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

PMBPREP305 Mapping and Delivery Guide
Change extrusion die and setup

Version 1.0
Issue Date: March 2024


Qualification -
Unit of Competency PMBPREP305 - Change extrusion die and setup
Description
Employability Skills
Learning Outcomes and Application This unit of competency covers the skills and knowledge required to remove and refit dies, pins, sizing dies (calibrator), vacuum blocks and seals as used in extrusion line processes.This unit of competency is typically performed by experienced operators or those in similar roles who are required to plan and prepare the change, select dies that match product/process specification, make the changeover and test the changeover, and fine tune settings to meet specifications.This unit of competency applies to an individual working alone or as part of a team or group and working in liaison with other shift team members, team leader and supervisor, as appropriate.No licensing, legislative 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 unit should be assessed holistically and the judgement of competence shall be based on a holistic assessment of the evidence.

In all plants it may be appropriate to assess this unit concurrently with units such as:

teamwork

communication.

The collection of performance evidence:

should occur over a range of situations which include typical disruptions to normal, smooth operations and provide for demonstration of responding to problems

will typically include a supervisor/third-party report or other evidence, focusing on consistent performance and problem recognition and solving. A supervisor/third-party report must be prepared by someone who has a direct, relevant, current relationship with the person being assessed and who is in a position to form a judgement on workplace performance relevant to the unit of competency

must include the use of industry appropriate materials, tools, equipment, data and documentation

may use industry-based simulation for all or part of the unit particularly where safety, lack of opportunity or significant cost is an issue.

Assessment should occur in operational workplace situations. Where this is not possible or where personal safety or environmental damage are limiting factors assessment must occur in a sufficiently rigorous simulated environment that reflects realistic operational workplace conditions. This must cover all aspects of workplace performance, including environment, task skills, task management skills, contingency management skills and job role environment skills.

Assessment in a simulated environment should use evidence collected from demonstration of skills and one or more of:

walk-throughs

pilot plant operation

industry-based case studies/scenarios

‘what ifs’.

Knowledge evidence may be collected concurrently with performance evidence or through an independent process, such as workbooks, written assessments or interviews.

Assessment processes and techniques must be appropriate to the language, literacy and numeracy requirements of the work being performed and the needs of the candidate.

Conditions for assessment must include access to all tools, equipment, materials and documentation required, including relevant workplace procedures, product and manufacturing specifications associated with this unit.

The regulatory framework will be reflected in workplace policies and procedures and is not required to be independently assessed.

Foundation skills are integral to competent performance of the unit and should not be assessed separately.

Assessors must satisfy the assessor competency requirements that are in place at the time of the assessment as set by the VET regulator.

In addition the assessor or anyone acting in subject matter expert role in assessment shall demonstrate both technical competency and currency. If the assessor cannot demonstrate technical competency and currency they shall assess with a subject matter expert who does meet these requirements.

Technical competence can be demonstrated through one or more of:

relevant VET or other qualification/Statement of Attainment

appropriate workplace experience undertaking the type of work being assessed under routine and non-routine conditions

appropriate workplace experience supervising/evaluating the type of work being assessed under routine and non-routine conditions

Currency can be demonstrated through one or more of:

being currently employed undertaking the type of work being assessed

being employed by the organisation undertaking the type of work being assessed and having maintained currency in accordance with that organisation’s policies and procedures

having consulted/had contact with an organisation undertaking the type of work being assessed within the last twelve months, the consultation/contact being related to assessment

conducting on the job training/assessments of the type of work being assessed

being an active member of a relevant professional body and participating in activities relevant to the assessment of this type of work.

Prerequisites/co-requisites
Competency Field Preparation
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 to change dies or cores
  • Plan process for closing down machinery and inform relevant personnel
  • Take last-off samples as required for die reports
  • Select dies or cores to match product/process specification
  • Implement measures to control identified hazards in line with procedures and duty of care
       
Element: Shut down extruder
  • Stop downstream equipment
  • Stop feed, drop temperatures, stop vacuum pump and purge the extruder
  • Activate isolating locks, disconnect power to heaters
       
Element: Change set-up
  • Remove, clean and store die according to workplace procedures
  • Fit replacement die ensuring that locating devices and marks are matched and securing devices are installed and tightened to specification
  • Remove and re-fit calibrator sleeve and seals as required
  • Set heats according to pre-start procedures
       
