This competency is typically performed by advanced operators applying knowledge of materials, product purpose and process in the production of composite products by pultrusion equipment. This competency also requires the use of a range of well developed skills, requiring some discretion and judgement to recognise and resolve a range of problems.
The operator will:
start up pultrusion equipment.
identify and plan own work requirements from production requests.
set up equipment, pullers, dies and formers
monitor equipment operation
make appropriate adjustments to correct materials, equipment or process variations.
deal with non-conforming products, waste and scrap
solve routine and non-routine composites forming equipment and process problems, seeking guidance where necessary or appropriate.
This competency covers preparation and operations for forming composite products using pultrusion processes 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 PMBPROD292B Operate pultrusion equipment.
Employability Skills
This unit contains employability skills.
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.
Where the assessee does not currently possess evidence of competency in PMBPROD292B Operate pultrusion 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 pultrusion composites process characteristics in relation to the process requirements and the end product
make adjustments to the process as required
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
Assessment will occur on an industrial pultrusion machine(s) equipment and will be undertaken in a work-like environment.
Competence in this unit may be assessed:
using an appropriate, operating plant requiring demonstration of start-up, operation and shutdown procedures
in a situation allowing for the generation of evidence of the ability to recognise, anticipate and 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, quality requirements at each production stage and relevant regulatory requirements and 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 pultrusion 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
properties of the materials required to form a composite structure of the required strength and surface finish
function and operating principles of equipment, machine components and ancillary equipment
adjustments to bring process on line
impact of machine speed, temperature, pressure, on product quality and production output
nature of mechanical, hydraulic, pneumatic, electrical and electronic principles which effect machine operation and product development
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
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 process
identify factors which may affect product quality or production output and appropriate remedies
identify when assistance is required to solve problems
set up dies, pullers or formers
use composites materials including release agents, resins and fibre reinforcement
use of surface finishing equipment
operation of equipment including PLC controls
curing of products including application of wraps, heat or pressure.
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, quality assurance records and production reports.
Numeracy is required to the level of determining required weights/volumes of materials in a resin mix for different circumstances (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 applies to the production of composite products by pultrusion processes. It includes the operation of all relevant additional equipment where that equipment is integral to the composites forming 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:
dies, formers
hand tools, eg knives, cutters
equipment for pultrusion and curing
relevant personal protective equipment.
Hazards
Typical hazards include:
spills
dust/vapours
slip and fall
hazardous substances (including resins and catalyst)
manual handling hazards
moving equipment
temperature (such as hot equipment or product)
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 i) do not have a known solution, ii) a solution recorded in the procedures.
Typical process and product problems may include:
die/tooling problems such as cracks, dents or imperfections
variations in materials, colour, consistency or mix
adjustment and settings of the equipment
curing conditions
variations in material properties and/or contamination of materials
variation in material flow rates
processing problems.
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:
operating temperatures
speed
colour and uniformity
cycle time
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 the most appropriate 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.
Implement measures to control identified hazards in line with procedure and duty of care.
Identify requirements for materials, quality, production and equipment checks.
Identify process settings required for products.
Set process to required settings.
Check materials, resins and fibres are correct.
Set up date, batch and materials markings to specifications, as required.
Complete pre-start checks.
Start up pultrusion process.
Operate pultrusion process noting key variables.
Monitor controls/displays/terminals for production and process data.
Take samples as required and identify product out of specification.
Monitor product/process quality.
Make adjustments to remedy faults and nonconformity to standard as required.
Establish a stable pultrusion process.
Adjust process to minimise scrap and waste.
Clean, adjust and lubricate equipment as required.
Determine type of shut down.
Select appropriate cleaning method.
Clean efficiently and adequately as required.
Leave machine in appropriate condition and with appropriate locks, tags or notices.
Complete relevant documentation.
Ensure area is clean and clear after shutdown, in readiness for the next start-up.
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 problem within area of responsibility.
Follow through items initiated until final resolution has occurred.
Forms
Assessment Cover Sheet
PMBPROD392B - Produce composites using pultrusion
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
PMBPROD392B - Produce composites using pultrusion
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