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Follow the links below to find material targeted to the unit's elements, performance criteria, required skills and knowledge

Elements and Performance Criteria

1. Check work requirements.
   • Identify work requirements from production plan or request.
   • Check product, materials and equipment meet requirements for job(s).
   • Recognise requirements which may not be in accordance with usual practice.
   • Ask questions of appropriate person to confirm unusual practice.
   • Ensure housekeeping is to requirements.
   • Identify hazards associated with the job and take appropriate action.
   • Perform other pre-operational checks in accordance with procedures.
2. Operate extruder to procedures.
   • Check process is operating within required limits.
   • Check product is in specification and to required quality standard.
   • Ensure product is consistently ready for next operation.
   • Maintain supply of material(s) as required.
   • Complete logs and records as required.
   • Collect and segregate scrap, trim and other materials as required.
   • Keep equipment and work area clean.
   • Pause machine cycle and perform emergency stop, as required.
3. Change product/grade while operating as required.
   • Run down/purge outgoing grade/product to procedures.
   • Make changes specified in procedures for oncoming product/grade.
   • Introduce oncoming materials/grade and check oncoming product.
   • Undertake other actions as specified in procedures.
4. 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 out of specification products process problems and materials faults

Knowledge of organisation 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 extrusion process Application of approved hazard control safety procedures and the use of PPE in relation to handling materials equipment operation and cleanup

Knowledge of and skills in the operation of extrusion equipment and main components sufficient for consistent production of quality products including

production workflow sequences and materials demand

the reasons for checking process control panels and reporting readings which are outside of normal range of process variability

accurately monitoring equipment operation and product quality

the potential effects of variations in raw materials and equipment operation in relation to quality of product

the relationship between the type of extruder and the materials being extruded

processing behaviour of polymers and the role of additives

waste management and knowing the importance of reusing nonconforming products wherever possible

correct selection and use of equipment materials processes and procedures

explain the effect of unauthorised or emergency shutdown in relation to safety and production requirements

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

Competence also includes the ability to

plan own work including predicting consequences and identifying improvements

identify when the operator is able to rectify faults when assistance is required and who is the appropriate source for assistance

identify and describe own role and role of others involved directly in the extrusion process

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

extrusion 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 extruder in a work environment

Competence in this unit may be assessed

by using an appropriate industrialextruder

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 work environments and sectors within the plastics, rubber and cablemaking sectors. It includes the operation of all relevant ancillary equipment where that equipment is integral to the extrusion 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.

Products

These may include:

rod

sheet

film

profile

tread profile

cable.

Competence under this competency unit is only required in one process.

Materials

This unit applies to most plastic and rubber materials, including compounded PVC fed to the extruder as pellets. It does not apply to dry blended PVC powder (refer to PMBPROD334A ).

Tools and equipment

This competency includes use of equipment and tools such as:

extruder equipment and components such as main drive, gearbox, thrust assembly, adapter, gate, breaker plate, screen pack, doser, screw/s, barrel, heaters, thermocouples

extruders, either single or twin screw

extrusion dies - rod, sheet, film, pipe, profile, tread profile and cable auxiliary equipment - water pump, feeders, hopper loader, pelletiser, dehumidifiers, etc

tools for taking samples

relevant personal protective equipment.

Hazards

Typical hazards include:

vapours

burns

moving equipment

hazardous materials

manual handling hazards.

Problems

Respond to 'routine problems' means 'apply known solutions to a variety of predictable problems'. Typical process and product problems may include:

equipment malfunction

variations in materials

contamination of materials or additives

temperature/speed variations

routine product extrusion faults - dimensions, surface appearance, colour, deformations

incorrect quantity of materials.

Variables

Key variables to be monitored include:

differences between actual and set temperatures

speeds, including screw speed and haul-off

colour and uniformity

surface finish and appearance

product finished thickness

output rate

product integrity and general conformance to specification/sample.

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