Assessor Resource

PMBPROD431
Trial a new, advanced or complex mould

Assessment tool

Version 1.0
Issue Date: May 2024


This unit of competency covers the skills and knowledge required to trial new, advanced or complex moulds. It applies to 'low pressure' moulds as used in rotomoulding, thermoforming and composites manufacturing.

This unit of competency applies to technicians who are required to install required tooling, prepare machines for trials, perform trial procedures and make adjustments as required.

This unit of competency applies to technicians demonstrating theoretical and technical knowledge and well developed skills in situations that require some discretion and judgement. The technicians 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

Determine trial requirements

1.1

Gather all relevant information available

1.2

Interpret job sheets or equivalent instructions correctly

1.3

Confirm machine/equipment suitability

1.4

Confirm mould state

1.5

Confirm readiness of raw materials

2

Set mould and machine

2.1

Follow safe working practices

2.2

Fit and set up mould

2.3

Set up process condition

2.4

Set machine to meet specifications and operational requirements

2.5

Dry cycle machine and mould to procedures

3

Perform mould trial

3.1

Carry out trial process following enterprise procedures

3.2

Identify and record variations from specifications

3.3

Monitor control panel and interpret test results for fluctuations, variations and trends

3.4

Determine process limitations with respect to product and production specifications

3.5

Adjust controls to ensure parameters are maintained to job specifications

4

Rectify equipment and quality problems

4.1

Identify range of faults that will affect product and production specifications

4.2

Determine changes required to tooling and equipment to meet product and production specifications

4.3

Maintain appropriate records related to machinery and equipment to enterprise standards

4.4

Identify problems

4.5

Identify worn or damaged tooling and change as required

4.6

Rectify problems that are within area of responsibility

4.7

Report problems that are outside area of responsibility to appropriate personnel

5

Complete trial

5.1

Shut down equipment as required

5.2

Record trial results

5.3

Return machine to service

5.4

Instruct machine operator

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 procedures, job specifications, material labels and safety data sheets (SDS)

determine production requirements

discuss work progress with other workers

conduct pre-start checks

start up and shut down equipment following appropriate procedures

inspect product conformance to requirements

identify and rectify routine faults

identify routine product problems and notify appropriate persons

distinguish between causes of problems, including:

operational problems

materials properties

process variables

procedural errors

store equipment, materials and product appropriately

adhere to safety requirements.

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

the impact of incorrect or faulty materials

types of products made with different processes

changes to raw materials during the process

production work flow sequences and materials demands

selection practices for equipment, materials, processes and procedures

production equipment capability

materials and process hazards

appropriate hazard control procedures

the importance of material properties and qualities

the importance of process conditions

approved procedures

appropriate action to resolve faults or report faults

start-up and shutdown procedures

safety requirements.

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

The collection of performance evidence:

should occur over a range of situations

will typically include a supervisor/third-party report or other evidence, focusing on consistent performance and problem recognition and solving. A supervisor/third-party report must be prepared by someone who has a direct, relevant, current relationship with the person being assessed and who is in a position to form a judgement on workplace performance relevant to the unit of competency

must include the use of appropriate industrial equipment requiring demonstration of operation, start and stop procedures and responding to problems

may use industry-based simulation for all or part of the unit particularly where safety, lack of opportunity or significant cost is an issue.

Assessment should occur in operational workplace situations. Where this is not possible or where personal safety or environmental damage are limiting factors assessment must occur in 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.

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

appropriate workplace experience supervising/evaluating the type of work being assessed

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

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.


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

Determine trial requirements

1.1

Gather all relevant information available

1.2

Interpret job sheets or equivalent instructions correctly

1.3

Confirm machine/equipment suitability

1.4

Confirm mould state

1.5

Confirm readiness of raw materials

2

Set mould and machine

2.1

Follow safe working practices

2.2

Fit and set up mould

2.3

Set up process condition

2.4

Set machine to meet specifications and operational requirements

2.5

Dry cycle machine and mould to procedures

3

Perform mould trial

3.1

Carry out trial process following enterprise procedures

3.2

Identify and record variations from specifications

3.3

Monitor control panel and interpret test results for fluctuations, variations and trends

3.4

Determine process limitations with respect to product and production specifications

3.5

Adjust controls to ensure parameters are maintained to job specifications

4

Rectify equipment and quality problems

4.1

Identify range of faults that will affect product and production specifications

4.2

Determine changes required to tooling and equipment to meet product and production specifications

4.3

Maintain appropriate records related to machinery and equipment to enterprise standards

4.4

Identify problems

4.5

Identify worn or damaged tooling and change as required

4.6

Rectify problems that are within area of responsibility

4.7

Report problems that are outside area of responsibility to appropriate personnel

5

Complete trial

5.1

Shut down equipment as required

5.2

Record trial results

5.3

Return machine to service

5.4

Instruct machine operator

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, equipment and production processes 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.

