Assessor Resource

PMBPROD303
Lay up and tape cables

Assessment tool

Version 1.0
Issue Date: March 2024


This unit of competency covers the skills and knowledge required to operate and adjust cable lay-up, taping and armouring equipment and ancillary equipment that is integral to the process. It applies to processing of armoured cable, screened cable or similar wires and cables.

This unit of competency applies to advanced operators who are required to start up and shut down cable lay-up, taping and armouring equipment, monitor equipment operation and make adjustments to remedy faults and non-conformity, maintain continuity of process and solve problems within area of responsibility.

This unit of competency applies to an advanced operator demonstrating theoretical and technical knowledge and well developed skills in situations that require some discretion and judgement. The advanced operator may work alone or as a member of a team or group and will work in liaison with other shift team members, team leader and supervisor, as appropriate.

This unit of competency may be contextualised and applied to similar processes using rotating plant and equipment which are not covered by specific units of competency.

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

Plan own work requirements

1.1

Identify equipment and processes used for production process and upstream and downstream operations from production plan or request

1.2

Identify materials required including additives

1.3

Recognise hazards and take appropriate action

1.4

Identify and check emergency stops, guards and controls

1.5

Identify requirements for materials, quality, production and equipment checks

1.6

Identify materials, waste management and housekeeping needs

2

Check equipment set-up

2.1

Determine equipment requirements

2.2

Set process to specifications as required

2.3

Check materials are correct

2.4

Check tensions, tape lay-up or tensions of armouring materials to requirements

2.5

Check rotating plant and equipment settings and adjustments, including tensions, lay length, attachments to spools and threading path adjustments, to specifications

2.6

Attach wire to spools and fit appropriate taping materials

2.7

Discard, or make adjustments to the process for, non-conforming materials

2.8

Set up date, batch and materials markings to specifications, as required

2.9

Complete other pre-start checks to procedures

3

Operate lay-up and taping equipment to procedures

3.1

Check and load materials using correct manual handling methods

3.2

Start up equipment and make adjustments to reach required settings

3.3

Monitor controls/displays/terminals for production/process data

3.4

Monitor product/process quality as required

3.5

Maintain continuity of process

3.6

Make adjustments to remedy faults and non-conformity to standard as required

3.7

Collect and reprocess/discard scrap/trim and other materials as required

3.8

Complete required workplace documentation/records.

3.9

Clean, adjust and lubricate equipment as required

3.10

Pause or stop equipment in an emergency, as required

4

Shut down equipment to procedures

4.1

Shut down equipment as required

4.2

Complete equipment cleanup, adjustments and waste management

4.3

Place suitable guards, locks and notices to prevent inadvertent start-up

5

Anticipate and solve problems

5.1

Recognise a problem or a potential problem

5.2

Determine problems needing priority action

5.3

Refer problems outside area of responsibility to appropriate person, with possible causes

5.4

Seek information and assistance as required to solve problems

5.5

Solve problems within area of responsibility

5.6

Follow through items initiated until final resolution has occurred

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, material labels and safety data sheets (SDS)

set up lay-up and/or taping equipment to meet specifications

operate the equipment and monitor key variables, including:

operating temperatures

operating speed pressure

time

tension

wind off speed

product integrity and general conformance to specification

maintain output and product quality using appropriate instruments, controls, test information and readings

safely shut down equipment in normal and abnormal circumstances

leave machine in appropriate condition with any required locks, tags or notices

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

distinguish between causes of problems, including:

operational problems

instrument failure/malfunction

electrical failure/malfunction

mechanical failure/malfunction

wrong readings

equipment design deficiencies

wire properties

process variables

recognise and prioritise problems requiring action

resolve non-routine problems

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 independently and to solve routine and non-routine problems, including knowledge of:

products, materials and material characteristics

behaviour of materials in relation to key process variables

quality requirements at each production stage

function and operating principles of layup/taping equipment, equipment components and ancillary equipment

layup/taping manufacturing processes

behaviour of materials in relation to speed, temperature and tension

impact of machine operating parameters on product quality and production output

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

cable properties and their interactions with process conditions

impact of variations in raw materials and equipment operation in relation to final product

routine and non-routine problems that may arise, the range of possible causes and appropriate 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

Plan own work requirements

1.1

Identify equipment and processes used for production process and upstream and downstream operations from production plan or request

1.2

Identify materials required including additives

1.3

Recognise hazards and take appropriate action

1.4

Identify and check emergency stops, guards and controls

1.5

Identify requirements for materials, quality, production and equipment checks

1.6

Identify materials, waste management and housekeeping needs

2

Check equipment set-up

2.1

Determine equipment requirements

2.2

Set process to specifications as required

2.3

Check materials are correct

2.4

Check tensions, tape lay-up or tensions of armouring materials to requirements

2.5

Check rotating plant and equipment settings and adjustments, including tensions, lay length, attachments to spools and threading path adjustments, to specifications

2.6

Attach wire to spools and fit appropriate taping materials

2.7

Discard, or make adjustments to the process for, non-conforming materials

2.8

Set up date, batch and materials markings to specifications, as required

2.9

Complete other pre-start checks to procedures

3

Operate lay-up and taping equipment to procedures

3.1

Check and load materials using correct manual handling methods

3.2

Start up equipment and make adjustments to reach required settings

3.3

Monitor controls/displays/terminals for production/process data

3.4

Monitor product/process quality as required

3.5

Maintain continuity of process

3.6

Make adjustments to remedy faults and non-conformity to standard as required

3.7

Collect and reprocess/discard scrap/trim and other materials as required

3.8

Complete required workplace documentation/records.

