Google Links

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 (recipe card).
   • Check equipment and materials including base raw materials, additives and curatives and accelerators meet requirements for job(s).
   • Plan task sequences as per procedures, including noting times for checks of product quality.
   • Identify non-conformity in materials.
   • 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. Check process set-up.
   • Check safety gates and guards are in position and working.
   • Check materials are correct.
   • Check control panel to ensure all variable settings are within procedures guidelines.
   • Complete pre-start checks.
3. Weigh materials.
   • Check scales are zeroed correctly.
   • Minimise dust and rubbish in scales and feed mechanisms.
   • Accurately weigh powders, rubber, etc, according to computer display, digital readout or other means, according to recipe card.
   • Adjust rubber feed to ensure correct quantity delivered.
4. Operate equipment to procedures.
   • Start machine safely and correctly in accordance with procedures.
   • Check to ensure mixing is occurring appropriately according to equipment operating temperature, speed, amperages and pressures.
   • Monitor control panel in accordance with procedures.
   • Complete logs and records as required.
   • Notify Dump Mill Operators when the cycle is close to completion.
   • Pause machine cycle and perform emergency stop, as required.
5. Liaise with dump mill operator.
   • Advise dump mill operator that compound/batch is being made.
   • Ensure that batch is sampled and correctly labelled.
   • Communicate any non-routine process or product events to required personnel.
6. 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 knowledge of the materials equipment and process sufficient to recognise out of specification products process problems and materials faults For example

A knowledge of organization procedures relevant regulatory requirements and the ability to implement them within appropriate time constraints and work standards For example

Application of the knowledge of managing risks using the hierarchy of controls applied to operate an internal mill blender Application of approved hazard control and safety procedures and the use of PPE in relation to handling materials equipment operation and cleanup

Show knowledge of and skills in theoperation of an internal mill blender and its maincomponents sufficient for the consistent production of quality products including

production workflow sequences and materials demand

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

accurately monitoring equipment operation and product quality

the potential effects of variations in materials quantities temperature and equipment etc in relation to quality of product

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 remedieshazard policies and procedures

issue resolution procedures

guidelines relating to the safe use of machinery and equipment

quality assurance procedures where existing

security procedures

waste pollution and recycling management processes

emergency procedures

reporting of accidents and incidents within regulatory requirements and following workplace procedures

appropriate workplace language and communication technologies

manufacturer specifications

supplier andor client instructions

materials safety data sheets

Competence also includes the ability to

plan own work including predicting consequences and identifying improvements

identify the role friction plays in the blending of product

describe causes and effects of variations in blended batches

identify and describe own role and the roles of others involved in the open mill blender process

Language literacy and numeracy requirements

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

Writing is required to the level of completing workplace forms

Basic numeracy is also required for example to measure quantities of raw materials additives etc to be blended calculate volumes from formulae measure and extract an exact quantity of compound from the mixed product for a sample to be tested

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 required skills an knowledge to operate an internal mill blender

apply approved procedures

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

Assessment method and context

Assessment will occur on an internal mill blender and will be undertaken in a work like environment

Competence in this unit may be assessed

by using an appropriate internal mill blending 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

---

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 the operation of 'Shaw Intermix', 'Banbury' and similar internal mill mixers in work environments specific to the rubber sector. It includes the operation of all relevant additional equipment where that equipment is integral to the blending process. It excludes shifting of materials and rubber compounds by forklift.

This competency would typically apply to the mixing of rubbers or plastics, but may be applied to other materials mixed in an internal 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.

Tools and equipment

This competency includes use of equipment and tools such as:

hoppers and other material feeding equipment

manual hoists/lifting equipment not requiring any special permits or licences

bung spanners and similar

bale hooks

basic hand tools required for opening of material packaging

relevant personal protective equipment.

Hazards

Typical hazards include:

restricted spaces

heat

hazardous chemicals

dust/fumes

moving machinery hazards

manual handling hazards

knife hazards.

Problems

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

contamination of materials and/or additives

non adherence to recipe mix or sequence specifications

incorrect machine set-up

inadequate/excessive mixing time

float pressure

out of specification product

incorrect quantity of materials and/or additives.

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

---