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Elements and Performance Criteria

1. Plan own work requirements.
   • Identify equipment and processes used for production process, upstream and downstream operations from production plan or request.
   • Identify materials required including additives.
   • Recognise hazards and take appropriate action.
   • Identify and check emergency stops, guards and controls.
   • Identify requirements for materials, quality, production and equipment checks.
   • Identify materials, waste management and housekeeping needs.
2. Check wire drawing process set-up.
   • Determine equipment requirements.
   • Check equipment settings and adjustments are as required.
   • Select appropriate dies (number and sizes) and arrange in correct production sequence.
   • Identify and check dies, capstans, head, wire reel pack and gears, replacing or maintaining as required.
   • Coat wire drawing capstan with lubricant to procedures.
   • Check materials are correct.
   • Check material spool sizes for conformity with requirements.
   • Discard, or make adjustments to the process for, non-conforming materials.
   • Thread new materials checking free operation through dies and secure fixing to reels or spools.
   • Conduct equipment and component checks to ensure safe and efficient operation to procedures.
   • Set up date, batch and materials markings as required.
   • Complete other pre-start checks to procedures.
3. Operate wire drawing process to procedures.
   • Operate wire drawing equipment, noting key variables.
   • Monitor controls/displays/terminals for production/process data.
   • Monitor product/process quality.
   • Make adjustments to remedy faults and nonconformity as required.
   • Maintain continuity of process.
   • Collect and reprocess/discard scrap/trim and other materials.
   • Clean, adjust and lubricate equipment as required.
   • Complete required workplace documentation/records.
   • Pause equipment, or stop equipment in an emergency, as required.
4. Shut down equipment to procedures.
   • Shut down equipment as required.
   • Complete equipment cleanup, adjustments and waste management.
   • Place suitable guards, locks and notices to prevent inadvertent 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.

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

Knowledge of the enterprises 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 wire drawing process Application of approved hazard control safety procedures the use of PPE in relation to handling materials equipment operation and cleanup

Knowledge as a basis for solving processing and material problems including

products materials and material characteristics

function of wire drawing equipment equipment components and ancillary equipment

impact of die wear and build up faulty capstan and wire welds on product quality and production output

wire drawing manufacturing processes

behaviour of materials in relation to speed temperature and tension

waste management and importance of nonconforming materials

wire properties and their interactions with process conditions

relationships between wire properties and process conditions

changes to wire properties to better suit process requirements

product problems related to wire properties

product problems related to process conditions

adjustments to process conditions to meet wire and product requirements

Competence also includes the ability to

plan own work including predicting consequences and identifying improvements

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

identify and describe own role and role of others involved directly in the wire drawing process

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

identify when assistance is required to solve problems

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 and production reports

Basic numeracy is required eg to determine how many kg kg and 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

identify critical materials properties and wire drawing process characteristics in relation to the process requirements and the end product

plan own work process within workplace procedures and explain the reasons for the steps in the process

take appropriate action to observe equipment materials and products for outofspecification results make adjustments and identify problems to be reported

Consistent performance should be demonstrated For example look to see that

production quality and output standards are met consistently

problems are anticipated from process observations

problems are efficiently resolved

the process runs consistently and smoothly

Assessment method and context

Assessment will occur on an industrial wire drawing machine in a worklike environment

Competence in this unit may be assessed

by using an appropriate industrial wire drawing machine

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 the operation of all wire drawing equipment within the plastics, rubber and cablemaking industries. It includes the operation of all relevant additional equipment where that equipment is integral to the wire drawing process.

Procedures

All operations are performed in accordance with procedures.

Procedures include all relevant workplace procedures, work instructions, temporary instructions, manufacturer operating instructions and relevant industry and government codes and standards.

Tools and equipment

This competency includes use of equipment and tools such as:

wire drawing equipment and components, including die box, payoff, capstan, internal cooling system, annealer, tinner, accumulator, spooler, main drive, control unit, wire drawing dies (diamond, tungsten, carbide, compax)

associated equipment, including manual handling equipment, pointers, taggers, welders, lubrication system, packaging

measuring equipment

hand tools used in production process

relevant personal protective equipment.

Hazards

Typical hazards include:

temperature

hazardous materials

manual handling hazards

equipment operations.

Problems

Anticipate and solve problems means resolve a wide range of routine and non-routine problems, using product and process knowledge to develop solutions to problems which do not have a known solution/a solution recorded in the procedures.

Typical process and product problems may include:

equipment malfunctions (eg wire breaks - raw material contamination, die wear, die build-up, faulty capstan bands, faulty wire welds)

materials problems (eg incorrect quantity of materials, raw material contamination)

processing problems (eg incorrect diameter, ovality, surface appearance, colour, inclusions, elongation, tensile strength, weight, wrap)

Variables

Key variables to be monitored include:

machine speed

lubrication

wire quality.

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