3.9

Clean, adjust and lubricate equipment as required

3.10

Pause or stop equipment in an emergency, as required

4

Shut down equipment to procedures

4.1

Shut down equipment as required

4.2

Complete equipment cleanup, adjustments and waste management

4.3

Place suitable guards, locks and notices to prevent inadvertent start-up

5

Anticipate and solve problems

5.1

Recognise a problem or a potential problem

5.2

Determine problems needing priority action

5.3

Refer problems outside area of responsibility to appropriate person, with possible causes

5.4

Seek information and assistance as required to solve problems

5.5

Solve problems within area of responsibility

5.6

Follow through items initiated until final resolution has occurred

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, manual handling 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 one or more of:

taping machine

lay-up machine

armouring machine

ancillary equipment that is integral to the process.

Additional tools and equipment will be selected as required from:

hand tools used in the process

lubrication system

measuring equipment

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:

wire breakages

weight, shape, volume of materials to be handled

hazardous products and materials

sharp edges, protrusions or obstructions

slippery surfaces, spills or leaks

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.

Problems

Routine and non-routine problems must be resolved.

Non-routine problems must be resolved by applying operational knowledge to develop new solutions, either individually or in collaboration with relevant experts, to:

determine problems needing action

determine possible fault causes

develop solutions to problems which do not have a known solution

follow through items initiated until final resolution has occurred

report problems outside area of responsibility to designated person.

Non-routine problems are unexpected problems or variations of previous problems and include one or more of:

unstable process variables

sub-optimal operation

variations in feed rates

variations in quality

emergency situations.

Operational knowledge includes one or more of:

procedures

training

technical information such as journals, engineering specifications

remembered experience

relevant knowledge obtained from appropriate people.

Routine problems are predictable and have known solutions and include one or more of:

processing problems (e.g. tensions, breaks and taping problems)

equipment malfunctions

materials problems (e.g. raw material contamination, and incorrect quantity of materials).

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, material labels and safety data sheets (SDS)

set up lay-up and/or taping equipment to meet specifications

operate the equipment and monitor key variables, including:

operating temperatures

operating speed pressure

time

tension

wind off speed

product integrity and general conformance to specification

maintain output and product quality using appropriate instruments, controls, test information and readings

safely shut down equipment in normal and abnormal circumstances

leave machine in appropriate condition with any required locks, tags or notices

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

distinguish between causes of problems, including:

operational problems

instrument failure/malfunction

electrical failure/malfunction

mechanical failure/malfunction

wrong readings

equipment design deficiencies

wire properties

process variables

recognise and prioritise problems requiring action

resolve non-routine problems

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 independently and to solve routine and non-routine problems, including knowledge of:

products, materials and material characteristics

behaviour of materials in relation to key process variables

quality requirements at each production stage

function and operating principles of layup/taping equipment, equipment components and ancillary equipment

layup/taping manufacturing processes

behaviour of materials in relation to speed, temperature and tension

impact of machine operating parameters on product quality and production output

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

cable properties and their interactions with process conditions

impact of variations in raw materials and equipment operation in relation to final product

routine and non-routine problems that may arise, the range of possible causes and appropriate 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
Identify equipment and processes used for production process and upstream and downstream operations from production plan or request 
Identify materials required including additives 
Recognise hazards and take appropriate action 
Identify and check emergency stops, guards and controls 
Identify requirements for materials, quality, production and equipment checks 
Identify materials, waste management and housekeeping needs 
Determine equipment requirements 
Set process to specifications as required 
Check materials are correct 
Check tensions, tape lay-up or tensions of armouring materials to requirements 
Check rotating plant and equipment settings and adjustments, including tensions, lay length, attachments to spools and threading path adjustments, to specifications 
Attach wire to spools and fit appropriate taping materials 
Discard, or make adjustments to the process for, non-conforming materials 
Set up date, batch and materials markings to specifications, as required 
Complete other pre-start checks to procedures 
Check and load materials using correct manual handling methods 
Start up equipment and make adjustments to reach required settings 
Monitor controls/displays/terminals for production/process data 
Monitor product/process quality as required 
Maintain continuity of process 
Make adjustments to remedy faults and non-conformity to standard as required 
Collect and reprocess/discard scrap/trim and other materials as required 
Complete required workplace documentation/records. 
Clean, adjust and lubricate equipment as required 
Pause or stop equipment in an emergency, as required 
Shut down equipment as required 
Complete equipment cleanup, adjustments and waste management 
Place suitable guards, locks and notices to prevent inadvertent start-up 
Recognise a problem or a potential problem 
Determine problems needing priority action 
Refer problems outside area of responsibility to appropriate person, with possible causes 
Seek information and assistance as required to solve problems 
Solve problems within area of responsibility 
Follow through items initiated until final resolution has occurred 

Forms

Assessment Cover Sheet

PMBPROD303 - Lay up and tape cables
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

PMBPROD303 - Lay up and tape cables

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: