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Elements and Performance Criteria

1. Take over operation of the machine
   • Arrange handover from the operator (if necessary)
   • Determine type and reason for shutdown
   • Implement measures to control identified hazards in line with procedures and duty of care
   • Notify relevant associated personnel
2. Perform long-term shutdown
   • Stop material feed
   • Purge, using appropriate materials as required
   • Switch off ancillaries as required
   • Make required adjustments to ensure the safety of machine and materials
   • Isolate, lock out and make machine safe for personnel, and leave with appropriate tags or notices
   • Complete relevant documentation
3. Perform post-shutdown preventive maintenance and cleanup after long-term shutdown
   • Clean all components as required
   • Apply required surfaces treatments
   • Leave all parts in required condition
   • Confirm all isolations have been done
   • Pack/process any remaining goods/ product and label as required
   • Sort material that can be salvaged from waste and arrange reprocessing/disposal to procedures
   • Ensure area is clean and clear, ready for restarting of the machine
4. 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: production plant/equipment machine control systems safety interlocks and systems measuring instruments ancillary equipment that is integral to the process. Additional tools and equipment will be selected as required from: hand tools used in the process hoists/lifting equipment not requiring any special permits or licences manual handling aids, such as hand carts and trolleys 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.
Problems	Routine and non-routine problems must be resolved. 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 and engineering specifications remembered experience relevant knowledge obtained from appropriate people. Routine problems are predictable and have known solutions and include one or more of: cycle interruptions degradation of materials cooling and solidification of compounds rusting and corrosion of moulds put in storage clearing jams damage to equipment.

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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)

safely shutdown the machine, feed and ancillary equipment by adjusting machine control system, including one or more of:

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

monitor key variables, including:

temperature

fill rate

screw RPM

speed

brakes

stopping distance

safely shut down equipment in normal and abnormal circumstances

isolate, lock out and make machine safe

apply preventive maintenance, clean up and housekeeping procedures

identify hazards and apply relevant hazard controls

apply safety 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

raw material variations/contamination

process abnormalities

procedural errors

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:

structure, functions and principles of operation of equipment, machine components and ancillary equipment

impact of variations in production cycle/process/sequence on shutdown of equipment systems

functions and applications of analogue controls, digital controls, and microprocessor based process controls

function of and readings from measuring instruments, including one or more of:

levelling

thermocouples

pyrometers

transducers

thermometers

pressure gauges

vacuum gauges

flow meters

purpose and operation of safety interlocks and systems, including one or more of:

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

characteristics of materials and behaviour in relation to heat, pressure, flow rate and time

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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