be assessed holistically and the judgement of competence shall be based on a holistic assessment of the evidence.

In all plants it may be appropriate to assess this unit concurrently with units such as:

teamwork

communication.

The collection of performance evidence:

should occur over a range of situations which include typical disruptions to normal, smooth operation of an operating plant

will typically include a supervisor/third-party report or other evidence, focusing on consistent performance and problem recognition and solving. A supervisor/third-party report must be prepared by someone who has a direct, relevant, current relationship with the person being assessed and who is in a position to form a judgement on workplace performance relevant to the unit of competency

must include the use of an appropriate industrial item of equipment requiring demonstration of operation, start and stop procedures and responding to problems

may use industry-based simulation for all or part of the unit particularly where safety, lack of opportunity or significant cost is an issue.

Assessment should occur in operational workplace situations. Where this is not possible or where personal safety or environmental damage are limiting factors assessment must occur in a sufficiently rigorous simulated environment that reflects realistic operational workplace conditions. This must cover all aspects of workplace performance, including environment, task skills, task management skills, contingency management skills and job role environment skills.

Assessment in a simulated environment should use evidence collected from demonstration of skills and one or more of:

walk-throughs

pilot plant operation

industry-based case studies/scenarios

‘what ifs’.

Knowledge evidence may be collected concurrently with performance evidence or through an independent process, such as workbooks, written assessments or interviews.

Assessment processes and techniques must be appropriate to the language, literacy and numeracy requirements of the work being performed and the needs of the candidate.

Conditions for assessment must include access to all tools, equipment, materials and documentation required, including relevant workplace procedures, product and manufacturing specifications associated with this unit.

The regulatory framework will be reflected in workplace policies and procedures and is not required to be independently assessed.

Foundation skills are integral to competent performance of the unit and should not be assessed separately.

Assessors must satisfy the assessor competency requirements that are in place at the time of the assessment as set by the VET regulator.

In addition the assessor or anyone acting in subject matter expert role in assessment shall demonstrate both technical competency and currency. If the assessor cannot demonstrate technical competency and currency they shall assess with a subject matter expert who does meet these requirements.

Technical competence can be demonstrated through one or more of:

relevant VET or other qualification/Statement of Attainment

appropriate workplace experience undertaking the type of work being assessed under routine and non-routine conditions

appropriate workplace experience supervising/evaluating the type of work being assessed under routine and non-routine conditions

Currency can be demonstrated through one or more of:

being currently employed undertaking the type of work being assessed

being employed by the organisation undertaking the type of work being assessed and having maintained currency in accordance with that organisation’s policies and procedures

having consulted/had contact with an organisation undertaking the type of work being assessed within the last twelve months, the consultation/contact being related to assessment

conducting on the job training/assessments of the type of work being assessed

being an active member of a relevant professional body and participating in activities relevant to the assessment of this type of work.

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
Check safety equipment is in place and working 
Check moulds, closures and fitting to procedures 
Check moulds for cracks, chips marks and cleanliness 
Check materials, including fibres, resins, additives and release agents are correct 
Undertake other pre-operational checks in accordance with procedures 
Check process is operating within required limits 
Check product is in specification and to required quality standard 
Collect products and store as required 
Maintain supply of materials as required 
Complete logs and records as required. 
Collect and segregate scrap, waste and other materials as required 
Keep equipment and work are 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 problems and report to designated person 

Forms

Assessment Cover Sheet

PMBPROD290 - Operate filament winding 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

PMBPROD290 - Operate filament winding 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: