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Elements and Performance Criteria

1. Plan own work requirements.
   • Identify equipment and processes used for production process and upstream and downstream operations from production plan or request.
   • Identify and check materials required.
   • Implement measures to control identified hazards in line with procedures and duty of care.
   • Identify requirements for materials, quality, production and equipment checks.
2. Check compression moulding process set-up 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 press/compression moulding process.
3. Operate and make adjustments as required to the compression moulding process
   • Operate compression moulding 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 non-conformity as required.
   • Establish a stable compression moulding process.
   • Adjust process to minimise scrap and trim.
   • Clean, adjust and lubricate equipment as required.
   • Shut down process as required.
   • Leave machine in appropriate condition and ready for the next start up.
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.

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 changes in presstemperature prescorching of rubber or changes in pressure can all lead to faulty mouldings but with different properties

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 injection moulding process Application of approved hazard control and safety procedures and the use of PPE in relation to handling materials equipment operation and cleanup

Skill to identify the range of possible causes of product faults

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 compression moulding equipment machine components and ancillary equipment

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

compression moulding cycle and the importance of machine setup and warmup for effective processing of materials

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

changes to materials at various stages of production

quality requirements at each production stage

identify and read transducers for hydraulic position and clamping force

distinguish between causes of faults

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 sequence including identification of key checkpoints for equipment monitoring product quality checks and monitoring of supplies and downstream operations

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 compression moulding process

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

identify when the operator is able to rectify faults and when assistance is required

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 the sizeweight of blanks and how many moulded products can be obtained from a batchtray of green rubber

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

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 compression moulding process characteristics in relation to the process requirements and the end product

Consistent performance should be demonstrated For example look to see that

production quality and output standards are met consistently

the process runs consistently and smoothly

Assessment method and context

Assessment will occur on an industrial compression moulding equipment and will be undertaken in a worklike environment

Competence in this unit may be assessed

by using an appropriate industrial compression moulding machine 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

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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 compression moulding within the plastics and rubber industries. It includes the operation of all relevant additional equipment where that equipment is integral to the moulding process.

Procedures

All operations are performed in accordance with procedures.

Procedures mean all relevant workplace procedures, work instructions, temporary instructions and relevant industry and government codes and standards. These may include:

original manufacturer instructions and guidelines for the use of the moulding equipment

relevant procedures relating to safe working practices prescribed for the equipment

local OHS legislation and/or Regulations

site-specific instructions based on production requirements.

Tools and equipment

This competency includes use of equipment and tools such as:

knives/scissors

scoops, measures, scales, fixed gauges

levers and other mould handling devices

mould release sprays or other means of application

relevant personal protective equipment.

Hazards

Typical hazards include:

fumes/vapours

crushing hazards

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:

variations in materials/scorchy rubber

contamination of materials

blank/charge/shot size

mould temperature/temperature

profile demoulding

dirty moulds, damaged moulds.

Causes of faults

Causes of faults include:

wrong raw materials

incorrect quantity of materials

contaminated materials

dirty mould; damaged mould

mould open too long

mould/product temperature/temperature profile

pressure.

Variables

Key variables to be monitored include:

operating temperatures

colour

cycle time

output rate

product weight

product integrity and general conformance to specification/sample.

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