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Elements and Performance Criteria

1. Check work requirements.
   • Identify work requirements from production plan.
   • Identify product, materials and equipment requirements for job(s).
   • Identify hazards associated with the job and take appropriate action.
   • Check with supervisor/appropriate person if requirements are not in accordance with usual practice.
2. Conduct pre-start checks as required.
   • Check safety gates, guards and emergency stops are in position and working.
   • Check raw materials are correct.
   • Undertake other pre-start checks to procedures.
3. Check winding equipment setup.
   • Observe spool condition and tag and return non-conforming spools to procedures.
   • Check winding equipment settings and adjustments, spool size and length settings to procedures.
   • Ensure product is checked for conformity with quality requirements.
   • Tag and deal with non-conforming product to procedures
   • Thread product through the equipment and feed on to the spool.
   • Use appropriate fixing devices, methods or materials.
   • Adjust tensions and check laying pattern to procedures
   • Check emergency cut-off switches and other safety devices to procedures.
4. Operate equipment.
   • Start machine safely and correctly when required.
   • Check product/process is within required limits.
   • Check product is in specification.
   • Maintain supply of material(s) as required.
   • Complete logs and records when required.
   • Clean up equipment and work area to procedures.
   • Pause equipment, or stop equipment in an emergency, to procedures.
5. Monitor winding machine operation.
   • Monitor winding machine equipment operations noting cooling line temperatures, amperages, tensions, colour, thickness and product integrity compared to product specification.
   • Identify sections of product requiring repair and follow procedures to remedy the fault.
   • Make adjustments to remedy faults and non-conformity to specifications where applicable.
   • Collect material for reprocessing and reuse where possible, and deal with waste and scrap to procedures.
   • Complete equipment cleanup, lubrications, adjustments and waste management to procedures.
6. Complete work process.
   • Cut product and secure free ends.
   • Remove and set down reel using appropriate manual handling techniques.
   • Relocate reel and transport without damage to materials, personnel or equipment.
   • Fit new spool and recommence product winding operations.
7. Respond to routine problems to procedures.
   • Recognise known faults that occur during the operation.
   • Identify and take action on causes of routine faults.
   • Log problems as required.
   • Identify non-routine process and quality problems and take appropriate action.

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 outofspecification products process problems and materials faults

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 polystyrene shape 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 of and skills in the operation of cable winding equipment and main components sufficient for consistent production of quality products including

the function of winding equipment machine components and the materials used

the impact of winding machine cooling temperatures tension wind off speed on product quality and product output

the effect of unauthorised shutdown of equipment on the winding process

Competence also includes the ability to

plan own work sequence including identification of key checkpoints for equipment monitoring product quality checks and monitoring of supplies and downstream operations

monitor equipment operation and product quality

explain own role and the roles of others involved directly in the winding process

identify factors which may influence product quality and production output and appropriate remedies

make appropriate authorised alterations to own work plan and equipment to maintain both product quality and required production output

locate interpret and apply relevant information and maintain workplace records

identify and 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 procedures material labels and safety information as provided to operators

Writing is required to the level of completing workplace forms

Basic numeracy is required eg to determine that two kg bags are needed to make up a requirement for kg

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

recognise the importance of material properties and qualities

apply approved procedures

take appropriate action to resolve faults or report faults to appropriate personnel

explain and implement emergency shutdown procedures

Consistent performance should be demonstrated For example look to see that

cable winding production standards are met consistently

upstream and downstream communication is timely and effective

operating procedures and work instructions are read and interpreted correctly

problems are identified and appropriate action is taken ie the problem is fixed or reported

all safety procedures are followed

Assessment method and context

It is preferred that assessment takes place on an industrial cable winder in a work 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 all cable winding operations within the plastics, rubber and cablemaking sectors. It includes the operation of all relevant additional equipment where that equipment is integral to the cable winding 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:

reels and spools used in storing cable

mechanical handling equipment

computers

traverse controls

hand tools and safety equipment

mechanical and computerised measuring devices

relevant personal protective equipment

cable (eg power, single cable, multi-core)

other relevant winding/cables/products.

Hazards

Typical hazards include:

moving equipment, cable and reels

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:

incorrect reel/spool size and winding speed

quality problems

equipment failure.

Variables

Key variables to be monitored include:

differences between actual and set conditions (eg speeds, temperature)

product colour, uniformity, surface condition and appearance

output rate

product integrity and general conformance to specification.

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