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Elements and Performance Criteria

1. Set up and load creel racks according to procedures.
   • Complete set up checks.
   • Report non-conforming items.
   • Load spools onto creel rack.
   • Complete required set-up.
   • Re-check wire sequence and set-up.
2. Maintain continuous flow of cord during production.
   • Replace broken cord.
   • Reload creel racks with spools as required.
   • Crimp/join cord as required.
3. Complete operations
   • Despatch empty spools
   • Clean area and dispose of waste as required.
   • Park crane in required manner.
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 an operational 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 creel rack 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 creeling 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

waste management

correct selection and use of equipment materials processes and procedures

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

procedures and guidelines for safe operation of creel racks

typical fault conditions and related fault finding procedures

crimping techniques

quality standards and practices

OHS practices including hazard identification and control measures

workplace practices

recording and reporting practices

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 creeling moulding process

Language literacy and numeracy requirements

This unit requires the ability to read and interpret typical product specifications job sheets procedures basic machine control panels material labels and safety information as provided to operators

Writing is required to the level of completing workplace forms

Basic numeracy is required for measuring and recording data

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 apply

skills and knowledge required to operate creel rack equipment

skills and knowledge required to operate the overhead crane

approved procedures

Consistent performance should be demonstrated For example look to see that creel rack production standards are met consistently

Assessment method and context

Assessment will occur on industrial creeling equipment and will be undertaken in a worklike environment

Competence in this unit may be assessed

by using an appropriate industrial creel racklifting device

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 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 creeling operations within the industry. It includes the operation of all relevant additional equipment where that equipment is integral to the creeling 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:

spools and components of spools

ancillary equipment integral to the operation of the creel racks (does not include belt building or pressing)

hand tools used in the creel rack process

material loading/removing equipment

relevant personal protective equipment.

Set-up checks

Set-up checks includes checking:

crane components for wear

crane safety catch on hook

warning and flashing lights are operating

kinks in crane operating cable

passage for crane is clear

correct materials have been brought to creel racks on pallets that are sealed and dry

steel wire for conformity to specifications

all components are clean of dirt, oil and other contaminants.

Hazards

Typical hazards include:

broken wire

moving wire spools

moving equipment (such as spools/creel components)

manual handling hazards.

Completing set-up

Completing set-up includes:

loading top rack with wire fed from bottom of spool.

pulling wires through eyelet boards at front of creel

placing poly between creel and organiser where wire will cross floor

crimping wire using hydraulic crimping press (one to one or doubled).

Parking crane

Parking crane includes ensuring it:

is in position to avoid blocking work area / walk ways

has crane hook raised in line with OHS procedures.

Problems

'Respond to routine problems' means 'apply known solutions to a limited range of predictable problems'. Typical process problems may include:

equipment malfunction

variations in process conditions such as speed

variations in materials or contamination of materials.

Appropriate action for non-routine problems may be reporting to designated person or other action specified in the procedures.

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