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Elements and Performance Criteria

1. Check work requirements.
   • Identify work requirements from procedures.
   • Identify product, materials and equipment requirements for job(s).
   • Recognise hazards and take appropriate action.
   • Check with supervisor/appropriate person if requirements are not in accordance with usual practice.
2. Conduct pre-start checks as required.
   • Check safety gates and guards are in position and working.
   • Check raw materials are correct.
   • Undertake other pre-start checks to procedures.
   • Start up equipment safely and 'dry run' to warm hydraulics and components to operating temperature before production, as required.
3. Operate equipment to procedures.
   • Check condition of equipment and introduce raw materials as required.
   • Check product/process is within required limits.
   • Collect products and store as required.
   • Check product is in specification/to required quality standard.
   • Maintain supply of material(s) as required.
   • Complete logs and records when required.
   • Collect and reprocess/discard scrap/trim and other materials.
   • Clean up equipment and work area.
   • Pause equipment, or stop equipment in an emergency, as required.
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 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 injection blow moulding 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 injection blow moulding 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

processing behaviour of polymers and the role of additives

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

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 remedies

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 injection 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

Basic numeracy is required eg to determine that two kg bags are needed for 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

recognise the importance of material properties and qualities

apply approved procedures

take appropriate action to resolve faults or report faults to appropriate personnel

explain and implement emergency shutdown procedures

Consistent performance should be demonstrated For example look to see that

injection blow moulding production standards are met consistently upstream and downstream communication is timely and effective operating procedures and work instructions are read and interpreted correctly

problems are identified and appropriate action is taken ie the problem is fixed or reported

all safety procedures are followed

Assessment method and context

Assessment will occur on industrial blow moulding equipment in a worklike environment

Competence in this unit may be assessed

by using an appropriate industrial injection blow moulding 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 injection blow moulding operations within the plastics and rubber sectors. It includes the operation of all relevant additional equipment where that equipment is integral to the injection blow moulding 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:

electrical, pneumatic, mechanical, electromechanical and hydraulic injection blow moulding machines and components such as base, frame, feed hoppers and material supply mechanisms, barrel and screw plastification unit, injection blow units, die/ mould tool additional equipment, including chillers/cooling towers, die heating equipment, hopper driers, mixing hoppers, dehumidifying driers, air compressors, dosing machines, colour blending equipment and conveyors

hand tools used in the injection blow moulding process

material loading equipment used for loading of raw materials

relevant personal protective equipment.

Hazards

Typical hazards include:

spills

dusts/vapours

slip and fall, particularly due to spilt granules

temperature

hazardous substances

moving equipment

manual handling 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 malfunction

variations in temperature, pressure, speed, inflation

variations in materials or contamination of materials

mould damage

routine injection blow moulding faults - wall thinning, holes, poor surface finish, warping, poor colour dispersion, ejection damage, colour contamination, black spots and other defects

mould/tooling problems.

Variables

Key variables to be monitored include:

operating temperatures

speed

cycle time

output rate

concentration or dispersion of colour

product weight

product wall thickness

product integrity and general conformance to specification/sample.

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