PMBPROD312C - Produce continuous thermoforming products
Assessor Resource
PMBPROD312C Produce continuous thermoforming products
Assessment tool
Version 1.0 Issue Date: March 2024
Application of this unit
This competency is typically performed by advanced operators applying knowledge of materials, product purpose and processes to the operation thermoforming equipment to produce product conforming to requirements. It also requires using a range of well developed skills requiring some discretion and judgement to recognise and resolve a range of problems.
The operator should:
start up the thermoforming machine
check settings and adjustments of equipment
monitor equipment operation
make appropriate adjustments to correct materials, equipment or process variations
solve thermoforming equipment, material and process problems, seeking guidance where necessary or appropriate.
This competency covers production of continuous thermoforming products using thermoforming equipment and the solving of problems.
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 unit has the prerequisite of PMBPROD212A Operate thermoforming equipment.
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
Assessment will occur on an industrial thermoforming machine(s) equipment and will be undertaken in a work like environment.
Where the assessee does not currently possess evidence of competency in PMBPROD212 Operate thermoforming equipment, 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:
identify critical materials properties and continuous thermoforming process characteristics in relation to the process requirements and the end product
make adjustments and identify problems to be reported
identify and take appropriate action on problems and potential problems.
Consistent performance should be demonstrated. For example, look to see that:
the process runs consistently and smoothly, with the minimum need for human intervention
all safety procedures are always followed.
Assessment method and context
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. A holistic approach should be taken to the assessment.
Competence in this unit may be assessed:
by use of an appropriate, thermoforming machine requiring demonstration of start up, operation and shut down procedures
in a situation allowing the generation of evidence of the ability to recognise, anticipate and solve problems
by use of a suitable simulation and/or a range of case studies/scenarios
by 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 of variables 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 material and equipment conditions which may lead to out of specification production. For example, static electricity can increase the potential for contamination of materials by dust and dirt. This can be minimised by vacuuming or blowing air sheet surfaces immediately before forming, and also maintaining a clean plant to prevent dust and dirt from entering the thermoforming area.
Knowledge of organization procedures, quality requirements at each production stage 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 thermoforming process. Application of approved hazard control and safety procedures and the use of PPE in relation to handling materials, equipment operation and cleanup.
Knowledge as a basis for solving processing and material problems including:
characteristics of materials and behaviour in relation to heat pressure, and time
function and operating principles of continuous thermoforming equipment, machine components and ancillary equipment, including the mechanical, hydraulic, pneumatic, electrical and electronic principles which effect machine operation
impact of machine speed, temperature, pressure, time during cycles on product quality and production output
phases of the thermoforming cycle and the effect of the key variables on product quality, in order to make appropriate adjustments to machine settings. For example. pre-stretching a heated sheet in the air before it makes contact with the mould improves material distribution by increasing the sheet surface area so it more closely matches that of the mould.
changes to materials at various stages of production
waste management and importance of non-conforming materials
impact of variations in raw materials and equipment operation in relation to final product
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
maintain output and product quality using appropriate instruments, controls, test information and readings
identify and describe own role and role of others involved directly in the thermoforming process
identify factors which may affect product quality or production output and appropriate remedies
identify when assistance is required to solve problems.
Language, literacy and numeracy requirements
This unit requires the ability to read and interpret typical product specifications, job sheets and material labels as provided to operators.
Writing is required to the level of completing workplace forms and production reports.
Basic numeracy is required, eg, to determine how many 2 kg, 3 kg and 5 kg bags are needed to make up a requirement for 50 kg.
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 continuous thermoforming processes and includes the use of air pressure or vacuum processes. It includes the operation of all relevant additional equipment where that equipment is integral to the thermoforming process.
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 competency includes use of equipment and tools such as:
stationary and moving machinery, parts and components.
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 routine faults include:
sheet sag
non-uniform pre-stretching
non-uniform wall thickness
sheet pulling out
bubbles, blisters or pits
scorching
whitening of formed part
blushing
loss of embossing detail
chill marks, drag-off lines
pinholes/pimples
shiny streaks
shrink marks
plug sticking
sheet tearing during forming.
Non-routine faults, which may have multiple causes include:
warpage or shrinkage after moulding
cracking
surface marks
webbing or wrinkling
mould sticking.
Typical process and product problems may include:
equipment malfunction
variations in temperature (eg uneven oven temperatures)
pressure
speed (eg cycle times)
variations in sheet or contamination of sheet
product tool damage
machine malfunction
mould/tooling problems
variations in materials and/or contamination of materials.
Variables
Key variables to be monitored include:
temperature
speeds (eg rollers, mould opening and closing)
times (including cycle times)
surface finish/appearance
product weight and output rate
product integrity and general conformance to specification and quality sample.
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 the most appropriate equipment to be used for production and upstream and downstream operations from production plan or request.
Identify and check materials required, including additives and regrind and their amounts or percentages.
Implement measures to control identified hazards in line with procedures and duty of care.
Identify requirements for materials, quality, production and equipment checks.
Identify process settings required for product.
Set process to required settings.
Check materials are correct.
Take appropriate action for non-conforming materials.
Set up date, batch and materials markings to specifications, as required.