1. Plan own work requirements.
   • Identify the most appropriate equipment to be used for production process, 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 blow moulding equipment to procedures.
   • Identify process settings required for product.
   • Set up and adjust blow moulding equipment for shot size, parison control, die gap, temperature, screw speed, cycle speed, slow close setting (or cushion) and timing.
   • Check safety gates and guards are located in their correct working positions and emergency stops are identified and checked as required.
   • Verify equipment, raw material and mould all match job requirement.
   • Set up date, batch and materials markings.
   • Complete other pre-start checks.
   • Start up equipment safely and 'dry run' to warm hydraulics and components to operating temperature before production, as required.
3. Operate and make adjustments to the blow moulding process to procedures.
   • Check condition of equipment and introduce raw materials as required.
   • Operate blow moulding equipment, noting key variables
   • Monitor controls/displays/terminals for production and process data.
   • Monitor product/process quality.
   • Make adjustments to remedy faults and nonconformity as required.
   • Establish a stable blow moulding process.
   • Collect and reprocess/discard scrap/trim and other materials.
   • Clean, adjust and lubricate equipment as required.
   • Complete logs and records as required.
   • Pause or stop equipment in an emergency, as required.
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.

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 For example foreign material in the polymer feed leading to black spots in the product

Knowledge of organization procedures quality requirements at each production stage 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 blow moulding 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

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

function and operating principles of blow moulding equipment machine components and ancillary equipment

purpose and requirements of dry running before process materials are introduced

impact of blow moulding machine speed temperature blow pressure sequence time parison control on product quality and production output

nature of mechanical hydraulic pneumatic electrical and electronic principles which affect machine operation and product development

processing behaviours of the materials blow moulded in the workplace

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

changes to materials at various stages of production

waste management and importance of nonconforming materials

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

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 extrusion process

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

identify when assistance is required to solve problems

Distinguish between causes of faults such as

routine blow moulding faults burn marks flow marks poor surface finish poor colour dispersion blistering colour contamination black spots

incorrect quantity of materials

contaminated materialsadditives

equipment faults

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

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 posses evidence of competency in PMBPRODB Operate blow moulding equipment it may be coassessed with this unit

Where the assessee does not currently posses evidence of competency in PMBPROD211B Operate blow moulding equipment, it may be co-assessed 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

identify critical materials properties and blow moulding 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 out of specification 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

It is preferred that assessment takes place on an industrial blow moulding machine in a worklike environment

Competence in this unit may be assessed

on a processing plant allowing for operation under all normal and a range of abnormal conditions

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