- PMBPROD398B - Produce composites using pre-pregs
Assessor Resource
PMBPROD398B
Produce composites using pre-pregs
Assessment tool
Version 1.0
Issue Date: April 2024
Application of this unit
This competency applies to advanced operators who are required to apply knowledge of materials, product purpose and processes to the operation of equipment for the production of composites using pre-pregs. 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 composites production equipment and process problems, seeking guidance where necessary or appropriate
completing logs and reports.
This competency covers the operation of equipment using pre-pregs to make composite products 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 has the prerequisite of PMBPROD298A Operate equipment using pre-pregs material.
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 PMBPROD298A Operate equipment using pre-pregs material, 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 composites moulding 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 pre-pregs and equipment and will be undertaken in a work-like environment.
Competence in this unit may be assessed:
using an appropriate, industrial pre-preg and equipment
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 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 pre-preg 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:
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 composites forming equipment, machine components and ancillary equipment
impact of temperature, pressure, time during cycles on product quality and production output
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
make adjustments to equipment operation to rectify variations in equipment operation or product quality
check composites forming equipment for correct set-up to job specifications and implement adjustments or report deviations immediately
make measurements when required and identify product out of specification
distinguish between causes of faults
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 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.
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 applies to manufacture of composites products using pre-pregs within the plastics and rubber industries.
It includes all moulds, pumps and programmable logic controllers (PLCs) if fitted and all relevant ancillary equipment 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:
moulds, formers, closures and fittings
equipment including presses and ancillaries
controller, such as PLC if fitted
relevant personal protective equipment (PPE)
hand tools used in the production process
material loading equipment used for loading of raw materials
release films and fabrics
pre-pregs.
Hazards
Typical hazards include:
hazardous vapours and materials
fibres, airborne and handled
humidity, air temperatures, radiant heat, hot moulds
stationary and moving machinery, parts and components
manual handling hazards.
Problems
Respond to/rectify 'non-routine problems' means 'apply known solutions to a variety of predictable problems'.
Typical process and product problems may include:
pre-preg incorrectly applied to mould
release agents performance
contamination
temperature variations, affecting resin cure-rate
blemishes
missing detail
warped moulds or dies
worn or damaged mould parts or fittings
variations in materials and/or contamination of materials
processing
heat
poor handling or storage of pre-pregs
equipment - adjustments/set-up
equipment - maintenance requirements incorrect quantity of materials
contaminated materials.
Variables
Key variables to be monitored include:
operating temperatures
cycle time
output rate
surface finish and condition
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, 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. | |||
Adjust control panel (eg cycle time, heating, cooling) as required for factors such as temperature, material etc. | |||
Check equipment, raw material and die/tool all match job requirements. | |||
Check materials, pre-pregs, release agents etc, 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. | |||
Start up pre-preg process | |||
Operate composites forming equipment, noting key variables. | |||
Monitor controls/displays/terminals for production/process data. | |||
Monitor product/process quality, thickness and integrity to procedures. | |||
Make adjustments to remedy faults and nonconformity to standard as required. | |||
Maintain continuity of process. | |||
Collect and reprocess/discard scrap/waste and other materials in accordance with procedures. | |||
Clean, adjust and lubricate equipment as required. | |||
Pause or stop equipment in an emergency, following procedures. | |||
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 the 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 problems within area of responsibility. | |||
Follow through items initiated until final resolution has occurred. |
Forms
Assessment Cover Sheet
PMBPROD398B - Produce composites using pre-pregs
Assessment task 1: [title]
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Result: Competent Not yet competent
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Assessment Record Sheet
PMBPROD398B - Produce composites using pre-pregs
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Assessment task 1: [title] Result: Competent Not yet competent
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Overall assessment result: Competent Not yet competent
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