This competency applies to operators who are involved in the operation of thermal bending equipment (eg for acrylic, PET or PVC) monitoring production, maintaining personal safety and the safety of others within the context of required production output and product quality standards. The key factors are the setting up of sheet feed fabrication vacuum forming equipment, monitoring production 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
solving routine and non-routine equipment and process problems, seeking guidance where necessary or appropriate
completing logs and reports.
This competency covers the use of thermal bending equipment.
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 has no prerequisites.
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.
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 thermal bending process characteristics in relation to the process requirements and the end product
plan own work process within workplace procedures and explain the reasons for the steps in the process
take appropriate action to observe equipment, materials and products for out of specification results, make adjustments and identify problems to be reported.
Consistent performance should be demonstrated. For example, look to see that:
production quality and output standards are met consistently
problems are anticipated from process observations
problems are efficiently resolved
the process runs consistently and smoothly.
Assessment method and context
Assessment will occur on an industrial thermal bending machine(s) equipment and will be undertaken in a work-like environment.
Competence in this unit may be assessed:
by using an appropriate, industrial thermal bending machine requiring demonstration of operation and emergency stop procedures
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.
Application of the knowledge of managing risks using the hierarchy of controls applied to the moulding 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:
difference between materials such as PVC, acrylic and/or PET materials
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 thermal bending equipment, machine components and ancillary equipment
impact of machine speed, temperature, pressure, time during cycles on product quality and production output
nature of mechanical, hydraulic, pneumatic, electrical and electronic principles which affect machine operation and product development
thermal bending cycle and the importance of machine set-up and warm-up for effective processing of materials
safety procedures and the use of PPE in relation to handling materials, equipment operation and cleanup
the hierarchy of control, including engineering controls
changes to materials at various stages of production
waste management and importance of non-conforming materials
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
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
identify and describe own role and role of others involved directly in the thermal bending 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
distinguish between causes of faults.
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 unit covers the use of thermal bending equipment. It includes the operation of all relevant additional equipment where that equipment is integral to the thermal bending 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:
hand tools as required
relevant personal protective equipment.
Hazards
Typical hazards include:
spills
dusts/vapours
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 process and product problems may include:
incorrect angle
sag
distortion
change in appearance
contaminated materials
contaminated equipment.
Variables
Key variables to be monitored include:
operating temperatures
speed
colour
output rate
product weight
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.
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.
Plan thermal bending operations within scope of authority.
Identify materials, waste management and housekeeping needs.
Determine equipment requirements.
Set process to specifications as required.
Check thermal bending equipment settings and adjustments are as required.
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 in accordance with procedures.