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Elements and Performance Criteria

  1. Plan own work requirements.
  2. Start up extrusion process to procedures.
  3. Operate and make adjustments to the extrusion process to procedures.
  4. Shut down extruder to procedures.
  5. Anticipate and solve problems

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 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 extrusion 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 extruder equipment machine components and ancillary equipment eg stackers haul off sawcutter printing embossing coil winder packaging

impact of extruder machine speed temperature pressure time hauloff speed on product quality and production output

the relationship between the type of extruder and the materials being extruded

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

processing behaviours of the materials extruded 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 product extrusion 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

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 posses evidence of competency in PMBPRODB Operate extruders it may be coassessed with this unit

Where the assessee does not currently posses evidence of competency in PMBPROD213B Operate extruders, 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 extrusion process characteristics in relation to the process requirements and the end product

make adjustments to the process as required

identify and take appropriate action on problems and potential problems

Consistent performance should be demonstrated For example look to see that

extrusion production quality and output standards are met consistently the process runs consistently and smoothly with the minimum need for human intervention

all safety procedures are adhered to

Assessment method and context

It is preferred that assessment takes place on an industrial extruder in a worklike environment

Competence in this unit may be assessed

by using an appropriate industrial extrusion system requiring demonstration of start up operation and shut down procedures

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


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 work environments and sectors within the plastics, rubber and cablemaking industry. It includes the operation of all relevant ancillary equipment where that equipment is integral to the extrusion 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:

extruder equipment and components (eg main drive, gear box, thrust assembly, adapter, gate, breaker plate, screen pack, doser, screw/s, barrel, heaters, thermocouples)

extrusion dies (eg rod, sheet, pipe, profile and cable)

extruders, either single or twin screw

auxiliary equipment (eg water pump, feeders, hopper loader, pellitiser, dehumidifiers)

tools for taking samples

relevant personal protective equipment.

Products

These may include:

rod

sheet

film

profile

tread profile

cable.

Competence under this competency unit is only required in one process.

Materials

This unit applies to most plastic and rubber materials, including compounded PVC fed to the extruder as pellets. It does not apply to dry blended PVC powder (refer to PMBPROD334A ).

Hazards

Typical hazards include:

spills

dusts/vapours

slip and fall (eg due to spilt granules)

temperature (eg due to heated barrel, head and die)

hazardous materials (including decomposing polymer during start up and shut down)

moving equipment (eg moving moulds, robots and ancillary equipment)

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 routine faults include:

burn marks

flow marks

poor surface finish

poor colour dispersion

blistering

colour contamination

black spots.

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

product distortion

residual stresses

intermittent faults.

Typical process and product problems may include:

die/tooling problems such as damage or build-up

equipment malfunction

variations in temperatures, pressures, speeds and times

variations in material properties and/or contamination of materials

variation in material flow rates

processing problems.

Appropriate action for problems outside of area of responsibility may be reporting to an appropriate person.

Appropriate action for solving problems within area of responsibility includes asking questions and seeking assistance from appropriate persons/sources.

Variables

Key variables to be monitored include:

differences between actual and set temperatures

speeds (including screw speed and haul-off)

colour and uniformity

surface finish and appearance

product finished thickness

output rate

product integrity and general conformance to specification/sample.