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Elements and Performance Criteria

1. Plan own work requirements
   • Identify the most appropriate equipment to be used for production and upstream and downstream operations from production plan or request
   • Identify and check materials required, including additives and regrind and their amounts or percentages
   • Implement measures to control identified hazards in line with procedures and duty of care
   • Identify requirements for materials, quality, production and equipment checks
2. Start up equipment/ process to procedures
   • Identify process settings required for product
   • Set process to required settings
   • Check materials are correct
   • Take appropriate action for non-conforming materials
   • Set up date, batch and materials markings to specifications, as required
   • Complete pre-start checks
   • Start up moulding process
3. Operate and make adjustments to the equipment/ process to procedures
   • Operate equipment/process, noting key variables
   • Monitor controls/displays/terminals for production and process data
   • Take samples as required and identify product out of specification
   • Monitor product/process quality
   • Make adjustments to remedy faults and nonconformity as required
   • Establish a stable process
   • Adjust process to minimise scrap and trim
   • Clean, adjust and lubricate equipment as required
4. Shut down machine to procedures
   • Determine type of shutdown
   • Select appropriate purging method
   • Purge efficiently and adequately as required
   • Leave machine in appropriate condition and with appropriate locks, tags or notices.
   • Complete relevant documentation
   • Ensure area is clean and clear after the shutdown, in readiness for the next start-up
5. Anticipate and solve problems
   • Recognise a problem or a potential problem
   • Determine problems needing priority action
   • Refer problems outside area of responsibility to appropriate person, with possible causes
   • Seek information and assistance as required to solve problems
   • Solve problems within area of responsibility
   • Follow through items initiated until final resolution has occurred

Range Statement

This field allows for different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.
Regulatory framework	The latest version of all legislation, regulations, industry codes of practice and Australian/international standards, or the version specified by the local regulatory authority, must be used. Applicable legislation, regulations, standards and codes of practice include: health, safety and environmental (HSE) legislation, regulations and codes of practice relevant to the workplace, manual handling and hazardous materials Australian/international standards relevant to the materials being used and products being made any relevant licence and certification requirements. All operations to which this unit applies are subject to stringent HSE requirements, which may be imposed through state/territory or federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between performance criteria and such requirements the legislative requirements take precedence.
Procedures	All operations must be performed in accordance with relevant procedures. Procedures are written, verbal, visual, computer-based or in some other form, and include one or any combination of: emergency procedures work instructions standard operating procedures (SOPs) safe work method statements (SWMS) formulas/recipes batch sheets temporary instructions any similar instructions provided for the smooth running of the plant.
Tools and equipment	Tools and equipment include: process equipment and its major components. Additional tools and equipment will be selected as required from: hand tools used in the process material loading equipment used for loading of raw materials relevant personal protective equipment (PPE).
Hazards	Hazards must be identified and controlled. Identifying hazards requires consideration of: weight, shape, volume of materials to be handled hazardous products and materials sharp edges, protrusions or obstructions slippery surfaces, spills or leaks smoke, dust, vapours or other atmospheric hazards high temperatures electricity gas gases and liquids under pressure structural hazards equipment failures machinery, equipment and product mass other hazards that might arise.
Non-routine problems	Non-routine problems must be resolved by applying operational knowledge to develop new solutions, either individually or in collaboration with relevant experts, to: determine problems needing action determine possible fault causes develop solutions to problems which do not have a known solution follow through items initiated until final resolution has occurred report problems outside area of responsibility to designated person. Non-routine problems are unexpected problems or variations of previous problems and include one or more of: unstable process variables sub-optimal operation variations in feed rates variations in quality emergency situations. Operational knowledge includes one or more of: procedures training technical information such as journals, engineering specifications remembered experience relevant knowledge obtained from appropriate people.

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Performance Evidence

Evidence required to demonstrate competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria and demonstrate the ability to:

read and interpret procedures, job specifications, instruments/control panels, material labels and safety data sheets (SDS)

set up equipment to meet specifications

check and adjust/correct materials

start-up process and monitor key variables, including:

temperatures

speed

pressures

colour

cycle time/process timing

output rate

product weight

product integrity and general conformance to specification

make adjustments to process to:

remedy faults and nonconformity

establish a stable process

minimise scrap

maintain output and product quality using appropriate instruments, controls, test information and readings

determine shutdown type and purge methods

safely shut down equipment in normal and abnormal circumstances

leave machine in appropriate condition with any required locks, tags or notices

identify hazards and apply relevant hazard controls

apply safety procedures

apply housekeeping procedures

apply waste management procedures

recognise early warning signs of equipment/processes needing attention or with potential problems

distinguish between causes of problems, including:

operational problems

instrument failure/malfunction

electrical failure/malfunction

mechanical failure/malfunction

wrong readings

equipment design deficiencies

polymer properties

process variables

recognise and prioritise problems requiring action

resolve non-routine problems

communicate effectively with team/work group and supervisors

complete workplace records

do basic arithmetical manipulations, including additions, subtractions, divisions, fractions and percentages.

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Knowledge Evidence

Must provide evidence that demonstrates knowledge relevant to their job sufficient to operate independently and to solve routine and non-routine problems, including knowledge of:

products, materials and material characteristics

behaviour of materials in relation to key process variables

quality requirements at each production stage

function and operating principles of machine and components

impact of machine operating parameters on product quality and production output

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

impact of mechanical, hydraulic, pneumatic and electrical/electronic principles of the production process

polymer properties and their interactions with process conditions

impact of variations in raw materials and equipment operation in relation to final product

routine and non-routine problems that may arise, the range of possible causes and appropriate actions

organisation procedures relevant to the work environment/job role

hierarchy of control

hazards that may arise in the job/work environment and:

their possible causes

potential consequences

appropriate risk controls.

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