Assessor Resource

PMBPROD306B
Prepare and start equipment for production

Assessment tool

Version 1.0
Issue Date: March 2024


Application of this unit

This competency applies to operators who apply knowledge of the machine and the processes required to bring a 'cold' machine back into production.

The operator will:

plan the job

identify hazards and take appropriate action

perform pre-start checks

start up and shut down equipment as required

adjust operation to meet production requirements

hand over operating machine to operator.

This unit applies when start-up is performed as an activity by itself and the started plant is then handed over to an operator to operate. It does not apply when start-up is part of operation and is included in the relevant operate/produce unit of competency.

This competency covers the pre-start preparations and start-up operations to bring a production machine from 'power-off' to first-off product and handover to the operator to continue the production run. This competency is typically performed by senior operators working either independently or as part of a work team.

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

Prerequisites

Prerequisites

This competency has the prerequisite of a PROD200 series unit of competency.


Employability Skills

The required outcomes described in this unit contain applicable Employability Skills. The Employability Skills Summary of the qualification(s) in which this unit is packaged will assist in identifying Employability Skill requirements.




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.

The Evidence Guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, the range statement and the assessment guidelines for this training package.

Overview of assessment

A holistic approach should be taken to the assessment.

Assessors must be satisfied that the person can consistently perform the unit as a whole, as defined by the Elements, Performance Criteria and skills and knowledge.

Where the assessee does not currently possess evidence of competency in a relevant PROD200 unit, it may be co-assessed with this unit.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

It is essential that competence is demonstrated in the knowledge and skills defined in this unit. These may include the ability to:

bring a 'cold' machine into ready-for-production status methodically and smoothly in standard time.

Consistent performance should be demonstrated. For example, look to see that production quality and output standards are met consistently.

Assessment method and context

Assessment will occur on an industrial line in a work-like environment.

Competence in this unit may be assessed:

by using appropriate, industrial equipment

in a situation allowing for the generation of evidence of the ability to respond to problems

by using a suitable simulation and/or a range of case studies/scenarios

through a combination of these techniques.

In all cases it is expected that practical assessment will be combined with targeted questioning to assess the underpinning knowledge and theoretical assessment will be combined with appropriate practical/simulation or similar assessment. Assessors need to be aware of any cultural issues that may affect responses to questions.

Assessment processes and techniques must be culturally appropriate and appropriate to the oracy, language and literacy capacity of the assessee and the work being performed.

Specific resources for assessment

This section should be read in conjunction with the Range Statement for this unit of competency. Resources required include suitable access to an operating plant or equipment that allows for appropriate and realistic simulation. A bank of case studies/scenarios and questions will also be required to the extent that they form part of the assessment method. Questioning may take place either in the workplace, or in an adjacent, quiet facility such as an office or lunchroom. No other special resources are required.

Access must be provided to appropriate learning and/or assessment support when required. Where applicable, physical resources should include equipment modified for people with disabilities.


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.

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

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Check all emergency stops, guards, controls. 
Identify requirements for materials, quality, production run. 
Check and adjust equipment as required. 
Check that the equipment has been set-up correctly. 
Restore all power to the machine and ancillary equipment. 
Start up the ancillary equipment and set the temperature and other controllers as required. 
Check all machine settings as required. 
Select and load the correct raw material. 
Charge, purge and clean machine as required. 
Start and check machine. 
Adjust machine as required to bring to operational speed/ condition. 
Check and run machine until a quality product is obtained. 
Make adjustments to machine and extra equipment in line to produce an acceptable product. 
Make any adjustments required to ensure the machine and its upstream and downstream extra equipment in line are in balance. 
Give the operator all necessary instructions and hand over the machine. 
Shut down machine as required. 

Forms

Assessment Cover Sheet

PMBPROD306B - Prepare and start equipment for production
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

PMBPROD306B - Prepare and start equipment for production

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: