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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. Start up compounding equipment to procedures.
   • Conduct pre-start checks on equipment.
   • Start up compounding equipment.
3. Operate equipment 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.
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

Knowledge and ability to implement organisation procedures and relevant regulatory requirements within appropriate time constraints and work standards

Application of the knowledge of managing risks using the hierarchy of controls applied to the compounding 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 compounding process and equipment sufficient for consistent production of quality products including

production workflow sequences and materials demand

correct selection and use of equipment materials processes and procedures

accurately monitoring equipment operation and product quality

processing behaviour of polymers and the role of additives

purpose of developing elasticity and controlling temperatures

role of friction in the compounding of product

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

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

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

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

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 the roles of others involved in the compounding 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 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

apply the required skills and knowledge to operate compounding equipment

apply approved procedures

Consistent performance should be demonstrated For example look to see that

compounding standards are met consistently

all safety procedures are adhered to

Assessment method and context

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

Competence in this unit may be assessed

by using an appropriate compounding machine requiring demonstration of operation and emergency stop procedures

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 compounding operations within the plastics, and rubber industry. It includes the operation of all relevant additional equipment where that equipment is integral to the compounding process.

It does NOT include the use of internal or open mill blenders. (see PMBPROD253B Operate an internal mill blender or PMBPROD254B Operate an open mill blender)

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. These may include:

movement of materials

opening of packages in boxes

stacking and storing of materials

basic checking of materials and equipment

basic machine operations.

Tools and equipment

This unit of competency includes use of equipment and tools such as:

compounding equipment (such as single or twin screw extruders)

components of compounding machines (such as barrels and screw assemblies)

material loading equipment used for loading of raw materials

basic hand tools (such as knives and other bag opening tool)

hoists/lifting equipment not requiring any special permits or licences

bung spanners and similar

relevant personal protective equipment.

Hazards

Typical hazards include:

spills

dusts/vapours

hazardous materials

manual handling hazards

knife hazards.

Problems

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

equipment failures

uneven mixing

variations in materials

contamination of materials

inappropriate formula selected

quantity errors.

overheating.

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

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