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Elements and Performance Criteria

  1. Prepare to centrifugally cast polyurethane materials.
  2. Plan centrifugal casting operations.
  3. Set up and check centrifugal casting equipment.
  4. Centrifugally cast polyurethane products.
  5. 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 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

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

impact of incorrect or faulty 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

products materials and material characteristics

behaviour of materials in relation to heat pressure and time

quality requirements at each production stage

function and operating principles of centrifugal casting equipment and ancillary equipment

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

the importance of machine setup and warmup for effective processing of materials

safety procedures and the use of PPE in relation to handling materials equipment operation and cleanup

the hierarchy of control including engineering controls

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

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

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

distinguish between causes of faults

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 one kg batch of material and one kg batch of material are required to produce a kg product

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 centrifugal casting process characteristics in relation to the process requirements and the end product

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

the process runs consistently and smoothly

Assessment method and context

Assessment will occur on an industrial centrifugal casting machines equipment and will be undertaken in a worklike environment

Competence in this unit may be assessed

on an operating 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 of 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 applies to production of cast polyurethane products within the plastics and rubber industries. It includes the operation of all relevant additional equipment where that equipment is integral to the polyurethane products casting 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:

lifting equipment such as cranes an hoists not requiring licensed operators

spanners, hammers, wrenches and other hand tools

vertical or horizontal axis centrifugal rotational equipment

cylindrical and other moulds

relevant personal protective equipment

hand tools used in the casting process

material loading equipment used for loading of raw materials

This competency does not include the use of powered equipment/aids.

Hazards

Typical hazards include:

spills

noxious fumes or vapours

hazardous materials

manual handling hazards

rotational equipment hazards

temperature hazards

mechanical lifting 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

contamination of materials

mechanical failures or disruptions

incorrect casting temperatures

physical anomalies such as variations to wall thickness

inappropriate setting up of the mould for spinning

machine malfunction

mould/tooling problems

processing problems.

Fault causes

Fault causes include:

wrong raw materials/additives/catalyst

incorrect quantity of materials/additives/catalyst

contaminated materials/additives/catalyst

variations in section thickness

difficult product removal

material 'shuts' and other material problems

incorrectly or improperly prepared materials

inadequately mixed materials.

Variables

Key variables to be monitored include:

operating temperatures

speed of rotation or cure

colour

location of pouring basin

cycle time

use of separating agents

product weight

product integrity and general conformance to specification/sample.