Assessor Resource

PMBPROD355
Make pattern/plug for composites moulds

Assessment tool

Version 1.0
Issue Date: April 2024


This unit of competency covers the skills and knowledge required to plan and make a plug/pattern from which composite moulds can be made.

This unit of competency applies to experienced operators who are required to convert the specification or design into a plan for the tooling and mould, construct the plug/pattern, make adjustments to remedy faults and non-conformity and solve problems within area of responsibility.

This unit of competency applies to an experienced operator demonstrating theoretical and technical knowledge and well developed skills in situations that require some discretion and judgement. The experienced operator may work alone or as a member of a team or group and will work in liaison with other shift team members, team leader and supervisor, as appropriate.

No licensing, legislative or certification requirements apply to this unit at the time of publication.

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



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.

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Plan own work requirements

1.1

Identify equipment and processes to be used for production process and upstream and downstream operations from production plan or request

1.2

Identify and check materials required, including additives and regrind, and their amounts or percentages

1.3

Implement measures to control identified hazards in line with procedures and duty of care

1.4

Identify requirements for materials, quality, and production and equipment checks

2

Plan and set up plug/pattern construction to procedures

2.1

Produce a plan for the plug/pattern according to requirements

2.2

Plan all steps of the plug/pattern construction

2.3

Identify check points for measurements and tests

2.4

Identify and locate a work area, tools, materials and equipment for construction

2.5

Complete pre-start checks

3

Construct the plug/pattern to procedures

3.1

Start plug/pattern construction process, noting key variables

3.2

Take samples as required and identify product out-of-specification

3.3

Monitor plug/pattern conformity to requirements

3.4

Make adjustments to remedy faults and non-conformity as required

3.5

Complete construction process

3.6

Treat, prepare and repair the surface of the plug/pattern as necessary

3.7

Adjust process to minimise scrap and trim

3.8

Clean and adjust equipment as required

4

Respond to problems

4.1

Recognise a problem or a potential problem

4.2

Determine problems needing priority action

4.3

Refer problems outside area of responsibility to appropriate person, with possible causes

4.4

Seek information and assistance as required to solve problems

4.5

Solve problems within area of responsibility

4.6

Follow through items initiated until final resolution has occurred

Evidence required to demonstrate competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria and demonstrate the ability to:

read and interpret product specifications, job sheets and material labels

plan the plug/pattern according to requirements

plan and sequence steps to construct the plug/pattern

prepare equipment, tools and materials to meet specifications

construct and check/test the plug/pattern

monitor key variables, including:

actual and set temperatures

colour and uniformity

surface finish/appearance

times (including curing rates)

product weight and output rate product integrity and

general conformance to specification

make adjustments to remedy faults and non-conformity

identify hazards and apply relevant hazard controls

apply safety procedures

apply housekeeping procedures

apply waste management procedures

recognise early warning signs of equipment/processes needing attention or with potential problems

distinguish between causes of problems, including:

operational problems

equipment malfunction/wear

materials properties

raw material variations/contamination

procedural errors

recognise and prioritise problems requiring action

resolve routine and non-routine problems

communicate effectively with team/work group and supervisors

complete workplace records

do basic arithmetical manipulations, including additions, subtractions, divisions, fractions and percentages.

Must provide evidence that demonstrates knowledge relevant to their job sufficient to operate independently and to solve routine and non-routine problems, including knowledge of:

common composite moulding processes and function and operating principles of the moulding equipment

characteristics of materials and their behaviour in relation moulding process conditions and stages of production

moulding process variables that affect plug/pattern construction and materials

product requirements that affect plug/pattern construction and materials

common options/adjustments in plug/pattern construction and materials and their impact on product quality and production output

quality requirements at each stage of construction

factors which may affect plug/pattern quality and appropriate remedies

non-routine problems that may arise, the range of possible causes and appropriate actions

organisation procedures relevant to the work environment/job role

hierarchy of control

hazards that may arise in the job/work environment and:

their possible causes

potential consequences

appropriate risk controls.

