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Elements and Performance Criteria

1. Prepare for work.
   • Work instructions are used to determine job requirements, including: design, quality, materials, equipment and quantities.
   • Workplace health and safety requirements, including personal protection needs, are observed throughout the work.
   • Material for machining is selected and inspected for appropriate quality.
   • Procedures are determined for minimising waste material.
   • Procedures are identified for maximising energy efficiency while completing the job.
2. Set up for machining and processing.
   • Program is set to job requirements.
   • Safety equipment, including emergency stops, gauges, guards and controls are checked.
   • Machining and processing settings and adjustments are made in accordance with job requirements and machining and processing and tool manufacturer instructions.
   • Machining and processing, cutting tools and jigs are checked for safe and effective operation.
   • Trial runs are conducted to check machining and processing operation and quality of finished work.
   • Final adjustments are made to programs and equipment according to workplace procedures.
3. Operate machining and processing centres.
   • Machining and processing centres are operated and monitored to ensure product quality and output.
   • Waste quantities are checked and minimised.
   • Problems with the required work are identified and reported to appropriate persons.
   • Items that do not meet quality requirements are repaired, recycled or discarded according to workplace procedures.
   • Any authorised changes in working procedures are followed.
4. Clean up work area and maintain equipment.
   • Material that can be reused is collected and stored.
   • Waste and scrap are removed following workplace procedures.
   • Equipment and work area are cleaned and inspected for serviceable condition in accordance with workplace procedures.
   • Operator maintenance is completed in accordance with manufacturer specifications and site procedures.
   • Unserviceable equipment is tagged and faults identified in accordance with workplace.
   • Equipment and tooling is maintained in accordance with workplace procedures.
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.
   • 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 For example selection of the appropriate router bit or tool for the job

Knowledge of organization procedures quality requirements at each 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 machining process Application of approved hazard control safety procedures the use of PPE in relation to handling materials equipment operation and cleanup Use of materials safety management systems hazardous substances and dangerous goods are also covered

Knowledge as a basis for solving processing and material problems including

types characteristics uses and limitations of multiaxis routers

program and machine theory practices and techniques

reading and interpreting drawings

selecting and installing tooling setting jigs and fixtures

programming skills subprograms and parametrics

performance of CAM functions as relevant

downloading and storage of data to complete detailed profiling and other specified operations

effect of tool speed and tool movement speed on product quality and production output

characteristics of materials used and uses of products produced

waste management and importance of nonconforming materials

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 machining 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 and material labels as provided to operators

Writing is required to the level of completing workplace forms and production reports

Basic numeracy is required eg to interpret specifications and make dimensional checks of the finished product estimate materials quantities and compute input data

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 machining 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

machining production quality and output standards are met consistently the process runs consistently and smoothly with the minimum need for human intervention

all safety procedures are adhered to

Assessment method and context

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

Competence in this unit may be assessed

using an appropriate industrial router

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 work environments and sectors within the plastics, rubber and cablemaking industry. It includes the operation of all relevant ancillary equipment where that equipment is integral to the machining process.

Procedures

All operations are performed in accordance with procedures.

Procedures include all relevant workplace procedures, work instructions, temporary instructions, job sheets, cutting lists, plans drawings, designs, manufacturer specifications and relevant industry and government codes and standards.

Tools and equipment

This competency includes use of equipment and tools such as:

multi axis router (includes CNC controlled router, two, three, four or five axis routers, moving bed or moving bridge)

stand-alone or integral computing systems

work clamps, jigs and fixtures (includes vacuum tables)

machine specific tools

relevant personal protective equipment

measuring devices.

Materials

Typical materials, include:

thermally formed sheet un-finished products (eg. polyester or vinyl ester sheets)

mould materials (eg solid timber, MDF, ply, other plastics)

other moulded, cast or fabricated products requiring multi-axis routing to produce the required final shape.

Programming

Programming includes:

converting a computer aided design to data points for separate loading to the router's controller

downloading or passing computer design data (CAD or CAM data) to the machining centre

digitising directly using a 'teach pendant'

other computer programming process.

Hazards

Typical hazards include:

dusts/vapours

slip and fall (such as due to swarf)

temperature (such as due to operating tools)

hazardous materials, including decomposing polymer machining

moving equipment (such as bridges, table, tools and components)

manual handling hazards

equipment operations.

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:

machine settings, including tool speed and travel

work clamps, jigs and fixtures.

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

material degradation

tool selection and design

intermittent faults.

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:

speeds, including tool speed and travel

surface finish and appearance

output rate

product integrity and general conformance to specification/sample.

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