This competency applies to operators who are required to apply knowledge of materials, product purpose and processes to the operation of blown film lines. The key factors are the production of material meeting quality standards and product requirements and the recognition and resolving of a range of routine and non-routine problems.
It includes:
identifying and planning own work requirements from production requests
identifying and minimising any hazards connected with materials and process from materials safety data sheets, labels and workplace procedures
checking settings and adjustments of equipment
checking materials for conformity to job requirements
monitoring equipment operation and correcting process variations
correcting materials, equipment or process variations and making appropriate adjustments
discarding non-conforming products ensuring discarded materials are reused where possible and waste and scrap is disposed of in accordance with workplace instructions
solving routine and non-routine blown film equipment and process problems, seeking guidance where necessary or appropriate
completing logs and reports.
This competency covers the operation and adjustment of blown film lines and the solving of non-routine problems.
This competency is typically performed by advanced operators demonstrating some relevant theoretical knowledge and using a range of well developed skills requiring some discretion and judgement.
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 of competency has the prerequisite of PMBPROD216A Operate blown film 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.
Overviewof assessment
Assessment will occur on an industrial blown film machine(s) equipment and will be undertaken in a work-like environment.
Where the assessee does not currently possess evidence of competency in PMBPROD216A Operate blown film 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 blown film process characteristics in relation to the process requirements and the end product.
Consistent performance should be demonstrated. For example, look to see that
production quality and output standards are met consistently
the process runs consistently and smoothly.
Assessment method and context
Assessment will occur on an industrial blown film machine(s) equipment and will be undertaken in a work-like environment.
Competence in this unit may be assessed
by using an appropriate, industrial blown film 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 material and equipment conditions which may lead to out of specification production.
Knowledge of organization procedures and relevant regulatory requirements along with the ability to implement them within appropriate time constraints and work standards.
Competence includes the ability for the practical completion of the job to apply and/or explain:
products, materials and material characteristics
behaviour of materials in relation to heat, pressure and time
quality requirements at each production stage
function and operating principles of blown film equipment, machine components and ancillary equipment
impact of extruder speed, temperature, pressure on product quality and production output
impact of changes and adjustments to the winding gear on film properties
nature of mechanical, hydraulic, pneumatic, electrical and electronic principles which effect machine operation and product development
safety procedures and the use of PPE in relation to handling materials, equipment operation and cleanup
the hierarchy of control including engineering controls
impact of variations in raw materials and equipment operation in relation to final product
changes to materials at various stages of production
waste management and importance of non-conforming materials
plan own work, including predicting consequences and identifying improvements
interpret from production requests the correct selection and use of equipment, materials, processes and procedures
maintain output and product quality using appropriate instruments, controls, test information and readings
make adjustments to equipment operation to rectify variations in equipment operation or product quality
check blown film line for correct setup to job specifications and implement adjustments or report deviations immediately
start up equipment and make appropriate adjustments to bring process on line
make measurements when required and identify product out of specification
safely shut down equipment in normal or abnormal circumstances
identify and describe own role and role of others involved directly in the film process
identify factors which may affect product quality or production output and appropriate remedies
identify when the operator is able to rectify faults and when assistance is required
identify hazards of the materials and process
implement appropriate procedures for hazard control
use PPE, safely handle products and materials, read relevant safety information and apply safety precautions appropriate to the task
distinguish between causes of faults such as materials, contaminants, equipment - adjustments/set-up, equipment - maintenance requirements.
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 operators demonstrating some relevant theoretical knowledge and using a range of well developed skills requiring some discretion and judgement.
Procedures
All operations are performed in accordance with procedures.
Procedures means 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:
extruder
die, air ring and blower
bubble guides and rollers
film rollers, slitting, trimming and winding gear
coolers, heaters and ancillary equipment
hand tools, knives, adjustment tools
relevant personal protective equipment.
Hazards
Typical hazards include:
high air velocities
high voltage corona treatment systems sharp knives
high towers manual handling
fumes, humidity, air temperatures, radiant heat, hot dies 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.
blemishes, voids, gels, die and weld lines, burn marks, poor surface finish, poor colour dispersion, partially decomposed products, uneven colour, contamination of colour
alignment and control of trimming and winding gear
materials variations
worn/damaged dies and extruder adjustments
raw material contamination, wrong grade, variations of polymer properties
hydraulic pressure variations, temperature variations, loss of power or drives
process sequencing problems
variations in component speeds.
Variables
Key variables to be monitored include:
extruder operating temperatures, melt temperatures, back pressures and current (amps)
nip and winding speeds, nip roller settings
corona treatment settings
winder settings, slitters, trimmers and die gap adjustments
colour
output rate
product thickness
product integrity and general conformance to specification/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 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 follow appropriate hazard control/minimisation methods.
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.
Set up and adjust blown film line for extruder temperature, back pressures and currents, nip and winding speeds, nip roller settings, corona treatment settings, winder settings, slitters, trimmers and die gap adjustments according to specifications.
Check materials are correct.
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.
Start up blown film line as required.
Operate blown film line, noting key variables.
Monitor controls/displays/terminals for production/process data.
Monitor product thickness and quality to procedures.
Make adjustments to remedy faults and non-conformity to standard as required.
Maintain continuity of process.
Collect and reprocess/discard scrap/trim and other materials in accordance with procedures.
Clean, adjust and lubricate equipment as required.
Pause equipment, or stop equipment in an emergency, following workplace and emergency procedures.
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
PMBPROD316C - Produce blown film
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
PMBPROD316C - Produce blown film
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