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Elements and Performance Criteria

  1. Plan own work requirements.
  2. Start resin infusion moulding process to procedures.
  3. Operate and make adjustments to the resin infusion process to procedures.
  4. Shut down machine to procedures.
  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 productionFor example once resin infusion begins there is very little that can be done to rectify a problem at this point If a leak were to occur eventhe smallest amount of air introduced could potentially destroy a composite part There aresome cases where problems can be corrected but the best solution is to check and monitor equipment and set up before infusion

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 knowledge of managing risks using the hierarchy of controlsapplied to the resin infusion process Application of approved hazard control and safety procedures and the use of PPE in relation to handling materials equipment operation and cleanup

Skills 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 pressure and time

function and operating principles of composites forming equipment machine components and ancillary equipment including the mechanical hydraulic pneumatic electrical and electronic principles which effect machine operation

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

phases of the resin infusion composite forming cycle and the effect of the key variables on product quality in order to make appropriate adjustments to equipment settings For example the vacuum is applied while reinforcements are still dry which allows for any possible leaks to be sought out before resin is infused If something is not sitting properly the vacuum need only be released and readjusted This decreases the possibility of damaged composite products

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 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

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

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 Operate resin infusion moulding equipment it may be coassessed with this unit

Where the assessee does not currently possess evidence of competency in PMBPROD291B Operate resin infusion moulding equipment, 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 resin infusion process variables in relation to the process requirements and the end product

make adjustments to the process as required

identify and take 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 infusion moulding equipment and will be undertaken in a worklike environment

Competence in this unit may be assessed

using appropriate industrial resin infusion equipment requiring demonstration of starting operating and completing the composite moulding process

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 manufacture of composite products using resin infusion equipment within the plastics and rubber industries.

It includes all moulds, pumps and programmable logic controllers (PLCs) if fitted and all relevant ancillary equipment integral to the composites forming 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:

moulds, closures and fittings

vacuum pumps and fittings (such as couplings, hoses, breathers, bleeders)

additional equipment (such as resin bucket, resin line holder, zip-strips)

controller (such as PLC if fitted)

relevant personal protective equipment ( PPE)

hand tools used in the production process (such as clamps to stop resin moving up vacuum hose)

ancillary materials (such as release films and fabrics, sealant tapes, preforms, cores, and pre-pregs)

material loading equipment used for loading of raw materials.

Hazards

Typical hazards include:

hazardous vapours and materials

fibres, airborne and handled

humidity, air temperatures, radiant heat, hot moulds

stationary and moving machinery, parts and components

manual handling hazards.

Problems

'Anticipate and solve problems' means resolve a wide variety 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 may include:

resin pooling

under-saturation of resin

dry reinforcements not sitting flat

leaks in vacuum bag

poor colour dispersion

poor surface finish

dry spots

vacuum switch-off timing incorrect.

Non-routine faults which may have multiple causes include:

mould release problems

stoppage of resin flow

excess resin

warping or cracking after moulding

variations in vacuum

variations affecting cure rate.

Typical process and product problems may include:

resin, over or under supplied to mould

release agents performance

contamination

temperature variations, affecting resin cure-rate

blemishes

missing detail

warped moulds or dies

worn or damaged mould parts or fittings

variations in materials and/or contamination of materials.

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

cycle time (such as the resin filling time)

output rate

vacuum pressure

surface finish and condition

equipment - adjustments/setup

product weight

product integrity and general conformance to specification/sample.