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. For example changes in press/temperature, pre-scorching of rubber or changes in pressure can all lead to faulty mouldings, but with different properties.
Knowledge of organization procedures, quality requirements at each production stage 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 injection moulding process. Application of approved hazard control and safety procedures and the use of PPE in relation to handling materials, equipment operation and cleanup.
Skill to identify the range of possible causes of product faults.
Knowledge as a basis for solving processing and material problems including:
characteristics of materials and behaviour in relation to heat, pressure and time
function and operating principles of compression moulding equipment, machine components and ancillary equipment
impact of machine speed, temperature, pressure, time during cycles on product quality and production output
compression moulding cycle and the importance of machine set-up and warm-up for effective processing of materials
impact of variations in raw materials and equipment operation in relation to final product
changes to materials at various stages of production
quality requirements at each production stage
identify and read transducers for hydraulic position and clamping force
distinguish between causes of faults
polymer properties and their interactions with process conditions
relationships between polymer properties and process conditions
changes to polymer properties to better suit process requirements.
product problems related to polymer properties
product problems related to process conditions
adjustments to process conditions to meet polymer and product requirements.
Competence also includes the ability to:
plan own work sequence, including identification of key checkpoints for equipment monitoring, product quality checks and monitoring of supplies and downstream operations
maintain output and product quality using appropriate instruments, controls, test information and readings
identify and describe own role and role of others involved directly in the compression moulding process
identify factors which may affect product quality or production output and appropriate remedies
identify when the operator is able to rectify faults and when assistance is required.
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.
Basic numeracy is required, eg, to determine the size/weight of blanks and how many moulded products can be obtained from a batch/tray of green rubber.
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 all compression moulding within the plastics and rubber industries. It includes the operation of all relevant additional equipment where that equipment is integral to the moulding process.
Procedures
All operations are performed in accordance with procedures.
Procedures mean all relevant workplace procedures, work instructions, temporary instructions and relevant industry and government codes and standards. These may include:
original manufacturer instructions and guidelines for the use of the moulding equipment
relevant procedures relating to safe working practices prescribed for the equipment
local OHS legislation and/or Regulations
site-specific instructions based on production requirements.
Tools and equipment
This competency includes use of equipment and tools such as:
knives/scissors
scoops, measures, scales, fixed gauges
levers and other mould handling devices
mould release sprays or other means of application
relevant personal protective equipment.
Hazards
Typical hazards include:
fumes/vapours
crushing hazards
temperature
hazardous materials
manual handling hazards
equipment operations.
Problems
'Anticipate and solve problems' means resolve a wide range of routine and non-routine problems, using product and process knowledge to develop solutions to problems which do not have a known solution/a solution recorded in the procedures.
Typical process and product problems may include:
variations in materials/scorchy rubber
contamination of materials
blank/charge/shot size
mould temperature/temperature
profile demoulding
dirty moulds, damaged moulds.
Causes of faults
Causes of faults include:
wrong raw materials
incorrect quantity of materials
contaminated materials
dirty mould; damaged mould
mould open too long
mould/product temperature/temperature profile
pressure.
Variables
Key variables to be monitored include:
operating temperatures
colour
cycle time
output rate
product weight
product integrity and general conformance to specification/sample.
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