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Elements and Performance Criteria

1. Perform pre-start checks.
   • Check all emergency stops, guards, controls.
   • Identify requirements for materials, quality, production run.
   • Check and adjust equipment as required.
   • Check that the equipment has been set-up correctly.
2. Carry out pre-start operations to procedures.
   • Restore all power to the machine and ancillary equipment.
   • Start up the ancillary equipment and set the temperature and other controllers as required.
   • Check all machine settings as required.
   • Select and load the correct raw material.
   • Charge, purge and clean machine as required.
3. Start machine and hand over to operator.
   • Start and check machine.
   • Adjust machine as required to bring to operational speed/ condition.
   • Check and run machine until a quality product is obtained.
   • Make adjustments to machine and extra equipment in line to produce an acceptable product.
   • Make any adjustments required to ensure the machine and its upstream and downstream extra equipment in line are in balance.
   • Give the operator all necessary instructions and hand over the machine.
   • Shut down machine as required.

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 process problems and equipment

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 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

machine construction types of machines component parts of machines structure function and general operating principles

machine safety interlocks and systems

principles of operation

measuring instruments and their function

machine control systems

differences between analogue controls digital controls microprocessor based process controls

impact of incorrect or faulty setup

production workflow sequences

correct selection and use of equipment and procedures

the performance of dies and cores

relevant information and workplace records

safety precautions appropriate to the task

polymer properties and their interactions with process conditions

relationships between polymer properties and process conditions

changes to polymer properties to better suit process requirements

product problems related to polymer properties

product problems related to process conditions

adjustments to process conditions to meet polymer and product requirements

Competence also includes the ability to

plan own work including predicting consequences and identifying improvements

take samples when required and identify product out of specification

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

identify factors which may affect standard product quality or production output

Language literacy and numeracy requirements

Literacy is required to the level of being able to read and interpret technical specifications and production schedules and specifications

Numeracy is required to the level of being able to calculate cycle times and production rates An appreciation of numbers is also required to the extent needed to set and interpret numeric data

Verbal communication is required to the extent necessary to instruct the operator

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

Where the assessee does not currently possess evidence of competency in a relevant PROD unit it may be coassessed with this unit

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

bring a cold machine into readyforproduction status methodically and smoothly in standard time

Consistent performance should be demonstrated For example look to see that production quality and output standards are met consistently

Assessment method and context

Assessment will occur on an industrial line in a worklike environment

Competence in this unit may be assessed

by using appropriate industrial 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 sectors within the plastics, rubber and cablemaking industries which use dedicated production machines. It includes the operation of all relevant additional equipment where that equipment is integral to the production process.

Requirements

Requirements may be determined from set-up sheets, job cards, product data sheets or similar.

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:

hand carts and trolleys

hoists/lifting equipment not requiring any special permits or licences

hand tools used in the process

relevant personal protective equipment.

Measuring instruments

Measuring instruments include:

levelling

temperature sensing devices such as thermocouples, pyrometers, transducers, thermometers

pressure and vacuum gauges

flow meters.

Safety interlocks and systems

Safety interlocks and systems include:

limit switches

normally open/normally closed

overstroke control systems

hydraulic temperature control

material temperature control

machine guards

nozzle purge guard

mould protection systems

ejection limit switches.

Principles of operation

Principles of operation include:

production cycle/process/sequence

function tools/components

calculation of machine cycle time/production rate

safe work procedures for checking machine cycle time/production rate

variations to the cycle/process for different systems/products.

Machine control systems

Machine control systems include:

basic controls

open loop

closed loop

shot size and correction capacity

speed/cycle time

screw position

equipment/process pressure

clamp pressure

time

screw speed

screw back pressure

screw back time

melt decompress position

sprue break.

Hazards

Typical hazards include:

spills

dusts/vapours

slip and fall, particularly due to spilt polymer granules

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:

materials

equipment malfunction

process.

Variables

Key variables to be monitored include:

equipment condition

set up variables

product measurements and quality.

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