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Elements and Performance Criteria

1. Plan own work requirements.
   • Identify procedures, equipment and processes used for production process and upstream and downstream operations from production plan or request.
   • Select appropriate compound, adhesives and solvent type to meet product specifications.
   • Identify other materials required.
   • Recognise hazards and take appropriate action.
   • Identify and check emergency stops, guards and controls.
   • Identify requirements for materials, quality, production and equipment checks.
   • Identify materials, waste management and housekeeping needs.
2. Check roller building process set-up and materials.
   • Check roller building settings, stop bars and pressure wheel adjustments for conformity to procedures.
   • Check materials for conformity with requirements.
   • Measure and cut rubber sheet.
   • Discard or re-sand non-conforming materials to procedures.
3. Build rubber rollers.
   • Number rollers to procedures.
   • Sand off excess rubber to ensure a good metal surface for adhesion.
   • Take measurements and compare with specifications.
   • Trim edges flush with rollers and minimise waste.
   • Use plates to restrict flow of rubber during curing.
   • Monitor roller building operations, noting adhesion, rubber build-up, overlap, product quality, production outputs, equipment operating temperatures.
   • Make adjustments to remedy faults and non-conformity to production standards.
   • Collect and re-use material which is able to be reprocessed and deal with waste and scrap to procedures.
   • Complete equipment cleanup, lubrication, adjustment and waste management to procedures.
   • Compare product quality including thickness and product integrity with process specifications for green rubber product.
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

Knowledge of organisation procedures 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 roller building 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

identifying the function of roller building equipment machine components and the materials used

identifying faulty coresmandrels

describing changes to materials at the stages of production conducted by the employee

explaining the impact of roller building machine temperature pressure and adhesive flash off time on product quality and production output

identifying and describe own role and the roles of others involved directly in the roller building process

deciding if they the operator are able to rectify the fault or if assistance is required

explaining the effect of unauthorised or emergency shutdown of equipment on the roller building process

explaining the nature of the mechanical hydraulic pneumatic electrical and electronic principles which influence the roller building equipment operation and product development

explaining the impact that chemical reactionsmechanical processes have on changing the state form and condition of the 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 sequence including identification of key checkpoints for equipment monitoring product quality checks and monitoring of supplies and downstream operations monitor equipment operation and product quality

identify factors which may influence product quality and production output and appropriate remedies

make appropriate authorised alterations to own work plan and equipment to maintain both product quality and required production output

locate interpret and apply relevant information and maintain workplace records

identify and safely handle products and materials read relevant safety information and apply safety precautions appropriate to the task

apply andor explain impact of incorrect or faulty materials

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 to interpret specifications and lay out geometric shapes

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 roller building 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

Assessment will occur on industrial roller building equipment in a worklike environment

Competence in this unit may be assessed

by using appropriate industrial roller building equipment

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 the production/building of rubber rollers in the rubber industry. It includes the operation of all relevant additional equipment where that equipment is integral to the roller building 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:

hand carts and trolleys

knives and other sheet cutting equipment

hoists/lifting equipment not requiring any special permits or licences

solvent application/wiping gear

hand tools used in the roller building process

relevant personal protective equipment.

Hazards

Typical hazards include:

solvent

vapours

hazardous materials

manual handling hazards

knife hazards.

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 or wrong materials

contamination of materials

contamination of core/spindle

porous, damaged or unsuitable core/spindle

processing problems, including incorrect building.

Variables

Key variables to be monitored include:

operating temperatures

speed

colour

cushion specification

cycle time

output rate

product integrity and general conformance to specification/sample.

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