The unit should be assessed holistically and the judgement of competence shall be based on a holistic assessment of the evidence.

Where the assessee does not currently possess evidence of competency in PMBPROD247 Hand lay up composites and MEM09002B Interpret technical drawing, one or both may be co-assessed with this unit.

The collection of performance evidence is best done from a report and/or folio of evidence drawn from:

a single project which provides sufficient evidence of the requirements of all the elements and performance criteria

multiple smaller projects which together provide sufficient evidence of the requirements of all the elements and performance criteria.

A third-party report, or similar, may be needed to testify to the work done by the individual, particularly when the project has been done as part of a project team.

Assessment should use a real project in an operational workplace. Where this is not possible or where personal safety or environmental damage are limiting factors assessment must occur using a sufficiently rigorous simulated environment that reflects realistic operational workplace conditions. This must cover all aspects of workplace performance, including environment, task skills, task management skills, contingency management skills and job role environment skills.

Assessment in a simulated environment should use evidence collected from demonstration of skills and one or more of:

walk-throughs

pilot plant operation

industry based case studies/scenarios

‘what ifs’.

Knowledge evidence may be collected concurrently with performance evidence or through an independent process, such as workbooks, written assessments or interviews.

Assessment processes and techniques must be appropriate to the language, literacy and numeracy requirements of the work being performed and the needs of the candidate.

Conditions for assessment must include access to all tools, equipment, materials and documentation required, including relevant workplace procedures, product and manufacturing specifications associated with this unit.

The regulatory framework will be reflected in workplace policies and procedures and is not required to be independently assessed.

Foundation skills are integral to competent performance of the unit and should not be assessed separately.

Assessors must satisfy the assessor competency requirements that are in place at the time of the assessment as set by the VET regulator.

In addition the assessor or anyone acting in subject matter expert role in assessment shall demonstrate both technical competency and currency. If the assessor cannot demonstrate technical competency and currency they shall assess with a subject matter expert who does meet these requirements.

Technical competence can be demonstrated through one or more of:

relevant VET or other qualification/Statement of Attainment

appropriate workplace experience undertaking the type of work being assessed under routine and non-routine conditions

appropriate workplace experience supervising/evaluating the type of work being assessed under routine and non-routine conditions

Currency can be demonstrated through one or more of:

being currently employed undertaking the type of work being assessed

being employed by the organisation undertaking the type of work being assessed and having maintained currency in accordance with that organisation’s policies and procedures

having consulted/had contact with an organisation undertaking the type of work being assessed within the last twelve months, the consultation/contact being related to assessment

conducting on the job training/assessments of the type of work being assessed

being an active member of a relevant professional body and participating in activities relevant to the assessment of this type of work.


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.

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Plan own work requirements

1.1

Identify equipment and processes to be used for production process and upstream and downstream operations from production plan or request

1.2

Identify and check materials required, including additives and regrind, and their amounts or percentages

1.3

Implement measures to control identified hazards in line with procedures and duty of care

1.4

Identify requirements for materials, quality, and production and equipment checks

2

Plan and set up plug/pattern construction to procedures

2.1

Produce a plan for the plug/pattern according to requirements

2.2

Plan all steps of the plug/pattern construction

2.3

Identify check points for measurements and tests

2.4

Identify and locate a work area, tools, materials and equipment for construction

2.5

Complete pre-start checks

3

Construct the plug/pattern to procedures

3.1

Start plug/pattern construction process, noting key variables

3.2

Take samples as required and identify product out-of-specification

3.3

Monitor plug/pattern conformity to requirements

3.4

Make adjustments to remedy faults and non-conformity as required

3.5

Complete construction process

3.6

Treat, prepare and repair the surface of the plug/pattern as necessary

3.7

Adjust process to minimise scrap and trim

3.8

Clean and adjust equipment as required

4

Respond to problems

4.1

Recognise a problem or a potential problem

4.2

Determine problems needing priority action

4.3

Refer problems outside area of responsibility to appropriate person, with possible causes

4.4

Seek information and assistance as required to solve problems

4.5

Solve problems within area of responsibility

4.6

Follow through items initiated until final resolution has occurred

This field allows for different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.

