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Elements and Performance Criteria

  1. Plan own work requirements.
  2. Set up autoclave vulcanising process.
  3. Operate and make adjustments to the autoclave process to procedures.
  4. Respond to product quality improvement requests.
  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 For example

A knowledge of organization procedures quality requirements at each stage of production stage 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 vulcanising process 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 causes of product faults

Knowledge as a basis for solving processing and material problems including

characteristics of materials and behaviour in relation to heat thickness and cure rates

identify the function of vulcanising equipment components and the materials used

changes to materials at various stages of production

relationship between steam pressure and temperatures and the effects this and time will have on product quality and production output

impact of heat and pressure in relation to providing strength stiffness resistance to deformation fatigue and abrasion

monitor equipment operation and product quality

impact of product sectionthickness on cure requirements

impact of compound cure system on cure requirements

impact of heating too quicklyslowly on final product properties

compound properties and their interactions with process conditions

relationships between compound properties and process conditions

changes to compound properties to better suit process requirements

product problems related to compound properties

product problems related to process conditions

adjustments to process conditions to meet compound and product requirements

Competence also includes the ability to

plan own work including predicting consequences identifying improvements

maintain output and product quality using appropriate instruments controls checks test information and readings

identify and describe own role and the roles of others involved directly in the vulcanising process

identify when assistance is required to solve problems

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

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 also required eg to determine required steam pressure to give necessary timetemperature cycle

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 rubber vulcanising process characteristics in relation to the process requirements and the end product

make adjustment 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

the process runs consistently and smoothly with the minimum need for human intervention

all safety procedures are always followed

Assessment method and context

Assessment will occur on an industrial autoclave and will be undertaken in a worklike environment

Competence in this unit may be assessed

on anappropriate operating plant 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


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 of vulcanised rubber products within the rubber industries. It includes the operation of all relevant additional equipment where that equipment is integral to the vulcanising autoclave process. It includes the operation of all ancillary steam equipment, but not boiler operation.

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 trimming equipment

hoists/lifting equipment not requiring any special permits or licences

basic hand tools

relevant personal protective equipment.

Hazards

Typical hazards include:

heat

confined spaces

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:

air/water blinding of steam equipment

faulty/unreliable gauges

matching loads requiring the same cure conditions

adjusting temperature/pressure profile to match load and product

wrong cure cycle

changed product cure systems/section

steam problems.

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:

operating temperatures

stacking and loading off product for autoclaving

material composition

operating pressure

cycle time

output rate

product integrity and general conformance to specification and quality sample.