- PMBPREP305B - Change extrusion die and setup
Unit of Competency Mapping – Information for Teachers/Assessors – Information for Learners
PMBPREP305B Mapping and Delivery Guide
Change extrusion die and setup
Version 1.0
Issue Date: April 2024
Qualification | - |
Unit of Competency | PMBPREP305B - Change extrusion die and setup |
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Description | This competency covers the removal and refitting of dies, pins, sizing dies (calibrator), vacuum blocks and seals in preparation for production. This competency applies to extrusion, and similar, dies. For all other dies use PMBPREP304A Change equipment dies.This competency is typically performed by advanced operators demonstrating some relevant theoretical knowledge and using a range of well-developed skills requiring some discretion and judgement. | ||
Employability Skills | This unit contains employability skills. | ||
Learning Outcomes and Application | Application of this unitThis competency applies to advanced operators who are responsible for changing setups to meet the production schedule for an extrusion line process. Setup changes means the work involving the extrusion die and sizing equipment only. The key factors are the safe and precise removal and installation. The operator will:plan and prepare the change, including informing others selecting dies that match product/process specification removing, cleaning and storing the existing diesfit the replacement die according to specification testing the changeover and fine tuning as needed. | ||
Duration and Setting | X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting. |
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Prerequisites/co-requisites | PrerequisitesThis unit has no prerequisites. | ||
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 | |
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Elements of Competency | Performance Criteria | |||||||
Element: Prepare to change dies or cores. |
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Element: Shut down extruder. |
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Element: Change setup. |
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Element: Restart and test-run the new setup. |
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Element: Anticipate and solve problems |
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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.
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.
Critical aspects for assessment and evidence required to demonstrate competency in this unit
It is essential that competence is demonstrated in the ability to perform a die-change smoothly and methodically, which will put the extruder back into full production of in-specification product in standard time. In particular it is essential that the operator can:
select, install and check the performance of die and cores
locate, interpret and apply relevant information
maintain workplace records
identify and safely handle products and materials
apply safety precautions appropriate to the task
recognise potential situations requiring action and then implement appropriate action.
Consistent performance should be demonstrated. For example, look to see that production standards are met consistently.
Assessment method and context
It is preferred that assessment takes place on an industrial extruder in a work environment.
Competence in this unit may be assessed:
on a processing plant, allowing for operation under all normal and a range of abnormal conditions
in a situation allowing for the generation of evidence of the ability to respond to problems
by using a suitable simulation and/or a range of case studies/scenarios
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 practical/simulation 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 studies/scenarios 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.
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.
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 organisation 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 extrusion process. Application of approved hazard control, safety procedures, the use of PPE in relation to handling materials, equipment operation and clean up.
Knowledge as a basis for solving processing and material problems, including:
impact of incorrect or faulty fitting
production work-flow sequences
correct selection and use of equipment and procedures
hazards of the removal and fitting process and appropriate hazard control procedures
the performance of die and cores
relevant information and workplace records
safety precautions appropriate to the task.
Competence also includes the ability to:
plan own work, including predicting consequences and identifying improvements
start up equipment and make appropriate adjustments to bring process on line
take samples when required and identify product out of specification
safely shut down equipment in normal or abnormal circumstances
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 hazards of the materials and process
implement appropriate procedures for hazard control
use PPE
safely handle products and materials
read relevant safety information and apply safety precautions appropriate to the task.
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.
Writing is required to the level of completing workplace forms and production reports.
Basic numeracy is required, eg, to interpret and use dimensional and tolerance information relating to the die, design drawings and specifications.
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 unit includes the selection and fitting of dies and cores.
This competency applies to all work environments and sectors within the plastics, rubber and cablemaking industry which use extrusion type dies and cores. It includes the operation of all relevant ancillary equipment.
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:
hand carts and trolleys
hoists/lifting equipment not requiring any special permits or licences basic hand tools
hand tools
relevant personal protective equipment.
Hazards
Typical hazards include:
hazardous materials
manual handling hazards
hot surfaces.
Problems
Typical process and product problems may include:
lack of cleaning leading to corrosion
inadequate fitting
fine adjustments to optimise production.
Variables
Key variables to be monitored include:
fitting and adjustments to die
adjustments to extruder settings
quality of the product against product specifications.
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 |
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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 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
PMBPREP305B - 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:
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Date:
Assessment Record Sheet
PMBPREP305B - 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:
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Date:
Student signature:
Date: