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, if using styrofoam or polyurethane to construct the plug, it must be coated with an epoxy resin rather than a polyester resin because the styrofoam will dissolve. Therefore, careful attention to the combinations of the materials used needs to be made.
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 pattern/plug making 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, flow rate and time
function and processing principles of equipment, including the cost, construction, dimensional and production principles, which effect the pattern/plug making operation
impact of equipment and process speed, temperatures, and time during cycles on product quality and production output
phases of the moulding cycle and the effect of the key variables on product quality, in order to make appropriate adjustments to equipment settings. For example, the plug can be constructed of almost any material, but the finishing phase is the most important phase that will impact the moulded products made with the plug.
processing behaviour of those polymers which are moulded at the workplace
waste management and importance of non-conforming materials
changes to materials at various stages of production
impact of variations in raw materials and equipment operation in relation to final product.
Competence includes the ability for the practical completion of the job to:
plan own work, including predicting consequences and identifying improvements
maintain output and product quality using appropriate instruments, controls, and test information
identify and describe own role and role of others involved directly in making pattern/plugs for composite moulds
identify factors which may affect product quality or production output and appropriate remedies
identify when the 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.
Numeracy is required to the level of determining required weights/volumes of materials in a resin mix for different circumstances (say using a data sheet), number of layers of impregnated matrix required to yield the required product laminate thickness, and similar activities.
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 includes the use of equipment and materials to construct plugs/patterns from which composite moulds will be made. It includes the operation of all relevant additional equipment where that equipment is integral to the plug making 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 and power tools for use with composite and other materials (eg sheet metal and timber)
hand mixing equipment and stirrers
hand application tools (eg rollers, trowels, brushes, filleting tools)
finishing materials (eg gelcoat and acrylic finishes, paints)
construction materials (eg timber, styrofoam, and fibreglass)
relevant personal protective equipment.
Hazards
Typical hazards include:
spills
slip and fall
hand and power tools
temperature
toxic fumes/vapours (such as styrene in resins)
hazardous materials (such flammable 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 routine faults may include:
gel coat sag
slow curing rates
blistering
wrinkles
pinholes
brush marks
poor surface finish.
Non-routine faults, which may have multiple causes may include:
release agents failure
mould release failure
warping or cracking after moulding.
Typical process and product problems may include:
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
placement of flanges, closures, fitments, supports, struts and stiffeners
variations in materials and/or contamination of materials.
Appropriate action for problems outside of area of responsibility may be reporting to an appropriate person.
Appropriate action for solving problems within area of responsibility includes asking questions and seeking assistance from appropriate persons/sources.
Variables
Key variables to be monitored include:
differences between 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 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