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Elements and Performance Criteria

  1. Plan own work requirements.
  2. Check composites forming process set-up.
  3. Operate and make adjustments as required to the process.
  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 production

Knowledge of organization procedures 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 moulding 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

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 composites forming equipment machine components and ancillary equipment

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

nature of mechanical hydraulic pneumatic electrical and electronic principles which effect machine operation and product development

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

make adjustments to equipment operation to rectify variations in equipment operation or product quality

check composites forming equipment for correct set up to job specifications and implement adjustments or report deviations immediately

make measurements when required and identify product out of specification

distinguish between causes of faults

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 and identifying improvements

interpret from production requests the correct selection and use of equipment materials processes and procedures

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 the operator is able to rectify faults and when assistance is required

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 PMBPROD Operate equipment using moulding compounds it may be coassessed 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 composites moulding process characteristics in relation to the process requirements and the end product

plan own work process within workplace procedures and explain the reasons for the steps in the process

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

problems are anticipated from process observations

problems are efficiently resolved

the process runs consistently and smoothly

Assessment method and context

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

Competence in this unit may be assessed

using an appropriate industrial moulding machine

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 composites products using moulding compounds within the plastics and rubber industries.

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, dies, formers, closures and fittings

equipment, including presses and ancillaries

controller, such as PLC if fitted

relevant personal protective equipment (PPE)

hand tools used in the production process

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 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:

moulding compound, over or undersupplied 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

processing problems

heat

equipment - adjustments/setup

equipment - maintenance requirements incorrect quantity of materials

contaminated materials.

Variables

Key variables to be monitored include:

operating temperatures

cycle time

output rate

surface finish and condition

product weight

product integrity and general conformance to specification/sample.