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Elements and Performance Criteria

1. Identify electrical/ electronic control system problems.
   • Categorise the types of machine malfunctions due to electrical/electronic faults.
   • Describe the effects on product quality of electrical/electronic problems.
   • Isolate possible faulty components from a circuit diagram and knowledge of the function of each component.
2. Implement appropriate corrective action.
   • Examine other possible faults.
   • Short list possible fault causes.
   • Conduct investigations of machine, products or data to determine most likely fault cause(s).
   • Take appropriate action to ensure fault is rectified.
   • Follow up on action to ensure completion in an appropriate time frame.
   • Recheck after corrective action to ensure fault has been rectified.
3. Identify maintenance requirements.
   • Check manufacturer instructions to determine recommended maintenance schedule.
   • Check fault and maintenance history to determine adequacy of current regime and special requirements.
   • Determine criticality of machine to production/business.
   • Develop maintenance schedule/requirements for machine.
   • Liaise with all relevant stakeholders to ensure schedule is appropriate.
   • Report outcome to appropriate personnel.
4. Identify electronic control system problems.
   • Categorise the types of machine malfunctions due to electronic control system faults.
   • Describe the effects on product quality of electronic control system problems.
   • Isolate possible faulty components from a circuit diagram and knowledge of the function of each component.

Required Skills

This describes the essential skills and knowledge and their level required for this unit

Knowledge and understanding of the process and the interaction of process conditions on product quality sufficient to recognise and analyse control system faults

Knowledge of organisation procedures and policies along with the ability to implement them within appropriate time constraints and in a manner relevant to the job

Application of the knowledge of managing risks using the hierarchy of controls applied to the process Application of approved hazard control safety procedures use of PPE in relation to handling materials equipment operation and clean up

Knowledge as a basis for solving electronic control system problems including

fundamentals of electricity and electronics

electronic circuit diagrams

principles of electronic circuit components

principles of PLC programming troubleshooting and diagnosis

appropriate testing procedures and use of equipment for a range of equipment faults

urgency and timeliness factors in planning maintenance activities in relation to production requirements

collection analysis and reporting of data

Competence also includes the ability to

identify and select testing methods based on cost and time effectiveness

conduct inspections checks and tests on equipment as appropriate

read and interpret circuit diagrams for mechanical hydraulic pneumatic and electricalelectronic operating systems

use technical information and manufacturer information to locate relevant data

interpret technical specifications and manufacturer instructions

ensure workplace is safe for testing and maintenance of equipment

identify hazards of the materials and process

implement appropriate procedures for hazard control

use PPE safely handle products and materials read relevant safety information and apply safety precautions appropriate to the task

Language literacy and numeracy requirements

This unit requires the ability to read and interpret technical specifications and manufacturer manuals

Writing is required to the level of writing procedures and schedules Basic numeracy is also required to allow the interpretation of machine and product data and the comparison of actual with desired readings

Evidence Required

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

It is preferred that assessment takes place on industrial equipment in a work environment

Critical aspects for assessment and evidence required to demonstrate competency in this unit

It is essential that competence is demonstrated in the ability to

recognise potential situations requiring action and then in implementing appropriate action

Consistent performance should be demonstrated For example look to see that

machine reliability is high

Assessment method and context

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

Competence in this unit may be assessed

on a processing plant allowing for operation under all normal and a range of abnormal conditions

in a situation allowing the generation of evidence of the ability to recognise anticipate and solve problems

by using a suitable simulation andor a range of case studiesscenarios

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 practicalsimulation 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 studiesscenarios 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

Additional resources might include the provision of equipment with known faultsproblems to allow for assessment of the ability to identify problems

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Range Statement

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 all common equipment used in the manufacturing industry and should be able to be applied to all equipment using electrical/ electronic control systems.

This competency applies to all work environments and sectors within the manufacturing industry. It assumes an understanding of the operation of all relevant equipment and processes but does not necessarily require them to be used personally.

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:

application and programming of PLC (programmable logic controls) and ancillaries

application of solid-state control/switching units

switches, relays and solenoids

position and pressure transducers

temperature controllers.

Hazards

Typical hazards include:

electricity

temperature from hot surfaces and equipment

malfunctioning equipment

test equipment.

Problems

Respond to/rectify 'non-routine problems' means 'apply known solutions to a variety of predictable problems'.

Typical process and product problems may include:

loss of flow, power

power failure

component malfunction

poor maintenance procedures

regular maintenance

shutdown

motor failure effect on cycle time

short shots

loss of clamp pressure

no power

electronic/electrical faults

analysis with PLC.

Variables

Key variables to be monitored include:

temperatures

cleanliness

poor performance

safety aspects.

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