Unit of Competency Mapping – Information for Teachers/Assessors – Information for Learners

FWPSAW3220 Mapping and Delivery Guide
Maintain wide band saw blades

Version 1.0
Issue Date: March 2024


Qualification -
Unit of Competency FWPSAW3220 - Maintain wide band saw blades
Description
Employability Skills
Learning Outcomes and Application This unit of competency describes the outcomes required to level, tension, back-gauge, weld and replace teeth on wide band saw blades. Work is completed in a forest products factory setting.The unit applies to Sawdoctor, Saw Repairer. No licensing, legislative, regulatory, or certification requirements apply to this unit at the time of publication.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.

The following resources must be made available:

tools and equipment used to repair and maintain wide band saw blades:

hammers

stretcher or tension rolls

levelling rolls

tension gauges and straight edges

welding equipment

welding jigs

run-off tabs

punches

engineers hammers

angle grinders

sanders

hand files

abrasive paper or cloth

welding material

tools and equipment to be repaired and maintained:

large heavy duty wide band and gang saws used to cut timber

personal protective equipment suitable for repairing and maintaining wide band saw blades

manufacturers’ instructions for use, repair and maintenance of equipment

work order for repair and maintenance activities with specific instructions for repairing wide band and gang saw blades in specified equipment

documents, spreadsheets and commonly used proformas for recording processing and equipment faults

relevant personnel for the purposes of communicating information

organisational policies and procedures for maintaining wide band saw blades.

Competency is to be assessed in the workplace or a simulated environment that accurately reflects performance in a real workplace setting.

Assessor requirements

Assessors must:

hold the appropriate assessor competency standards as outlined in regulations; and

be able to demonstrate vocational competencies at least to the level being assessed; and

be able to demonstrate how they are continuing to develop their VET knowledge and skills as well as maintaining their industry currency and assessor competence.

Prerequisites/co-requisites
Competency Field
Development and validation strategy and guide for assessors and learners Student Learning Resources Handouts
Activities
Slides
PPT
Assessment 1 Assessment 2 Assessment 3 Assessment 4
Elements of Competency Performance Criteria              
Element: Prepare for maintenance
  • Review work order and where required check with appropriate personnel.
  • Select appropriate repair, maintenance and personal protective equipment and check for operational effectiveness in line with manufacturer's recommendations.
  • Plan maintenance process in line with work order.
       
Element: Assess saw condition
  • Follow organisational safety procedures thoughout all maintenance and repair processes.
  • Remove wide band and gang saws from machinery.
  • Handle saws to avoid damaging teeth.
  • Clean foreign material on blade surfaces for inspection.
  • Inspect saw to assess condition of teeth, tips and saw blade.
  • Check and mark teeth or tips requiring repair or replacement.
  • Declare saw unserviceable where hazardous defects are found.
  • Segregate and dispose of unserviceable saws in line with organisational procedures and environmental protection practices.
       
Element: Level, tension and back-gauge saw blade
  • Assess and match ridges or lumps across and along saw on both sides of blade.
  • Use gauges and straight edges in both directions to test blade accuracy.
  • Remove ridges or lumps progressively through levelling and use stretcher or levelling rolls to flatten.
  • Localise stresses using controlled levelling or rolling patterns to avoid spring-back and re-occurrence of defects.
  • Check saw blade against required curvature using a gauge to identify tensioning requirements.
  • Obtain tension curvature across and along saw blade.
  • Check alignment of saw back against tolerances using a gauge; roll non-conforming areas to obtain required tolerance.
       
Element: Repair teeth and blade cracks
  • Place saw blade in welding jig for heat application and welding activities.
  • Check amount of damaged tooth to be removed or crack to be repaired and mark weld line.
  • Remove metal to proposed line, prepare edge for welding and clean burn marks.
  • Apply heat and pressure to prepare worn, broken or ground surface for metal build up or replacement.
  • Build up or replace teeth or cracked area using material and prcoesses that ensure specified metal penetration and density.
  • Use weld run-off tabs to limit stress and hollows at edges of saw blade.
  • Grind or file teeth or cracks to required shape, tolerance and pitch.
  • Dispose of saws with irreparable teeth, tips or blades in line with organisational procedures environmental protection practices.
  • Identify routine processing and equipment faults and resolve or report to appropriate personnel.
       


Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold italicised text is used, further information is detailed in the range of conditions.

1. Prepare for maintenance

1.1 Review work order and where required check with appropriate personnel.

1.2 Select appropriate repair, maintenance and personal protective equipment and check for operational effectiveness in line with manufacturer's recommendations.

