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 knowledge of the materials, equipment and process sufficient to recognise out of specification process problems and equipment.
Knowledge of organization procedures and relevant regulatory requirements along with the ability to implement them within appropriate time constraints and work standards.
Application of the knowledge of managing risks using the hierarchy of controls applied to the process. Application of approved hazard control, safety procedures, the use of PPE in relation to handling materials, equipment operation and cleanup.
Knowledge as a basis for solving processing and material problems, including:
machine construction (types of machines, component parts of machines, structure, function and general operating principles)
machine safety interlocks and systems
principles of operation
measuring instruments and their function
machine control systems
differences between analogue controls, digital controls, microprocessor based process controls
impact of incorrect or faulty set-up
production workflow sequences
correct selection and use of equipment and procedures
the performance of dies and cores
relevant information and workplace records
safety precautions appropriate to the task
polymer properties and their interactions with process conditions
relationships between polymer properties and process conditions
changes to polymer properties to better suit process requirements
product problems related to polymer properties
product problems related to process conditions
adjustments to process conditions to meet polymer and product requirements.
Competence also includes the ability to:
plan own work, including predicting consequences and identifying improvements
take samples when required and identify product out of specification
identify and describe own role and role of others involved directly in the process
identify factors which may affect standard product quality or production output.
Language, literacy and numeracy requirements
Literacy is required to the level of being able to read and interpret technical specifications and production schedules and specifications.
Numeracy is required to the level of being able to calculate cycle times and production rates. An appreciation of numbers is also required to the extent needed to set and interpret numeric data.
Verbal communication is required to the extent necessary to instruct the operator.
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 sectors within the plastics, rubber and cablemaking industries which use dedicated production machines. It includes the operation of all relevant additional equipment where that equipment is integral to the production process.
Requirements
Requirements may be determined from set-up sheets, job cards, product data sheets or similar.
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 unit of competency includes use of equipment and tools such as:
hand carts and trolleys
hoists/lifting equipment not requiring any special permits or licences
hand tools used in the process
relevant personal protective equipment.
Measuring instruments
Measuring instruments include:
levelling
temperature sensing devices such as thermocouples, pyrometers, transducers, thermometers
pressure and vacuum gauges
flow meters.
Safety interlocks and systems
Safety interlocks and systems include:
limit switches
normally open/normally closed
overstroke control systems
hydraulic temperature control
material temperature control
machine guards
nozzle purge guard
mould protection systems
ejection limit switches.
Principles of operation
Principles of operation include:
production cycle/process/sequence
function tools/components
calculation of machine cycle time/production rate
safe work procedures for checking machine cycle time/production rate
variations to the cycle/process for different systems/products.
Machine control systems
Machine control systems include:
basic controls
open loop
closed loop
shot size and correction capacity
speed/cycle time
screw position
equipment/process pressure
clamp pressure
time
screw speed
screw back pressure
screw back time
melt decompress position
sprue break.
Hazards
Typical hazards include:
spills
dusts/vapours
slip and fall, particularly due to spilt polymer granules
temperature
hazardous materials
manual handling hazards
equipment operations.
Problems
Anticipate and solve problems means resolve a wide range of routine and non-routine problems, using product and process knowledge to develop solutions to problems which do not have a known solution/a solution recorded in the procedures.
Typical process and product problems may include:
materials
equipment malfunction
process.
Variables
Key variables to be monitored include:
equipment condition
set up variables
product measurements and quality.
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