Equipment

Equipment includes the setting and trial of one or more of:

rotational moulding machines:

rock and roll

clamshell

vertical or up and over rotational

shuttle

swing arm

carousel

thermoforming:

wood patterns moulds

cast aluminium moulds

machined aluminium moulds

composite moulds

complex moulds

vacuum forming systems

similar systems.

Operational requirements

Operational requirements include one or more of:

mould set up and adjustment

machine speed

ratios for rotation

cycle time

external temperatures

humidity

type of heating used

cooling rates

product quality measures

any other specified requirement.

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.

Hazards

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

material spills or leaks

hazardous products and materials

manual handling hazards

stationary and moving machinery

machinery hazards

protrusions or obstructions

slippery surfaces

smoke, dust, fumes, vapours or other atmospheric hazards

humidity, air temperatures and radiant heat

noise, light and energy sources

other hazards that might arise.

Causes of faults

Causes of faults include one or more of:

materials

heat

equipment adjustment

equipment set-up.

Problems/solutions

Problems/solutions include one or more of:

selecting the right tools for a new job

using new and untried moulds

adapting the process to the new product and die/tool

observing the process to obtain useful trial data

comparing the product to the desired specification

determining the cause of non-compliances.

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 procedures, job specifications, material labels and safety data sheets (SDS)

determine production requirements

discuss work progress with other workers

conduct pre-start checks

start up and shut down equipment following appropriate procedures

inspect product conformance to requirements

identify and rectify routine faults

identify routine product problems and notify appropriate persons

distinguish between causes of problems, including:

operational problems

materials properties

process variables

procedural errors

store equipment, materials and product appropriately

adhere to safety requirements.

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

the impact of incorrect or faulty materials

types of products made with different processes

changes to raw materials during the process

production work flow sequences and materials demands

selection practices for equipment, materials, processes and procedures

production equipment capability

materials and process hazards

appropriate hazard control procedures

the importance of material properties and qualities

the importance of process conditions

approved procedures

appropriate action to resolve faults or report faults

start-up and shutdown procedures

safety requirements.

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

The collection of performance evidence:

should occur over a range of situations

will typically include a supervisor/third-party report or other evidence, focusing on consistent performance and problem recognition and solving. A supervisor/third-party report must be prepared by someone who has a direct, relevant, current relationship with the person being assessed and who is in a position to form a judgement on workplace performance relevant to the unit of competency

must include the use of appropriate industrial equipment requiring demonstration of operation, start and stop procedures and responding to problems

may use industry-based simulation for all or part of the unit particularly where safety, lack of opportunity or significant cost is an issue.

Assessment should occur in operational workplace situations. Where this is not possible or where personal safety or environmental damage are limiting factors assessment must occur in 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.

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

appropriate workplace experience supervising/evaluating the type of work being assessed

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

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.

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
Gather all relevant information available 
Interpret job sheets or equivalent instructions correctly 
Confirm machine/equipment suitability 
Confirm mould state 
Confirm readiness of raw materials 
Follow safe working practices 
Fit and set up mould 
Set up process condition 
Set machine to meet specifications and operational requirements 
Dry cycle machine and mould to procedures 
Carry out trial process following enterprise procedures 
Identify and record variations from specifications 
Monitor control panel and interpret test results for fluctuations, variations and trends 
Determine process limitations with respect to product and production specifications 
Adjust controls to ensure parameters are maintained to job specifications 
Identify range of faults that will affect product and production specifications 
Determine changes required to tooling and equipment to meet product and production specifications 
Maintain appropriate records related to machinery and equipment to enterprise standards 
Identify problems 
Identify worn or damaged tooling and change as required 
Rectify problems that are within area of responsibility 
Report problems that are outside area of responsibility to appropriate personnel 
Shut down equipment as required 
Record trial results 
Return machine to service 
Instruct machine operator 

Forms

Assessment Cover Sheet

PMBPROD431 - Trial a new, advanced or complex mould
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

PMBPROD431 - Trial a new, advanced or complex mould

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: