1. Plan own work requirements.
   • Identify equipment 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 in line with procedures and duty of care.
   • Identify requirements for materials, quality, production and equipment checks.
   • Identify materials, waste management and housekeeping needs.
2. Plan mould construction.
   • Produce a plan for the mould construction to specification.
   • Have design approved as necessary according to enterprise specifications.
   • Plan all steps of the mould production.
   • Check points are examined for measurements and tests according to specifications.
3. Set up equipment, tools and materials.
   • Clear and set up work area.
   • Identify and locate materials and equipment for the mould construction according to job specification.
4. Construct mould.
   • Apply mould materials as per specification.
   • Check dimensions, structural reinforcements, supports and flanges to the specifications or design.
   • Cure mould and release as per procedures.
   • Recheck dimensions of the finished mould.
   • Check fit with other matching mould parts and adjust where necessary.
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.
   • Solve problems within area of responsibility.
   • Seek information and assistance as required to solve problems.
   • Follow through items initiated until final resolution has occurred.

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 excess resin will only add weight and weaken the finished product Therefore care needs to be taken to ensure the correct resin to fibre ratio is used

Knowledge of organization procedures quality requirements at each stage relevant regulatory requirements and 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 construction of composite moulds 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 product faults

Knowledge about appropriate resins includes

polyester resin materials knowledge basic ingredients and their functions types and uses grades fillers shelf life storage and safety cure process exotherm graph factors affecting the cure process post curing

epoxy resin materials knowledge uses cure reaction exotherm graph effects of temperature effects of hardener advantages and disadvantages safety precautions

vinylester resin materials knowledge uses cure reaction catalystpromoter systems types and effects advantages and disadvantages compared with other resins safety precautions

dicyclopentadiene DCPD filled resin system

catalysts and promoters materials knowledge terminology

types grades uses storage and safety

Knowledge about appropriate reinforcement materials includes

basic characteristics and property differences of E Glass S Glass Carbon Aramid

formulations

manufacturing terminology

types of finish and binders

common weights available

resin to glass ratios

glass content and comparative strength of the basic forms

the effect of increasing fibre content on reducing thickness and flexural properties

basic effect of proportion and direction of fibre orientation

Knowledge as a basis for solving processing and material problems including

characteristics of materials and behaviour in relation to heat pressure flow rates resin to fibre ratios and outside air temperatures and conditions

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

waste management and importance of nonconforming materials

key requirements of the product which impact on the mould construction

hazards of the materials and process and appropriate hazard control procedures

Competence also includes the ability to

plan own work including predicting consequences and identifying improvements

maintain output and product quality using appropriate tools controls and test information

identify and describe own role and role of others involved directly in the process or constructing composite moulds

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 competency requires the ability to communicate with a wide range of personnel and to interpret product specifications and mould requirements

Numeracy is required to the level of determining required weightsvolumes of materials in a resin mix for different circumstances say using a data sheet number of layers of impregnated matrix required to yield the required product laminate thickness and similar activities

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 PMBPRODB Hand lay up composites and PMBPREPA Prepare moulds for composites production it may be coassessed with this unit

Where the assessee does not currently possess evidence of competency in PMBPROD247B Hand lay up composites and PMBPREP201A Prepare moulds for composites production, 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 process variables in relation of 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

composites production standards are met consistently

all safety procedures are always followed

Assessment method and context

Assessment will occur using appropriate equipment to construct composite moulds and will be undertaken in a worklike environment

Competence in this unit may be assessed

in an appropriate industrial mouldmaking situation in a worklike environment

in a situation allowing for the generation of evidence of the ability to recognise anticipate and solve 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