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Elements and Performance Criteria

  1. Plan own work requirements.
  2. Set up mould and materials to procedures.
  3. Hand lay up composites to procedures.
  4. 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 out of specification products process problems and materials faults For example outside temperatures can affect the setting and curing time of resin mixtures Therefore ratios of resins mixtures need to be strictly monitored to ensure an appropriate curing time for production output

Knowledge of organisation procedures quality requirements at each production stage and the ability to implement them within appropriate time constraints and work standards

Skill to identify the range of possible causes of product faults

Application of the knowledge of managing risks using the hierarchy of controls applied to the hand lay up 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 and properties of materials required to form a composite structure of the required strength and surface finish including fibres and pot life of the resins used

impact of resin mixtures laying of materials and temperatures on product quality and production output

changes to materials at various stages of production

waste management and importance of nonconforming materials

impact of variations in raw materials and application in relation to final product

setting up moulds

selection and preparation of resins including mixing as required

selection and preparation of fibre reinforcement including cutting and trimming

use of composites materials including gel coats resins and fibres

use and application of cores fillers and surface finishes

application of composite materials to the mould by hand lay up

material properties and their interactions with process conditions

relationships between material properties and process conditions

changes to material properties to better suit process requirements

product problems related to material properties

product problems related to process conditions

adjustments to process conditions to meet material and product requirements

Competence also includes the ability to

plan own work including predicting consequences and identifying improvements

make measurements when required and identify product out of specification

identify and describe own role and role of others involved directly in the 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 procedures material labels and safety information as provided to operators

Writing is required to the level of completing workplace forms

Numeracy is required to the level of reading tables of figures and graphs and applying the resultant information using formula percentagesratios to determine the required mass of an additive catalyst pigment etc for a given amount of resin and similar manipulations and interpretation

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 possess evidence of competency in PMBPRODC Hand lay up composites it may be coassessed with this unit

Where the assessee does not currently possess evidence of competency in PMBPROD247C Hand lay up composites, 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 hand lamination 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

products are consistently produced which meet specification

all safety procedures are always followed

Assessment method and context

Assessment will occur during the hand lay up process for complex composites and will be undertaken in a worklike environment

Competence in this unit may be assessed

through use of industrial hand lay up composite manufacture using jobs of appropriate complexity

in a situation allowing for the generation of evidence of the ability to recognise anticipate and 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 unit includes the use of equipment and materials to form complex composite products using hand lamination processes. It includes the operation of all relevant additional equipment where that equipment is integral to the hand lay up process.

Composites may be regarded as 'complex' due to their shape (eg acute angle corners), technical specification (eg high strength/rigidity/low weight) or the conditions under which the work must be undertaken (eg poor access, hot/cold environment)

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:

open moulds for composite products

hand mixing equipment and stirrers

knives and cutters

hand application tools, rollers, brushes, etc

relevant personal protective equipment.

Hazards

Typical hazards include:

hazardous materials and vapours

manual handling hazards

fire hazards due to flammable nature of resins used

knife hazards

slip 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 routine faults include:

incorrect resin ratios

fibre wet out

shifting of fibres during lay up

lay up sequence.

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

mould release problems,

warping or cracking after moulding

voids due to resin drainage.

Typical process and product problems may include:

cracks, dents or imperfections of the mould

use of incorrect materials

variations in materials, colour, consistency or mix

contamination of materials.

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:

temperature of environment/resin

time since mixing vs pot life of resin

air flow/ventilation

viscosity of resin

differing fibres and fabrics

compacting density of application.