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Elements and Performance Criteria

1. Identify work requirements for vulcanising operations.
   • Identify the job and vulcaniser characteristics and product quality outcomes required.
   • Obtain specifications relevant to the material being vulcanised.
   • Identify and obtain equipment and materials required for the vulcanising process.
   • Identify hazards associated with the job and take appropriate action.
   • Check materials, ancillary supplies, and equipment for quality, access and condition.
   • Identify and check emergency stops, gauges, guards and controls.
2. Plan vulcanising operations.
   • Identify time, pressure and temperature requirements.
   • Plan the task sequences
   • Plan for waste management, maintenance and housekeeping requirements.
3. Prepare vulcanising equipment.
   • Check vulcaniser, ancillary, equipment and attachments are fit for purpose.
   • Set up vulcanising press according to procedures.
   • Set equipment control parameters to specifications.
   • Obtain appropriate clearances for vulcanising to commence.
4. Conduct and monitor vulcanising operations.
   • Start the unit and commence vulcanising.
   • Monitor the unit operation throughout the entire process
   • Note and report non-conformity to specifications to procedures.
   • Make adjustments as required.
   • Shut down unit when cycle completed.
   • Follow procedure to disassemble equipment as required.
   • Assess the outcome of the vulcanising process and take remedial action as necessary and report to the appropriate person.
   • Brand splice as per company policy
   • Clean up, lubricate and adjust equipment as required.
   • Complete waste removal or recycling as required.
5. Respond to routine problems to procedure.
   • 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 organization 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 vulcanising 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 portable vulcanising equipment and main components sufficient for consistent production of quality products including

importance of correct selection and use of equipment materials processes and procedures

identifying the function of vulcanising equipment components and the materials used

describing changes to materials during the vulcanising process

explaining the impact of vulcanising speed pressure time temperature and tension on product quality and production output

describing the role of heat and pressure in relation to providing strength stiffness resistance to deformation fatigue and abrasion

explaining any differences in vulcanising processes and additives for natural synthetic and mixed rubber compounds

deciding if they the operator are able to rectify the fault or if assistance is required

explaining the effect of unauthorised or emergency shutdown of equipment on the vulcanising process

understand the underlying risks in the process and how best to manage them

Competence includes the ability to

plan own work sequence including identification of key checkpoints for equipment monitoring and product quality checks

operate equipment and monitor product quality

identify factors which may influence product quality and production output and appropriate remedies

make appropriate authorised alterations to own work plan and equipment to maintain both product quality and required production output

locate interpret and apply relevant information and maintain workplace records

identify and safely handle products and materials read relevant safety information and apply safety precautions appropriate to the task

Distinguish between causes of faults such as

equipment condition

materials eg contaminated or wrong raw materialsadditivescatalyst

process conditions eg incorrect temperatures or pressures and entrapped air in the vulcanised area

Language literacy and numeracy requirements

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

Writing is required to the level of completing workplace forms

Basic numeracy is also 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

understand the inherent risk associated with using a vulcaniser and the potential consequences of incorrect use

understand procedures

understand the importance of critical material properties and quantities

recognise potential situations requiring action

implement appropriate action and explain logic

Consistent performance should be demonstrated For example look to see that

production standards are met consistently

wire or reinforcing is not visible in the finished product

bonding is achieved in accordance with specifications

Assessment method and context

Assessment will occur on industrial equipment in a worklike environment

Competence in this unit may be assessed

by using an appropriate portable vulcanising equipment

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 rubber industry. It includes the operation of all relevant additional equipment where that equipment is integral to the vulcanising 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 unit of competency includes use of equipment and tools such as:

portable vulcanising equipment (including dispersion plates, pressure bags, edge bars, controllers)

knives and other rubber cutting and shaping equipment

hoists/lifting equipment not requiring any special permits or licences

manual handling aids such as handcarts

relevant personal protective equipment

powered equipment/aids.

Hazards

Typical hazards include:

pressure

heat and hot rubber

chemical splashes or spills

dust or vapours/fumes

manual handling hazards

knife hazards.

Task sequences

Task sequences include:

location of vulcaniser

process monitoring

quality checks.

Monitoring of vulcanisation

Monitoring of vulcanisation includes noting:

times,

vulcanisation quality,

equipment operating temperatures and times

additional pressures applied.

Problems

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

incorrect vulcaniser set-up

variations in materials

contamination of materials

unsuccessful vulcanising processes

entrapped gasses

wire or reinforcing exposure

inappropriate material specification.

Variables

Key variables to be monitored include:

heat

pressure

time

tension.

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