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Elements and Performance Criteria

1. Check work requirements.
   • Identify work requirements from production plan or request.
   • Check product, material, and equipment meet requirements for the job(s).
   • Recognise requirements which may not be in accordance with usual practice.
   • Ask questions of appropriate person to confirm unusual practice.
   • Identify hazards associated with the job and take appropriate action.
   • Perform other pre-operational checks in accordance with procedures.
2. Set up mould and materials as required.
   • Set up mould ready for production.
   • Ensure materials are available in the form and quantities required.
   • Ensure safety equipment is available and fit for use.
3. Hand lay up composites.
   • Apply materials to the mould to specification.
   • Monitor product/process quality.
   • Make adjustments or seek assistance to remedy faults and non-conformity as required.
   • Adjust work to minimise scrap and trim.
4. Respond to routine problems in accordance with 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 For example excess resin will only add weight and weaken the finished product Therefore care needs to be taken to ensure the correct resin to fibre ratio is used

Knowledge of organization procedures relevant regulatory requirements and 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 hand lay up 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 hand lay up equipment and the main components sufficient for consistent production of quality products including

production workflow sequences and materials demand

accurately monitoring equipment and product quality

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

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

correct selection and use of equipment materials processes and procedures

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

setting up moulds

preparation of resins including mixing as required

preparation of fibre reinforcement including cutting and trimming

use of composites materials including gel coats resins and fibres

methods of application of composite materials to the mould by hand lay up

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 moulding 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

Numeracy is required to the level of reading tables of figures and graphs and applying the resultant information using formula percentagesratios to determine the required mass of an additive catalyst pigment etc and similar manipulations and interpretation

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 the required skills and knowledge to the hand lay up process

apply approved procedures

Consistent performance should be demonstrated For example look to see that

composites production standards are met consistently

all safety procedures are always followed

Assessment method and context

Assessment will occur during the hand lay up process for composites and will be undertaken in a worklike environment

Competence in this unit may be assessed

through use of industrial hand lay up composite manufacture using jobs of appropriate complexity

in a situation allowing for operation under all normal and a range of abnormal conditions

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 unit includes the use of equipment and materials to form composite products using hand lay up processes. It includes the operation of all relevant additional equipment where that equipment is integral to the hand lay up 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:

open moulds for composite products

hand mixing equipment and stirrers

knives and cutters to trim fibres

hand application tools, rollers, brushes, etc

relevant personal protective equipment.

Hazards

Typical hazards include:

hazardous materials and vapours

manual handling hazards

fire hazards due to flammable nature of resins used

knife hazards

glass (and other) fibre hazards (inhalation and skin penetration)

slip hazards (spilled resin).

Problems

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

cracks, dents or imperfections of the mould

incorrect resin ratios

contamination of materials

shifting of fibres before resin laid

stacking of fibre and resin sequence problems.

Typical product problems may include:

voids

poor surface finish

colour contamination

release from mould damage.

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

Variables

Key variables to be monitored include:

ambient temperature

air flow/ventilation rate

viscosity of resin

time since resin mixed vs pot life of mix

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