This competency covers the operation of centrifugal casting equipment for composite products and the resolving of routine problems to procedure in the production process.This competency is typically performed by operators working either independently or as part of a work team.
Employability Skills
The required outcomes described in this unit contain applicable Employability Skills. The Employability Skills Summary of the qualification(s) in which this unit is packaged will assist in identifying Employability Skill requirements.
Learning Outcomes and Application
Application of this unitThis competency applies to operators who are required to undertake the routine operation of centrifugal casting equipment. The key factors are the making of products to meet quality standards and workplace requirements. It includes:checking job sheets for work requirementsfollowing approved hazard minimisation procedures for any hazards connected with materials and process, using work instructions, labels and materials safety data sheets, in accordance with occupational health and safety (OHS) legislative responsibilitiesmonitoring equipment operation and reporting process variations checking product for quality and conformity to specifications discarding non-conforming products ensuring discarded materials are reused where possible and waste and scrap is disposed of in accordance with workplace instructionsidentifying and taking action on routine process problems completing logs and reports.
Duration and Setting
X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.
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
Elements of Competency
Performance Criteria
Element: Check work requirements.
Identify work requirements from procedures.
Identify product, materials and equipment requirements for job(s).
Recognise hazards and adopt steps required to ensure safety.
Check with supervisor/appropriate person if requirements are not in accordance with usual practice.
Element: Conduct pre-start checks as required.
Check safety gates and guards are in position and working.
Check moulds, closures and fittings to procedures.
Check moulds for cracks, chips, marks and cleanliness.
Check materials, including fibres, resins, additives and release agents are correct.
Undertake other pre-start checks in accordance with procedures.
Element: Operate equipment.
Start machine safely and correctly when required.
Check process is within required limits.
Collect products and store as required.
Check product/process is in specification/to required quality standard.
Maintain supply of material(s) as required.
Complete logs and records when required.
Collect and reprocess/discard scrap, waste and other materials in accordance with procedures.
Clean up equipment and work area in accordance with procedures.
Pause or stop equipment in an emergency, following workplace and emergency procedures.
Element: Respond to routine problems to procedures.
Recognise known faults that occur during the operation.
Identify and take action on causes of routine faults.
Log problems as required.
Identify non-routine process and quality problems and take appropriate action.
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 knowledge and skills defined in this unit. These may include the ability to:
recognise the importance of material properties and qualities
apply approved procedures
take appropriate action to resolve faults or report faults to appropriate personnel
explain and implement emergency shutdown procedures.
Consistent performance should be demonstrated. For example, look to see that:
production standards are met consistently
upstream and down stream communication is timely
effective operating procedures and work instructions are read and interpreted correctly
problems are identified and appropriate action is taken (ie the problem is fixed or reported)
all safety procedures are followed.
Assessment method and context
Assessment will occur on an industrial centrifugal casting machine(s) equipment and will be undertaken in a work-like environment.
Competence in this unit may be assessed:
by using an appropriate, industrial centrifugal casting machine requiring demonstration of operation and emergency stop procedures
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. No other special resources are required.
Access must be provided to appropriate learning and/or assessment support when required. Where applicable, physical resources should include equipment modified for people with disabilities.
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 an operational knowledge of the materials, equipment and process sufficient to recognise out of specification products, process problems and materials faults.
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 centrifugal casting process. Application of approved hazard control, safety procedures and the use of PPE in relation to handling materials, equipment operation and cleanup.
Knowledge of and skills in the operation of centrifugal casting equipment and main components sufficient for consistent production of quality products including:
operation of centrifugal casting equipment and components
production workflow sequences and materials demand
reasons for checking process control panels and reporting readings which do not conform to the work instructions
approved hazard control and safety procedures and the use of PPE in relation to handling materials, equipment operation and cleanup
potential effects of variations in raw materials and equipment operation in relation to quality of product
waste management and importance of reusing non-conforming products wherever possible
correct selection and use of equipment, materials, processes and procedures
identify factors which may affect product quality or production output and appropriate remedies
distinguish between possible causes of routine faults.
Competence also includes the ability to:
plan own work, including predicting consequences and identifying improvements
monitor equipment operation and product quality
identify when the operator is able to rectify faults, when assistance is required and who is the appropriate source for assistance
identify and describe own role and role of others involved directly in the process
Language, literacy and numeracy requirements
This unit requires the ability to read and interpret typical product specifications, job sheets, procedures, material labels and safety information as provided to operators.
Writing is required to the level of completing workplace forms.
Basic numeracy is required, eg to determine that two 25 kg bags are needed to make up a requirement for 50 kg.
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 the operation of centrifugal casting equipment for the manufacture of composite products (eg pipes) including moulds, pumps, sprays and programmable logic controllers (PLC) if fitted.
It includes the operation of all relevant additional equipment where that equipment is integral to the process.
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:
centrifugal casting equipment
pumps and fittings, such as hoses and couplings
controller, such as PLC if fitted
hand tools used in the this process
material loading equipment used for loading of raw materials
relevant personal protective equipment.
Hazards
Typical hazards include:
spills
dusts/vapours
slip and fall
temperature
hazardous substances
moving equipment
manual handling hazards.
Problems
'Respond to routine problems' means 'apply known solutions to a limited range of predictable problems'. Typical process problems may include:
equipment malfunction
variations in process conditions
variations in materials or contamination of materials
equipment, tool or mould damage
incorrect quantity of materials
mould damage
wrong raw materials/additives.
Typical product problems may include:
routine product faults
machine malfunction
mould/tooling problems
variations in materials and/or contamination of materials
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
Identify work requirements from procedures.
Identify product, materials and equipment requirements for job(s).
Recognise hazards and adopt steps required to ensure safety.
Check with supervisor/appropriate person if requirements are not in accordance with usual practice.
Check safety gates and guards are in position and working.
Check moulds, closures and fittings to procedures.
Check moulds for cracks, chips, marks and cleanliness.
Check materials, including fibres, resins, additives and release agents are correct.
Undertake other pre-start checks in accordance with procedures.
Start machine safely and correctly when required.
Check process is within required limits.
Collect products and store as required.
Check product/process is in specification/to required quality standard.
Maintain supply of material(s) as required.
Complete logs and records when required.
Collect and reprocess/discard scrap, waste and other materials in accordance with procedures.
Clean up equipment and work area in accordance with procedures.
Pause or stop equipment in an emergency, following workplace and emergency procedures.
Recognise known faults that occur during the operation.
Identify and take action on causes of routine faults.
Log problems as required.
Identify non-routine process and quality problems and take appropriate action.