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Elements and Performance Criteria

1. Plan process stages for polyurethane foam production.
   • Plan the stages in the polyurethane foaming process and ensure these comply with the quality requirements for production.
   • Identify and allow for changes in materials at each stage of the polyurethane foaming process.
   • Plan the availability of the equipment and components for each production stage.
   • Anticipate the impact of the process on product characteristics and product quality and useability.
   • Plan work requirements based on procedures.
2. Identify work requirements for polyurethane foaming operations
   • Prepare materials, including base raw materials and additives.
   • Recognise hazards and follow appropriate hazard control/minimisation methods.
   • Check materials, ancillary supplies and equipment are correct Check equipment and processes used for materials preparation, production process and for the downstream operations are available.
   • Check product quality requirements for the relevant process stage(s).
   • Identify and check emergency stops, gauges, guards and controls.
   • Plan the task sequences, including times and locations for product quality checks, equipment operation and required production outputs.
   • Provide for ongoing materials input, waste management and work area housekeeping requirements.
   • Arrange any required supplementary equipment for product quality testing or routine equipment maintenance and/or adjustments.
3. Check polyurethane foaming process set-up
   • Comply with equipment information, required quality specifications and set-up procedures.
   • Set up equipment in accordance with required quality specifications and standard operating procedures.
   • Check polyurethane foaming equipment settings and adjustments and conformity to documented procedures.
   • Inspect materials for conformity with requirements including surface condition and materials thickness.
   • Discard non-conforming materials or make adjustments to processing operations in accordance with procedures.
4. Operate and make adjustments as required to the foam process
   • Start up, operate and shut down foam equipment as required by procedures.
   • Monitor polyurethane foaming operations noting product quality, production outputs, equipment operating temperature, amperage, pressures, colour, thickness and product integrity.
   • Make adjustments to remedy faults and non-conformity to production standards where applicable.
   • Collect material which is able to be reprocessed and reused, and dispose of waste and scrap in accordance with workplace procedures.
   • Clean up equipment, lubricate, and adjust in accordance with procedures.
5. 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

Knowledge of organization procedures and relevant regulatory requirements along with the ability to implement them within appropriate time constraints and work standards

Competence includes the ability for the practical completion of the job to apply andor explain

products materials and material characteristics

behaviour of materials in relation to heat pressure and time

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

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

production workflow sequences and materials demand

focus of operation of work systems and equipment

correct selection and use of equipment materials processes and procedures

hazards of the materials and process and appropriate hazard control procedures

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

Competency 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

make adjustments to equipment operation to rectify variations in equipment operation or product quality

identify and describe own role and role of others involved directly in the foam 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

Basic numeracy is also required eg to determine that units and units are equal to a total of units

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 polyurethane foaming 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 polyurethane foam machines equipment and will be undertaken 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

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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 advanced operators working either independently or as part of a work team.

Procedures

All operations are performed in accordance with procedures.

Procedures means 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:

manual handling aids - hand carts and trolleys

knives and other bag opening equipment

hoists/lifting equipment not requiring any special permits or licences

basic hand tools required for opening of material packaging

relevant personal protective equipment

material loading equipment used for loading of raw materials.

Hazards

Typical hazards include:

spills

dusts/vapours

slip and fall, particularly due to spilt granules

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:

machine malfunction

out of specification equipment operation

contamination of materials

variations in materials and/or contamination of materials

processing problems.

Variables

Key variables to be monitored include:

operating temperatures

speed

colour

cushion specification

cycle time

output rate

product weight

product integrity and general conformance to specification/sample.

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