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Elements and Performance Criteria

1. Confirm requirements of modified/new product.
   • Check that specifications for new product are complete and unambiguous.
   • Clarify items which are unclear or beyond the normal scope of work.
   • Investigate the type of changes/modifications which are likely to meet these requirements.
   • Clarify any possible issues if processes, plant, equipment or tooling outside the plant's normal range are likely to be required.
   • Identify tests required on trial product.
2. Identify similar existing product(s).
   • Identify existing product(s) with similar specifications.
   • Estimate required changes to existing product(s).
   • Check practicality of proposed changes.
   • Check HSE impacts of proposed changes.
   • Draft initial product design and manufacturing process.
3. Prepare trial products.
   • Identify and control all hazards for pilot/trial production.
   • Identify and check all required plant and equipment.
   • Obtain and prepare all required materials and tooling.
   • Make trial product and obtain sample(s).
   • Interpret test results.
   • Modify product design/manufacturing process and repeat trials as required.
4. Check initial factory trial.
   • Check availability of required resources and plant availability.
   • Ensure all authorities and permissions have been obtained.
   • Check all hazard controls have been implemented.
   • Monitor factory trial manufacture of product.
   • Obtain sample(s) and interpret test results.
   • Modify product design/manufacturing process and repeat factory trial as required.
5. Complete trial
   • Complete all required records and reports.
   • Check any changes to resources and procedures have been incorporated into standard procedures.
   • Ensure any additional HSE or skill requirements have been included in future plans.

Required Skills

This describes the essential skills and knowledge and their level required for this unit

Competence in this unit requires knowledge of

product features and their impact on product properties

tests which might be used and the applicability of the different tests for different product properties

relevant manufacturing methods and the impacts of different methodsprocesses on product properties

relevant existing products and their properties

requirements for factory trialling and scaling up from laboratorypilot scale

suppliers of materials and tooling

sources of information about materials and tooling

Language literacy and numeracy requirements

This unit requires the ability to read and interpret technical specifications and literature and to communicate with all relevant stakeholders

Writing product design specifications processing instructions and similar documents

Numeracy is required to interpret technical specifications and test results and to calculate quantities and proportions required for the specification make adjustments and then to scale up to factory trials

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

This unit may be best assessed either through a portfolio of products developed modified or the use of projects to developmodify a range of existing products

Critical aspects

It is essential that competence is demonstrated in the knowledge and skills defined in this unit These may include the ability to

clarify the requirements of the modified product

make an initial design and process and justify that initial design and process

modify the designprocess based on test data and justify the modifications

make final adjustments for the scaled up product to work successfully in the factory

Consistent performance should be demonstrated through the evidence from several formula modifications requiring different types of changes

Context of 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 A holistic approach should be taken to the assessment

Competence in this unit may be assessed

on the plant

using questions to assess knowledge

in a laboratorypilot plant

by using a suitable simulation andor a range of case studiesscenarios

through a combination of these techniques

Method of assessment

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 advanced operators who modify products. They will typically be based in a laboratory or similar pilot/product development area but will also have responsibility in the factory for monitoring new products and ensuring that modified products are suitable when released for standard production.

An operator working at this level would typically be responsible to a more senior operator and would work closely with them on new products and major modifications of existing products.

The operator would not be expected to develop a new product or make a major modification to an existing product unless under the direction of a more senior operator.

Procedures

All operations are performed in accordance with procedures.

Procedures means all relevant workplace procedures, work instructions, temporary instructions and relevant industry and government codes and standards.

Health, Safety and Environment (HSE)

All operations are subject to stringent health, safety and environment requirements, which may be imposed through State or federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between performance criteria and HSE requirements, the operator needs to ensure the HSE requirements take precedence.

Tests

Tests includes the normal range of physical, chemical and environmental (weathering) tests which might be applied to the product.

Trial product

The trial product may be full sized, or a scale version. Trial production will typically be 'one off' or small run compared to final production which will occur in normal run sizes under normal conditions.

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