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Elements and Performance Criteria

1. Plan own work requirements.
   • Identify most appropriate equipment or tool/s and processes to be used for production process and upstream and downstream operations from production plan or request.
   • Identify and check materials required, including additives.
   • Implement measures to control identified hazards and follow appropriate hazard control/ minimisation methods.
   • Identify requirements for materials, quality, production and equipment or tool/s checks.
   • Establish the sequence of work maximising potential of the applied finish for the production operation.
2. Start up surface coating process to procedures.
   • Identify process settings required for the product.
   • Set process to specifications as required.
   • Check surface coating equipment or tool/s settings and adjustments are as required.
   • 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 surface coating process.
3. Operate and make adjustments as required to the surface coating process to procedures.
   • Operate liquid surface coating process, noting key variables.
   • Make trial applications of surface materials to check equipment operation.
   • Monitor controls/displays/terminals for production/process data.
   • Monitor product/process quality in accordance with procedures.
   • Take samples as required and identify product out of specification.
   • Make adjustments to remedy faults and nonconformity to standard as required.
   • Establish a stable surface coating process.
   • Adjust process to minimize scrap and overspray.
   • Clean, adjust and lubricate equipment or tool/s as required.
4. Shut down machine to procedures.
   • Determine type of shutdown.
   • Select appropriate cleaning method.
   • Clean efficiently and adequately as required.
   • Leave machine in appropriate condition and with appropriate locks, tags or notices.
   • Complete relevant documentation.
   • Ensure area is clean and clear after the shutdown, in readiness for the next start up.
5. Anticipate and solve problems.
   • Recognise a problem or anticipate potential problems.
   • Determine problems needing priority action.
   • Determine possible fault causes.
   • 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 quality and safety requirements at each production stage and relevant regulatory requirements and the ability to implement them within appropriate time constraints and work standards

Application of knowledge of managing risks using the hierarchy of controls applied to the liquid surface coating 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 problem solving process and material problems including

function and operating principles of liquid surface coating equipment or tools

characteristics of materials and behaviour in relation to temperature application rate ventilation rate thinning liquid viscosity

impact of equipmentprocess variables eg speed temperature pressure on product quality and production output

phases of the coating cycle and the effect of key variables on product quality in order to make appropriate adjustments to machine settings

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

changes to materials at various stages of production

waste management and significance of nonconforming materials

basic preblending of materials

application of coatings

coating properties and their interactions with process conditions

relationships between coating properties and process conditions

changes to coating properties to better suit process requirements

product problems related to coating properties

product problems related to process conditions

adjustments to process conditions to meet coating 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 coating process

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 and material labels as provided to operators Writing is required to the level of completing workplace forms quality assurance records and production reports

Basic numeracy is required eg to determine how much diluent needs to be added to reduce a coating to a given concentration apply viscosity data to coating application and read simple graphscharts

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 PMBPROD B Apply liquid surface coatings it may be coassessed 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 liquid surface coating process characteristics in relation to the process requirements and the end product

make adjustments to the process materials and equipment as required

identify and take appropriate action on current and potential problems

Consistent performance should be demonstrated For example look to see that

the process runs smoothly with the minimum need for intervention

all safety procedures are always followed

Assessment method and context

Assessment will occur on industrial surface coating equipment and will be undertaken in a worklike environment

Competence in this unit may be assessed

by using appropriate industrial surface coating equipment requiring demonstration of startup operation and shutdown procedures

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

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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 liquid surface coating applications. It includes the operation of all relevant additional equipment integral to the coating 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:

coating equipment such as brushes, spray guns and/or immersion equipment

additional equipment such as ventilation and other fume/vapour removal equipment

manual handling aid such as hand carts and trolleys hoists/lifting equipment not requiring any special permits or licences

relevant personal protective equipment.

Hazards

Typical hazards include:

spills and splashes

toxic fumes or vapours

hazardous materials

manual handling hazards

flammable vapours.

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 known solution/s recorded in procedures.

Typical process and product problems may include:

incorrect selection of materials

variations in materials

contamination of materials or product surface

inappropriate application of coatings

drying rates

uniformity of film thickness

appropriate film thickness.

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

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

Variables

Key variables to be monitored include:

spray patterns

materials consistency

finished colour

surface finish

product integrity and general conformance to specification

coating viscosity

coating drying rate

coating application rate.

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