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.

Where the assessee does not currently possess evidence of competency in PMBPROD290B Operate filament winding equipment, it may be co-assessed with this unit.

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 critical materials properties and filament winding composites process variables in relation to the process requirements and the end product

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 process runs consistently and smoothly with minimum need for operator intervention

all safety procedures are followed.

Assessment method and context

Assessment will occur on an industrial filament winding machine(s) equipment and will be undertaken in a work-like environment.

Competence in this unit may be assessed:

by use of an appropriate, industrial moulding machine requiring demonstration of start up, operation and shut down procedures

in a situation allowing the generation of evidence of the ability to recognise, anticipate and resolve problems

by use of a suitable simulation and/or a range of case studies/scenarios

by 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 knowledge of the materials, equipment and process sufficient to recognise material and equipment conditions which may lead to out of specification production.For example, amount of applied tension is dependent on the fibre material, the diameter, and the pattern being wound and, if not correct, can affect the void content and fibre volume. Therefore, as the spools unwind the fibre the signals received from the tension bars need to be monitored

Knowledge of organization procedures, quality requirements at each production stage and relevant regulatory requirements, and the ability to implement them within appropriate time constraints and work standards.

Skills to identify the range of possible causes of product faults

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

Knowledge as a basis for solving processing and material problems including:

characteristics of materials in relation to temperature, tension and time for a required strength and surface finish of composite structure

function and operating principles of filament winding equipment, machine components and ancillary equipment including the mechanical, hydraulic, pneumatic, electrical and electronic principles which effect machine operation

impact of machine speed, temperature, pressure, time during cycles on product quality and production output

phases of the filament winding cycle and the effect of the key variables on product quality, in order to make appropriate adjustments to machine settings. For example. the resin wiping phase is needed to remove excess resin from the impregnated fibre, too much resin will affect curing time and strength of composite.

changes to materials at various stages of production

waste management and importance of non-conforming materials

impact of variations in raw materials and equipment operation in relation to final product

material properties and their interactions with process conditions

relationships between material properties and process conditions

changes to material properties to better suit process requirements

product problems related to material properties

product problems related to process conditions

adjustments to process conditions to meet material and product requirements.

Competence also includes the ability to:

plan own work, including predicting consequences and identifying improvements

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 process

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

identify when assistance is required to solve problems.

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.

Numeracy is required to the level of determining required weights/volumes of materials in a resin mix for different circumstances (say using a data sheet), number of layers of impregnated matrix required to yield the required product laminate thickness, and similar activities.

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 production of composite products by filament winding processes within the plastics and rubber industries. It includes the operation of all relevant additional equipment where that equipment is integral to the composites forming 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:

filament winding machines - electrical, pneumatic, mechanical, electromechanical and hydraulic

dies, moulds, mandrels, formers

hand tools, eg knives, cutters

equipment for filament winding equipment and curing

relevant personal protective equipment.

Hazards

Typical hazards may include:

hazardous vapours

hazardous materials

slip and fall

manual handling hazards

moving machinery hazards

temperature

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 routine faults may include:

voids

poor surface finish

colour contamination

curing damage

distorted winding angle pattern.

Typical non-routine faults may include:

damage from mandrel stripping

warping or cracking after moulding

inconsistent fibre spread

filament breakage and fuzz generation.

Typical process and product problems may include:

cracks, dents or imperfections of the mandrel, former, die

variations in materials, colour, consistency or mix

adjustment and settings of the equipment (such as creel-to-head transfer problems)

contamination of materials

curing conditions

variations in materials and/or contamination of materials

processing problems.

Appropriate action for problems outside of 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:

operating temperatures

speeds, including the rotating speed of the mandrel

spool tension

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