1.3 Plan maintenance process in line with work order.

2. Assess saw condition

2.1 Follow organisational safety procedures thoughout all maintenance and repair processes.

2.2 Remove wide band and gang saws from machinery.

2.3 Handle saws to avoid damaging teeth.

2.4 Clean foreign material on blade surfaces for inspection.

2.5 Inspect saw to assess condition of teeth, tips and saw blade.

2.6 Check and mark teeth or tips requiring repair or replacement.

2.7 Declare saw unserviceable where hazardous defects are found.

2.8 Segregate and dispose of unserviceable saws in line with organisational procedures and environmental protection practices.

3. Level, tension and back-gauge saw blade

3.1 Assess and match ridges or lumps across and along saw on both sides of blade.

3.2 Use gauges and straight edges in both directions to test blade accuracy.

3.3 Remove ridges or lumps progressively through levelling and use stretcher or levelling rolls to flatten.

3.4 Localise stresses using controlled levelling or rolling patterns to avoid spring-back and re-occurrence of defects.

3.5 Check saw blade against required curvature using a gauge to identify tensioning requirements.

3.6 Obtain tension curvature across and along saw blade.

3.7 Check alignment of saw back against tolerances using a gauge; roll non-conforming areas to obtain required tolerance.

4. Repair teeth and blade cracks

4.1 Place saw blade in welding jig for heat application and welding activities.

4.2 Check amount of damaged tooth to be removed or crack to be repaired and mark weld line.

4.3 Remove metal to proposed line, prepare edge for welding and clean burn marks.

4.4 Apply heat and pressure to prepare worn, broken or ground surface for metal build up or replacement.

4.5 Build up or replace teeth or cracked area using material and prcoesses that ensure specified metal penetration and density.

4.6 Use weld run-off tabs to limit stress and hollows at edges of saw blade.

4.7 Grind or file teeth or cracks to required shape, tolerance and pitch.

4.8 Dispose of saws with irreparable teeth, tips or blades in line with organisational procedures environmental protection practices.

4.9 Identify routine processing and equipment faults and resolve or report to appropriate personnel.

A person demonstrating competency in this unit must satisfy all of the elements, performance criteria and foundation skills of this unit. If a specific volume or frequency is not stated below, then evidence must be provided that the following requirements have been performed on at least one occasion:

follow organisational policies and procedures relvant to maintaining wide band saw blades

Maintain wide band and gang saw blades in line with the work order and within prescribed organisational requirements, including:

Remove and replace saws from equipment

Assess saw condition in line with standard operating procedures

Use welding processes and materials to produce:

weld beads which provides full penetration fusing together adjacent metal parts

welds free from any faults that would have the potential to weaken the strength and endurance capability of the weld deposit and weld zone.

A person competent in this unit must be able to demonstrate knowledge of:

purpose, features and operation of heavy duty wide band and gang saws for which repairs are completed

features and names of different parts of wide band saw blades

purpose, features and operation of tools and equipment used to repair and maintain wide band saw blades:

hammers

stretcher or tension rolls

levelling rolls

tension gauges and straight edges

welding equipment and welding materials

importance of levelling blades, setting tension, applying curvature and setting teeth to match requirements for:

characteristics of various materials sawn

speed of the sawing process

direction of the sawing process

cutting angle for sawing

saw blade specifications

methods for:

removing saw blades from heavy duty wide band and gang saws

assessing saw blade condition

hammering, levelling and tensioning blades to specified requirements

applying curvature

welding to build up and replace teeth

grinding and filing teeth to required shape, tolerance and pitch

characteristics of metal used in wide band saw blades and range of force which can be applied without damaging blades

organisational policies and procedures specific to maintaining wide band saw blades:

workplace health and safety with particular emphasis on equipment lock out and use of personal protective equipment

communication reporting lines

recording and reporting processing and equipment faults

environmental protection practices for repairing and maintaining tools and equipment in forest products factory settings:

reducing water and energy use

cleaning plant, tools and equipment

disposing of, recycling and reusing materials


Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assignment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)


Assessment Tasks

Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold italicised text is used, further information is detailed in the range of conditions.

1. Prepare for maintenance

1.1 Review work order and where required check with appropriate personnel.

1.2 Select appropriate repair, maintenance and personal protective equipment and check for operational effectiveness in line with manufacturer's recommendations.

1.3 Plan maintenance process in line with work order.

2. Assess saw condition

2.1 Follow organisational safety procedures thoughout all maintenance and repair processes.

2.2 Remove wide band and gang saws from machinery.

2.3 Handle saws to avoid damaging teeth.

2.4 Clean foreign material on blade surfaces for inspection.

2.5 Inspect saw to assess condition of teeth, tips and saw blade.

2.6 Check and mark teeth or tips requiring repair or replacement.

2.7 Declare saw unserviceable where hazardous defects are found.

2.8 Segregate and dispose of unserviceable saws in line with organisational procedures and environmental protection practices.

3. Level, tension and back-gauge saw blade

3.1 Assess and match ridges or lumps across and along saw on both sides of blade.

3.2 Use gauges and straight edges in both directions to test blade accuracy.

3.3 Remove ridges or lumps progressively through levelling and use stretcher or levelling rolls to flatten.

3.4 Localise stresses using controlled levelling or rolling patterns to avoid spring-back and re-occurrence of defects.

3.5 Check saw blade against required curvature using a gauge to identify tensioning requirements.

3.6 Obtain tension curvature across and along saw blade.

3.7 Check alignment of saw back against tolerances using a gauge; roll non-conforming areas to obtain required tolerance.

4. Repair teeth and blade cracks

4.1 Place saw blade in welding jig for heat application and welding activities.

4.2 Check amount of damaged tooth to be removed or crack to be repaired and mark weld line.

4.3 Remove metal to proposed line, prepare edge for welding and clean burn marks.

4.4 Apply heat and pressure to prepare worn, broken or ground surface for metal build up or replacement.

4.5 Build up or replace teeth or cracked area using material and prcoesses that ensure specified metal penetration and density.

4.6 Use weld run-off tabs to limit stress and hollows at edges of saw blade.

4.7 Grind or file teeth or cracks to required shape, tolerance and pitch.

4.8 Dispose of saws with irreparable teeth, tips or blades in line with organisational procedures environmental protection practices.

4.9 Identify routine processing and equipment faults and resolve or report to appropriate personnel.

Not Applicable

Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.

Observation Checklist

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Review work order and where required check with appropriate personnel. 
Select appropriate repair, maintenance and personal protective equipment and check for operational effectiveness in line with manufacturer's recommendations. 
Plan maintenance process in line with work order. 
Follow organisational safety procedures thoughout all maintenance and repair processes. 
Remove wide band and gang saws from machinery. 
Handle saws to avoid damaging teeth. 
Clean foreign material on blade surfaces for inspection. 
Inspect saw to assess condition of teeth, tips and saw blade. 
Check and mark teeth or tips requiring repair or replacement. 
Declare saw unserviceable where hazardous defects are found. 
Segregate and dispose of unserviceable saws in line with organisational procedures and environmental protection practices. 
Assess and match ridges or lumps across and along saw on both sides of blade. 
Use gauges and straight edges in both directions to test blade accuracy. 
Remove ridges or lumps progressively through levelling and use stretcher or levelling rolls to flatten. 
Localise stresses using controlled levelling or rolling patterns to avoid spring-back and re-occurrence of defects. 
Check saw blade against required curvature using a gauge to identify tensioning requirements. 
Obtain tension curvature across and along saw blade. 
Check alignment of saw back against tolerances using a gauge; roll non-conforming areas to obtain required tolerance. 
Place saw blade in welding jig for heat application and welding activities. 
Check amount of damaged tooth to be removed or crack to be repaired and mark weld line. 
Remove metal to proposed line, prepare edge for welding and clean burn marks. 
Apply heat and pressure to prepare worn, broken or ground surface for metal build up or replacement. 
Build up or replace teeth or cracked area using material and prcoesses that ensure specified metal penetration and density. 
Use weld run-off tabs to limit stress and hollows at edges of saw blade. 
Grind or file teeth or cracks to required shape, tolerance and pitch. 
Dispose of saws with irreparable teeth, tips or blades in line with organisational procedures environmental protection practices. 
Identify routine processing and equipment faults and resolve or report to appropriate personnel. 

Forms

Assessment Cover Sheet

FWPSAW3220 - Maintain wide band saw blades
Assessment task 1: [title]

Student name:

Student ID:

I declare that the assessment tasks submitted for this unit are my own work.

Student signature:

Result: Competent Not yet competent

Feedback to student

 

 

 

 

 

 

 

 

Assessor name:

Signature:

Date:


Assessment Record Sheet

FWPSAW3220 - Maintain wide band saw blades

Student name:

Student ID:

Assessment task 1: [title] Result: Competent Not yet competent

(add lines for each task)

Feedback to student:

 

 

 

 

 

 

 

 

Overall assessment result: Competent Not yet competent

Assessor name:

Signature:

Date:

Student signature:

Date: