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Elements and Performance Criteria

  1. Identify required materials and equipment.
  2. Set up welding equipment and materials for sequence or continuous operation.
  3. Prepare plastic materials or components for welding in a sequence or continuous operation.
  4. Weld to specification.
  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 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

Skill to identify the range of possible causes of product faults

Application of the knowledge of managing risks using the hierarchy of controls applied to the welding 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 solving processing and material problems including

characteristics of materials and behaviour in relation to heat pressure flow rate and time in the welding process

different welding processes and their effect on the welded product

selection of appropriate welding processes for a particular application

function and operating principles of welding equipment equipment components and ancillary equipment including the heating and feeding mechanisms and material supportingfeeding mechanisms

impact of weld speed temperature pressure on product quality and production output

phases of the welding process and the effect of the key variables on product quality in order to make appropriate adjustments to equipment settings

processing behaviour of those polymers which are welded at the workplace

changes to materials at various stages of production

waste management and importance of nonconforming materials

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

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

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 welding process

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

identify when the 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

Basic numeracy is also required to interpret specifications make measurements and monitor and interpret process variables

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 PMBPRODB Weld plastics materials it may be coassessed with this unit

Where the assessee does not currently possess evidence of competency in PMBPROD287B Weld plastics materials, 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 welding process variables 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

Weld quality must meet specification See Draft Australian Standard WD Qualification and certification of Plastics welding personnel or its replacement

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

upstream and down stream communication is timely and effective

Assessment method and context

Assessment will occur on an industrial plastics welding equipment and will be undertaken in a worklike environment

Competence in this unit may be assessed

using appropriate industrial welding 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


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 includes the processes required to weld plastic pipe, sheet and film materials to a required specification, including continuous production operations on specialised welding equipment, and often involves the use of ancillary equipment.

Materials may be from a range of thermoplastic materials in the form of pipeline systems and component parts, sheet where used in sequenced production operations including vinyl product fabrication, and film where associated with continuous production operations.

It includes the operation of hot plate (heated tool), extrusion, high frequency sound (ultrasonic), electrostatic (radio frequency) and thermal induction (heat) welding systems and production machinery designed for sequenced or continuous production operations, and all relevant ancillary equipment.

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 unit of competency includes use of equipment and tools such as:

welding equipment and machinery

hand tools as required

relevant personal protective equipment.

Hazards

Typical hazards include:

fumes from overheating or poor ventilation

cuts from sharp edges on components

burns from manual handling

eye injury

welding equipment, ancillary plant, parts and attachments.

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:

component materials incompatible or not to specification

incorrect alignment or assembly in welding process

welding edge, joint, fillet, gusset or seam not suitable for welding

material feed systems not correctly sequenced (continuous production)

incorrect selection of welding process

surface moisture contacting welding or fusion points

misalignment of welding contacts or die components

sequencing problems, procedure too fast or too slow

incorrect materials selected

poor surface preparation

bonding problems, weld does not meet specification

surface and finish defects.

Variables

Key variables to be monitored include:

differences between actual and set temperatures

speeds (including feed speed for filler, speed of weld head)

colour and uniformity

surface finish/appearance

tolerance for weld/joint

consistency of weld

product output rate

product integrity and general conformance to specification and quality sample

mechanical strength of weld (eg tensile strength results).