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Elements and Performance Criteria

1. Select equipment and materials.
   • Identify equipment and materials from job specification.
   • Check equipment and materials for conformity to specification.
   • Note any variances in materials (within materials supplier specifications) which may require variation in production process settings.
   • Identify requirements for special tooling and set up.
   • Note conformity deficiencies and report to appropriate personnel.
   • Identify production objectives and timelines.
   • Clarify product specifications.
   • Draft work process plan, noting key quality characteristics, check points and activities where other personnel will be involved.
2. Prepare tools, equipment and materials.
   • Locate tools and equipment within workplace ensuring safety and operational checks are performed and equipment is appropriate for purpose.
   • Obtain materials specifications and confirm materials are at site for the commencement of production in accordance with established procedures.
   • Check materials are prepared to achieve product specification.
3. Set up and check production process.
   • Follow procedures for setup in accordance with workplace procedures, customer requirements and specifications.
   • Set machine control parameters in accordance with specifications.
   • Check work process plan and set up for conformity with identified workplace procedures and customer requirements.
   • Make any required adjustments to own work plan.
   • Obtain appropriate clearances for production to commence.
   • Check equipment for function and make provisional control settings.
   • Check performance of equipment and materials.
   • Adjust process settings and materials to ensure production outcomes are within quality specifications.
   • Make and store records of required adjustments within specification ranges in accordance with workplace procedures.

Required Skills

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

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 equipment machine components and ancillary equipment

impact of machine operating parameters on product quality and production output

nature of mechanical hydraulic pneumatic electrical and electronic principles which may effect machine operation and product development

assessing operational capabilities of equipment

predict materials behaviour

adjust machine parameters

assess production workflow in relation to focus of operation of work systems and equipment

identify and correctly use equipment processes and procedures

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

make adjustments to equipment operation to rectify variations in equipment operation or product quality

check equipment for correct setup to job specifications and implement adjustments or report deviations immediately

start up equipment and make appropriate adjustments to bring process on line

take samples when required and identify product out of specification

safely shut down equipment in normal or abnormal circumstances

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

identify hazards of the materials and process

implement appropriate procedures for hazard control

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

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

Numeracy is also required eg to determine quantities required for production runbatch

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

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

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

select set up and adjust equipment

arrange materials supply

inspect results of checks for equipment and materials performance

locate interpret and apply relevant information

maintain workplace records

identify and handle products and materials safely applying safety precautions appropriate to the task

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

setup conforms to organisation requirements

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 using industrial equipment and materials and will be undertaken in a worklike environment

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 for the generation of evidence of the ability to respond to 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 No other special resources are required

Access must be provided to appropriate learning andor assessment support when required Where applicable physical resources should include equipment modified for people with disabilities

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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 applies to experienced operators working either independently or as part of a work team.

Procedures

All operations are performed in accordance with procedures.

Procedures means 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 carts and trolleys

hoists/lifting equipment not requiring any special permits or licences

relevant personal protective equipment.

Hazards

Typical hazards include:

moving heavy equipment/materials items

materials spills

fumes/dusts/vapours

hazardous materials in gaseous, liquid or solid form

manual handling hazards

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 process and product problems may include:

power or equipment failures

temperature variations

variations in materials

contamination of materials

faulty functioning of equipment.

Variables

Key variables to be monitored include:

variations in the timing of machine cycles

atmospheric variations

variations in the sequence of product availability

variations in the quality of the raw materials.

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