Element: Restart and test-run the new set-up
  • Check operation of die against product quality
  • Compare machine setting ranges against documented requirements
  • Check the first-off sample for required standards
  • Fine-tune settings and other production variables as required
  • Note variances between standard operating procedures (SOPs) and actual production run
  • Complete workplace documentation and report to appropriate personnel
       
Element: Anticipate and solve problems
  • Recognise a problem or a potential problem
  • Determine problems needing priority action
  • Refer problems outside area of responsibility to appropriate person, with possible causes
  • Seek information and assistance as required to solve problems
  • Solve problems within area of responsibility
  • Follow through items initiated until final resolution has occurred
       


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.

1

Prepare to change dies or cores

1.1

Plan process for closing down machinery and inform relevant personnel

1.2

Take last-off samples as required for die reports

1.3

Select dies or cores to match product/process specification

1.4

Implement measures to control identified hazards in line with procedures and duty of care

2

Shut down extruder

2.1

Stop downstream equipment

2.2

Stop feed, drop temperatures, stop vacuum pump and purge the extruder

2.3

Activate isolating locks, disconnect power to heaters

3

Change set-up

3.1

Remove, clean and store die according to workplace procedures

3.2

Fit replacement die ensuring that locating devices and marks are matched and securing devices are installed and tightened to specification

3.3

Remove and re-fit calibrator sleeve and seals as required

3.4

Set heats according to pre-start procedures

4

Restart and test-run the new set-up

4.1

Check operation of die against product quality

4.2

Compare machine setting ranges against documented requirements

4.3

Check the first-off sample for required standards

4.4

Fine-tune settings and other production variables as required

4.5

Note variances between standard operating procedures (SOPs) and actual production run

4.6

Complete workplace documentation and report to appropriate personnel

5

Anticipate and solve problems

5.1

Recognise a problem or a potential problem

5.2

Determine problems needing priority action

5.3

Refer problems outside area of responsibility to appropriate person, with possible causes

5.4

Seek information and assistance as required to solve problems

5.5

Solve problems within area of responsibility

5.6

Follow through items initiated until final resolution has occurred

Evidence required to demonstrate competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria and demonstrate the ability to:

read and interpret procedures and job specifications

plan and perform shutdown procedures for extruder and downstream equipment

remove, clean and store die according to procedures

select dies, calibration sleeves, seals and tools and install replacement die to meet specifications

set machine conditions for new die

check the installation and operation of new die to identify conformance and/or non-conformance to specifications

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

identify hazards and apply relevant hazard controls

distinguish between causes of problems/alarm/fault indications, such as:

operational problems

instrument failure/malfunction

electrical failure/malfunction

mechanical failure/malfunction

wrong readings

equipment design deficiencies

product parameters (temperature, flows, pressure and levels)

resolve non-routine problems

communicate effectively with team/work group and supervisors

complete workplace records

do basic arithmetical manipulations, including additions, subtractions, divisions, fractions and percentages.

Must provide evidence that demonstrates knowledge relevant to their job sufficient to fulfil their job role, including knowledge of:

function and principles of operation of extrusion equipment

methods of connecting extrusion dies to machines

extruder and ancillary equipment shut down processes

impact of incorrect or faulty fitting

the function of each machine setting and the appropriate ranges of settings for specific dies

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

routine and non-routine problems that may arise, the range of possible causes and appropriate actions

organisation procedures relevant to the work environment/job role

hierarchy of control

hazards that may arise in the job/work environment and:

their possible causes

potential consequences

appropriate risk controls.


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.

1

Prepare to change dies or cores

1.1

Plan process for closing down machinery and inform relevant personnel

1.2

Take last-off samples as required for die reports

1.3

Select dies or cores to match product/process specification

1.4

Implement measures to control identified hazards in line with procedures and duty of care

2

Shut down extruder

2.1

Stop downstream equipment

2.2

Stop feed, drop temperatures, stop vacuum pump and purge the extruder

2.3

Activate isolating locks, disconnect power to heaters

3

Change set-up

3.1

Remove, clean and store die according to workplace procedures

3.2

Fit replacement die ensuring that locating devices and marks are matched and securing devices are installed and tightened to specification

