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Elements and Performance Criteria

1. Identify required materials and equipment.
   • Identify work requirements from production plan or request.
   • Identify quantity and quality of product required and any special requirements, including welding specifications.
   • Interpret plans, patterns, designs or product specifications.
   • Recognise hazards and steps required to ensure safety.
   • Plan sequence of welding operations for the whole process to ensure work follows a logical procedure.
   • Recognise requirements which may not be in accordance with usual practice.
   • Ask questions of appropriate person to confirm unusual practice.
   • Examine process requirements to identify suitability of plastics materials for manual welding operations.
2. Set up equipment and materials.
   • Set up tools and equipment ready for production.
   • Locate materials, patterns and consumables.
   • Ensure safety equipment is available and fit for use.
   • Identify non-conformances and take required action.
3. Weld to specification
   • Assemble components using clamps and jigs as required.
   • Organise materials and equipment prior to welding.
   • Weld materials to specification.
   • Collect and segregate scrap, trim and other materials as required.
   • Complete logs and records as required.
   • Keep equipment and work area clean.
4. Respond to routine problems in accordance with procedures.
   • Check finished welds or products against specifications
   • 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 material and equipment conditions which may lead to out of specification production of welded plastic joints or components such as

different types of materials and their behaviour when prepared and welded

different welding equipment and procedures and suitability for material

types of welds and ways of achieving them

weld faults common with types of weld and materials welded

welding symbols

Knowledge of organization procedures and relevant regulatory requirements along with the ability to implement them within appropriate time constraints and work standards

Competence includes the ability for the practical completion of the job to identify

equipment controls used in welding

types of welders used

routine faults in products

routine problems in process

Competence also requires the ability to determine the appropriate action including reporting to the appropriate person by distinguishing between causes of faults such as

materials

changes to materials during the welding process

equipment adjustmentssetup

equipment maintenance requirements

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 ofcompleting workplace forms

Basic numeracy is also required to interpret specifications make measurements and read and interpret process conditions

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 in the welding process

apply approved procedures

respond to routine problems

Consistent performance should be demonstrated For example look to see that

welding production standards are met consistently

upstream and downstream communication is timely and effective operating procedures and work instructions are read and interpreted correctly

Assessment method and context

Assessment will occur on an industrial plastics welding machines equipment and will be undertaken in a worklike environment

Competence in this unit may be assessed

by use of an appropriate industrial plastics welding equipment requiring demonstration of operation

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 processes required to fabricate plastic products by welding or otherwise weld plastic materials or pipe to specified requirements. It includes welding the processes of:

butt fusion welding

electro fusion welding

extrusion welding

heated wedge welding

high speed nozzle

hot gas welding

infrared welding

socket fusion welding.

Materials may be from a range of thermoplastic materials for which a compatible welding polymer rod or filler can be provided to form a homogeneous melt. The material may be in any form: sheet, pipe, formed tube, solid section, formed profile, etc

It also includes the operation of hot air and other hand held welding equipment of various types and all relevant ancillary equipment. Procedures means all relevant workplace procedures, work instructions, temporary instructions and relevant industry and government codes and standards

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:

welding equipment

hand tools as required

jigs, clamps and other fixing devices

relevant personal protective equipment

Hazards

Typical hazards include:

fumes from overheating or poor ventilation

cuts from sharp edges on components

burns from manual handling

eye injury

power tools, leads and power supplies

welding equipment, parts and attachments

Problems

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

pattern incorrect or inaccurate assembly or clamping

incorrect filler rods selected

poor surface preparation

incorrect selection of welding nozzle or attachments

moisture contacting welding devices

burns to electrical leads

sequencing problems, weld run too fast or too slow

bonding problems, weld deposit incomplete or plastication not achieved.

Variables

Key variables to be monitored include:

weld temperature

feed rate of filler rod

variations in materials being welded

thickness of materials being welded.

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