Regulatory framework

The latest version of all legislation, regulations, industry codes of practice and Australian/international standards, or the version specified by the local regulatory authority, must be used.

Applicable legislation, regulations, standards and codes of practice include:

health, safety and environmental (HSE) legislation, regulations and codes of practice relevant to the workplace, manual handling and hazardous materials

Australian/international standards relevant to the materials being used and products being made

any relevant licence and certification requirements.

All operations to which this unit applies are subject to stringent HSE requirements, which may be imposed through state/territory or federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between performance criteria and such requirements the legislative requirements take precedence.

Procedures

All operations must be performed in accordance with relevant procedures.

Procedures are written, verbal, visual, computer-based or in some other form, and include one or any combination of:

emergency procedures

work instructions

standard operating procedures (SOPs)

safe work method statements (SWMS)

formulas/recipes

batch sheets

temporary instructions

any similar instructions provided for the smooth running of the plant.

Tools and equipment

Tools and equipment include:

hand tools

power tools

hand mixing equipment and stirrers

hand application tools (e.g. rollers, trowels, brushes and filleting tools)

ancillary equipment that is integral to the process.

Additional tools and equipment will be selected as required from:

hoists/lifting equipment not requiring any special permits or licences

manual handling aids, such as hand carts and trolleys

relevant personal protective equipment (PPE).

Hazards

Hazards must be identified and controlled. Identifying hazards requires consideration of:

weight, shape, volume of materials to be handled

hazardous products and materials

flammability

rotational equipment or vibration

sharp edges, protrusions or obstructions

slippery surfaces, spills or leaks

smoke, dust, vapours or other atmospheric hazards

high temperatures

electricity

gas

gases and liquids under pressure

structural hazards

equipment failures

machinery, equipment and product mass

other hazards that might arise.

Problems

Non-routine problems must be resolved by applying operational knowledge to develop new solutions, either individually or in collaboration with relevant experts, to:

determine problems needing action

determine possible fault causes

develop solutions to problems which do not have a known solution

follow through items initiated until final resolution has occurred

report problems outside area of responsibility to designated person.

Non-routine problems are unexpected problems or variations of previous problems and include one or more of:

emergency situations

release agents failure

mould release failure

warping or cracking after moulding

structural strength, rigidity and stability of the tooling

dimensional accuracy of the tooling

allowances in the design for shrinkage, deformations and alterations in the process from tooling to mould to finished composite product

intermittent faults.

Operational knowledge includes one or more of:

procedures

training

technical information, such as journals and engineering specifications

remembered experience

relevant knowledge obtained from appropriate people.

Evidence required to demonstrate competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria and demonstrate the ability to:

read and interpret product specifications, job sheets and material labels

plan the plug/pattern according to requirements

plan and sequence steps to construct the plug/pattern

prepare equipment, tools and materials to meet specifications

construct and check/test the plug/pattern

monitor key variables, including:

actual and set temperatures

colour and uniformity

surface finish/appearance

times (including curing rates)

product weight and output rate product integrity and

general conformance to specification

make adjustments to remedy faults and non-conformity

identify hazards and apply relevant hazard controls

apply safety procedures

apply housekeeping procedures

apply waste management procedures

recognise early warning signs of equipment/processes needing attention or with potential problems

distinguish between causes of problems, including:

operational problems

equipment malfunction/wear

materials properties

raw material variations/contamination

procedural errors

recognise and prioritise problems requiring action

resolve routine and non-routine problems

communicate effectively with team/work group and supervisors

complete workplace records

do basic arithmetical manipulations, including additions, subtractions, divisions, fractions and percentages.