3.3

Remove and re-fit calibrator sleeve and seals as required

3.4

Set heats according to pre-start procedures

4

Restart and test-run the new set-up

4.1

Check operation of die against product quality

4.2

Compare machine setting ranges against documented requirements

4.3

Check the first-off sample for required standards

4.4

Fine-tune settings and other production variables as required

4.5

Note variances between standard operating procedures (SOPs) and actual production run

4.6

Complete workplace documentation and report to appropriate personnel

5

Anticipate and solve problems

5.1

Recognise a problem or a potential problem

5.2

Determine problems needing priority action

5.3

Refer problems outside area of responsibility to appropriate person, with possible causes

5.4

Seek information and assistance as required to solve problems

5.5

Solve problems within area of responsibility

5.6

Follow through items initiated until final resolution has occurred

This field allows for different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.

Regulatory framework

The latest version of all legislation, regulations, industry codes of practice and Australian/international standards, or the version specified by the local regulatory authority, must be used.

Applicable legislation, regulations, standards and codes of practice include:

health, safety and environmental (HSE) legislation, regulations and codes of practice relevant to the workplace, manual handling and hazardous materials

Australian/international standards relevant to the materials being used and products being made

any relevant licence and certification requirements.

All operations to which this unit applies are subject to stringent HSE requirements, which may be imposed through state/territory or federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between performance criteria and such requirements the legislative requirements take precedence.

Procedures

All operations must be performed in accordance with relevant procedures.

Procedures are written, verbal, visual, computer-based or in some other form, and include one or any combination of:

emergency procedures

work instructions

SOPs

safe work method statements (SWMS)

formulas/recipes

batch sheets

temporary instructions

any similar instructions provided for the smooth running of the plant.

Tools and equipment

Tools and equipment include one or more of:

hand carts and trolleys

hoists/lifting equipment not requiring any special permits or licences

basic hand tools

hand tools

relevant personal protective equipment (PPE).

Hazards

Hazards must be identified and controlled. Identifying hazards requires consideration of:

weight, shape, volume of materials to be handled

hazardous products and materials

hot surfaces

sharp edges, protrusions or obstructions

slippery surfaces, spills or leaks

heat, smoke, dust, vapours or other atmospheric hazards

electricity

gas

gases and liquids under pressure

structural hazards

equipment failures

machinery, equipment, product mass

other hazards that might arise

Non-routine problems

Non-routine problems must be resolved by applying operational knowledge to develop new solutions, either individually or in collaboration with relevant experts, to:

determine problems needing action

determine possible fault causes

develop solutions to problems which do not have a known solution

follow through items initiated until final resolution has occurred

report problems outside area of responsibility to designated person.

Non-routine problems are unexpected problems or variations of previous problems and include one or more of:

corrosion of die surface

inadequate fitting

faulty components

machine malfunction

variation in product.

Operational knowledge includes one or more of:

procedures

training

technical information such as journals, engineering specifications

remembered experience

relevant knowledge obtained from appropriate people.

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
Plan process for closing down machinery and inform relevant personnel 
Take last-off samples as required for die reports 
Select dies or cores to match product/process specification 
Implement measures to control identified hazards in line with procedures and duty of care 
Stop downstream equipment 
Stop feed, drop temperatures, stop vacuum pump and purge the extruder 
Activate isolating locks, disconnect power to heaters 
Remove, clean and store die according to workplace procedures 
Fit replacement die ensuring that locating devices and marks are matched and securing devices are installed and tightened to specification 
Remove and re-fit calibrator sleeve and seals as required 
Set heats according to pre-start procedures 
Check operation of die against product quality 
Compare machine setting ranges against documented requirements 
Check the first-off sample for required standards 
Fine-tune settings and other production variables as required 
Note variances between standard operating procedures (SOPs) and actual production run 
Complete workplace documentation and report to appropriate personnel 
Recognise a problem or a potential problem 
Determine problems needing priority action 
Refer problems outside area of responsibility to appropriate person, with possible causes 
Seek information and assistance as required to solve problems 
Solve problems within area of responsibility 
Follow through items initiated until final resolution has occurred 

Forms

Assessment Cover Sheet

PMBPREP305 - Change extrusion die and setup
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

PMBPREP305 - Change extrusion die and setup

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: