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:

identify the key activities involved in performing a shutdown in relation to the specific process and machinery involved

make adjustments to the process as required

identify and take appropriate action on problems and potential problems

Consistent performance should be demonstrated. For example, look to see that:

the shutdown is done in an efficient manner, to standard requirements

all safety procedures are always followed.

Assessment method and context

Assessment will occur on an industrial equipment shutdown and will be undertaken in a work-like environment.

Competence in this unit may be assessed:

by using an appropriate equipment requiring long term shutdown

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.

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

Application of the knowledge of equipment and process sufficient to recognise equipment conditions which may lead to out of specification production. For example purging compound left in cylinder can lead to lamination defect

Knowledge and ability to implement organisation procedures and relevant regulatory requirements, within appropriate time constraints and work standards.

Application of the knowledge of managing risks using the hierarchy of controls applied to machine shutdown operations. Application of approved hazard control and safety procedures and the use of PPE in relation to handling materials, equipment operation and cleanup.

Knowledge of and skills in equipment shutdown operations sufficient for effective and efficient performance and solving of problems associated with the job, including:

machine construction, component parts ,structure, functions and general operating principles

machine safety interlocks and systems (including limit switches, overstroke control systems, hydraulic temperature control, material temperature control, machine guards, nozzle purge guard, mould protection systems, ejection limit switches)

production cycle/process/sequence and the effect ofvariations to the different systems/products

characteristics of materials and behaviour in relation to heat, pressure, flow rate and time

machine controls, their identification and function, includes basic controls, open loop, closed loop, shot size and correction capacity, speed, screw position, pressure, clamp pressure, time, screw speed, screw back pressure, screw back time, melt decompress position, sprue break

differences between analogue controls, digital controls, and microprocessor based process controls.

measuring instruments and their function: levelling, temperature sensing devices, thermocouples and pyrometers, transducers, thermometers, pressure and vacuum gauges, flow meters

waste management and importance of non-conforming materials.

Competence also includes the ability to:

plan own work, including predicting consequences and identifying improvements

identify and describe own role and role of others involved directly in equipment shutdown operations

identify when assistance is required to solve problems.

Language, literacy and numeracy requirements

Literacy is required to the level of being able to read and interpret technical specifications and production schedules and specifications.

Verbal communication is required to the extent necessary to instruct the operator.

An appreciation of numbers is also required to the extent needed to set and interpret numeric data.

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 long term shutdown of equipment within the plastics, rubber and cablemaking industries. A long-term stop is where the machine needs to be, or will become, 'cold'.

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.

Ancillaries

Ancillaries includes chillers and heaters.

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

hand tools used in the process

relevant personal protective equipment.

Hazards

Typical hazards include:

spills dusts/vapours

slip and fall, particularly due to spilt polymer granules

temperature

hazardous materials

manual handling hazards

mechanical hazards.

Problems

Anticipate and solve problems means resolve a wide range of routine and non-routine problems, using knowledge of equipment and materials to develop solutions to problems which do not have a known solution/s in the procedures.

Typical process and product problems may include:

cycle interruptions

degradation of materials

cooling and solidification of compounds

rusting and corrosion of moulds put in storage

clearing jams

damage to equipment.

Appropriate action for solving problems outside area of responsibility may be reporting to an appropriate person.

Appropriate action for solving problems within area of responsibility includes asking questions and seeking assistance from appropriate persons/sources.

Variables

Key variables to be monitored include:

temperature

fill rate

screw RPM

speed

brakes

stopping distance.

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