Must provide evidence that demonstrates knowledge relevant to their job sufficient to operate independently and to solve routine and non-routine problems, including knowledge of:

common composite moulding processes and function and operating principles of the moulding equipment

characteristics of materials and their behaviour in relation moulding process conditions and stages of production

moulding process variables that affect plug/pattern construction and materials

product requirements that affect plug/pattern construction and materials

common options/adjustments in plug/pattern construction and materials and their impact on product quality and production output

quality requirements at each stage of construction

factors which may affect plug/pattern quality and appropriate remedies

non-routine problems that may arise, the range of possible causes and appropriate actions

organisation procedures relevant to the work environment/job role

hierarchy of control

hazards that may arise in the job/work environment and:

their possible causes

potential consequences

appropriate risk controls.

The unit should be assessed holistically and the judgement of competence shall be based on a holistic assessment of the evidence.

Where the assessee does not currently possess evidence of competency in PMBPROD247 Hand lay up composites and MEM09002B Interpret technical drawing, one or both may be co-assessed with this unit.

The collection of performance evidence is best done from a report and/or folio of evidence drawn from:

a single project which provides sufficient evidence of the requirements of all the elements and performance criteria

multiple smaller projects which together provide sufficient evidence of the requirements of all the elements and performance criteria.

A third-party report, or similar, may be needed to testify to the work done by the individual, particularly when the project has been done as part of a project team.

Assessment should use a real project in an operational workplace. Where this is not possible or where personal safety or environmental damage are limiting factors assessment must occur using a sufficiently rigorous simulated environment that reflects realistic operational workplace conditions. This must cover all aspects of workplace performance, including environment, task skills, task management skills, contingency management skills and job role environment skills.

Assessment in a simulated environment should use evidence collected from demonstration of skills and one or more of:

walk-throughs

pilot plant operation

industry based case studies/scenarios

‘what ifs’.

Knowledge evidence may be collected concurrently with performance evidence or through an independent process, such as workbooks, written assessments or interviews.

Assessment processes and techniques must be appropriate to the language, literacy and numeracy requirements of the work being performed and the needs of the candidate.

Conditions for assessment must include access to all tools, equipment, materials and documentation required, including relevant workplace procedures, product and manufacturing specifications associated with this unit.

The regulatory framework will be reflected in workplace policies and procedures and is not required to be independently assessed.

Foundation skills are integral to competent performance of the unit and should not be assessed separately.

Assessors must satisfy the assessor competency requirements that are in place at the time of the assessment as set by the VET regulator.

In addition the assessor or anyone acting in subject matter expert role in assessment shall demonstrate both technical competency and currency. If the assessor cannot demonstrate technical competency and currency they shall assess with a subject matter expert who does meet these requirements.

Technical competence can be demonstrated through one or more of:

relevant VET or other qualification/Statement of Attainment

appropriate workplace experience undertaking the type of work being assessed under routine and non-routine conditions

appropriate workplace experience supervising/evaluating the type of work being assessed under routine and non-routine conditions

Currency can be demonstrated through one or more of:

being currently employed undertaking the type of work being assessed

being employed by the organisation undertaking the type of work being assessed and having maintained currency in accordance with that organisation’s policies and procedures

having consulted/had contact with an organisation undertaking the type of work being assessed within the last twelve months, the consultation/contact being related to assessment

conducting on the job training/assessments of the type of work being assessed

being an active member of a relevant professional body and participating in activities relevant to the assessment of this type of work.

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 to be used for production process 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, and production and equipment checks 
Produce a plan for the plug/pattern according to requirements 
Plan all steps of the plug/pattern construction 
Identify check points for measurements and tests 
Identify and locate a work area, tools, materials and equipment for construction 
Complete pre-start checks 
Start plug/pattern construction process, noting key variables 
Take samples as required and identify product out-of-specification 
Monitor plug/pattern conformity to requirements 
Make adjustments to remedy faults and non-conformity as required 
Complete construction process 
Treat, prepare and repair the surface of the plug/pattern as necessary 
Adjust process to minimise scrap and trim 
Clean and adjust equipment as required 
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

PMBPROD355 - Make pattern/plug for composites moulds
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

PMBPROD355 - Make pattern/plug for composites moulds

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: