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Elements and Performance Criteria

1. Identify production requirements.
   • Read specifications and standard operating procedures for production run and equipment.
   • Identify materials required.
   • Note production control requirements for production and warm up time, pressure(s), speed(s), temperature(s) and product specifications.
   • Note key stages in the process for quality checks.
   • Identify equipment and components required.
   • Check assembly requirements for items of production and downstream equipment or specialised componentry to ensure efficient work flow will occur.
2. Set up equipment
   • Check work area to ensure adequate space for the process.
   • Place equipment and components in required configuration.
   • Install guards, warning devices and cut-offs as required.
   • Check all connecting components and services for integrity and effectiveness.
   • Check dies/ moulds/jigs as required for suitability for production requirements.
   • Place standard operating procedures and quality procedures in appropriate work stations.
   • Check work area for operator ergonomic efficiency, access and egress requirements.
3. Explain process to operators when required
   • Explain particular requirements for machine adjustments, materials characteristics, quality specifications and key production stages to the operator.
   • Explain standard operating procedures and any particular OHS issues are identified.
   • Identify and explain appropriate contingency strategies for process faults, quality, OHS issues, materials supply or quality machine malfunctions.
   • Encourage operators to ask questions and clarify procedures.
4. Produce first-off production sample(s).
   • Start process following standard operating procedures.
   • Observe product quality through process and compare to standards.
   • Compare machine setting ranges to documented requirements.
   • Use observations of the process outcomes to fine tune the settings and other production variables.
   • Check final product for the required standards.
   • Compare standard operating procedures with actual production run and note variances.
5. Fine tune the process.
   • Use information collected during trial to modify workplace documentation, including standard operating procedures, machine settings and process instructions.
   • Obtain appropriate advice and permission where variations are outside of quality or specification range.
   • Advise operators of variations to process and document as required.

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 organisation 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

quality requirements at each production stage

function and operating principles of equipment machine components and ancillary equipment

impact of machine speed temperature pressure time during cycles on product quality and production output

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 nonconforming materials

identify impact of mechanical hydraulic pneumatic and electricalelectronic principles of the production process

distinguish particular requirements of products materials equipment and production process

identify likely faults and remedies

recognise focus of operation of work systems and equipment

assess production workflow and the relationships with equipment materials and product storage areas and workplace rosters and order systems

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

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 factors which may affect product quality or production output and appropriate remedies

identify hazards of the materials and process

implement appropriate procedures for hazard control

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 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 a run

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

identify equipment and components by name and operating principles and function and to locate interpret and apply relevant information

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

identify critical materials properties and 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 using industrial equipment 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

basic hand tools required for opening of material packaging

material loading equipment used for loading of raw materials

relevant personal protective equipment.

Hazards

Typical hazards include:

inadequate use of guards and warning signs

manual handling hazards

hazardous materials

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 do not have a known solution/a solution recorded in the procedures.

Typical process and product problems may include:

variations in materials

faulty components

machine malfunction

variation in product

contamination of materials

processing problems.

Variables

Key variables to be monitored include:

variations in the timing of machine cycles

variations in the sequence of product availability

variations in the quality of the raw materials

product integrity and general conformance to specification/sample.

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