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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 continuous thermoforming 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 thermoforming process.
3. Operate and make adjustments to the continuous thermoforming process to procedures.
   • Operate thermoforming 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 thermoforming process.
   • Adjust process to minimise scrap and trim.
   • Clean, adjust and lubricate equipment as required.
4. Shut down machine to procedures.
   • Determine type of shut down.
   • 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 designated 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 For example static electricity can increase the potential for contamination of materials by dust and dirt This can be minimised by vacuuming or blowing air sheet surfaces immediately before forming and also maintaining a clean plant to prevent dust and dirt from entering the thermoforming area

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 thermoforming process Application of approved hazard control and safety procedures and 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 and time

function and operating principles of continuous thermoforming equipment machine components and ancillary equipment including the mechanical hydraulic pneumatic electrical and electronic principles which effect machine operation

impact of machine speed temperature pressure time during cycles on product quality and production output

phases of the thermoforming cycle and the effect of the key variables on product quality in order to make appropriate adjustments to machine settings For example prestretching a heated sheet in the air before it makes contact with the mould improves material distribution by increasing the sheet surface area so it more closely matches that of the mould

changes to materials at various stages of production

waste management and importance of nonconforming materials

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

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 thermoforming 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

Assessment will occur on an industrial thermoforming machines equipment and will be undertaken in a work like environment

Where the assessee does not currently possess evidence of competency in PMBPROD Operate thermoforming equipment 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

identify critical materials properties and continuous thermoforming process characteristics in relation to the process requirements and the end product

make adjustments and identify problems to be reported

identify and take appropriate action on problems and potential problems

Consistent performance should be demonstrated For example look to see that

the process runs consistently and smoothly with the minimum need for human intervention

all safety procedures are always followed

Assessment method and context

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 A holistic approach should be taken to the assessment

Competence in this unit may be assessed

by use of an appropriate thermoforming machine requiring demonstration of start up operation and shut down procedures

in a situation allowing the generation of evidence of the ability to recognise anticipate and solve problems

by use of a suitable simulation andor a range of case studiesscenarios

by 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 of variables 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 continuous thermoforming processes and includes the use of air pressure or vacuum processes. It includes the operation of all relevant additional equipment where that equipment is integral to the thermoforming process.

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 competency includes use of equipment and tools such as:

heaters

moulds

stacker

winder

granulator

conveyors and chutes

relevant personal protective equipment.

hand tools as required

additional equipment (including programmable limit controllers)

relevant personal protective equipment.

Hazards

Typical hazards include:

spills

dust/vapours

slip and fall (eg due to leaks)

temperature (eg from ovens)

hazardous substances

moving equipment (eg changing heater rods)

manual handling hazards.

stationary and moving machinery, parts and components.

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 routine faults include:

sheet sag

non-uniform pre-stretching

non-uniform wall thickness

sheet pulling out

bubbles, blisters or pits

scorching

whitening of formed part

blushing

loss of embossing detail

chill marks, drag-off lines

pinholes/pimples

shiny streaks

shrink marks

plug sticking

sheet tearing during forming.

Non-routine faults, which may have multiple causes include:

warpage or shrinkage after moulding

cracking

surface marks

webbing or wrinkling

mould sticking.

Typical process and product problems may include:

equipment malfunction

variations in temperature (eg uneven oven temperatures)

pressure

speed (eg cycle times)

variations in sheet or contamination of sheet

product tool damage

machine malfunction

mould/tooling problems

variations in materials and/or contamination of materials.

Variables

Key variables to be monitored include:

temperature

speeds (eg rollers, mould opening and closing)

times (including cycle times)

surface finish/appearance

product weight and output rate

product integrity and general conformance to specification and quality sample.

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