PMBPROD396B - Produce composites using centrifugal casting Competency Mapping Template
Unit of Competency Mapping – Information for Teachers/Assessors – Information for Learners
PMBPROD396B Mapping and Delivery Guide Produce composites using centrifugal casting
Version 1.0 Issue Date: March 2024
Qualification
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Unit of Competency
PMBPROD396B - Produce composites using centrifugal casting
Description
This competency covers preparation and operations for forming composite products (typically pipes) using centrifugal casting processes and the solving of non-routine problems.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 operators who are involved in the production of composite products by centrifugal casting equipment. The key factors are the production of material meeting quality standards and product requirements and the recognition and resolving of a range of routine and non-routine problems.It includes:identifying and planning own work requirements from production requestsidentifying and minimising any hazards connected with materials and process from materials safety data sheets, labels and workplace proceduressetting up equipment, sprays, dies, mandrels, winders, moulds and formerschecking materials for conformity to job requirementsmonitoring equipment operation and correcting process variationscorrecting materials, equipment or process variations and making appropriate adjustmentsdiscarding non-conforming products ensuring discarded materials are reused where possible and waste and scrap is disposed of in accordance with workplace instructionssolving routine and non-routine composites forming equipment and process problems, seeking guidance where necessary or appropriatecompleting 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 the prerequisite of PMBPROD296A Operate centrifugal casting equipment.
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: Plan own work requirements.
Identify equipment and processes used for production process and upstream and downstream operations from production plan or request.
Identify materials required, including additives.
Recognise hazards and follow appropriate hazard control/minimisation methods.
Identify and check emergency stops, guards and controls.
Identify requirements for materials, quality, production and equipment checks.
Identify materials, waste management and housekeeping needs.
Element: Start up casting process.
Determine equipment requirements.
Set process to specifications as required.
Check centrifugal casting equipment settings and adjustments are as required.
Check materials, resins and fibres are correct.
Discard, or make adjustments to the process for, non-conforming materials.
Set up date, batch and materials markings to specifications, as required.
Complete other pre-start checks in accordance with procedures.
Start up casting process.
Element: Operate and make adjustments as required to the centrifugal casting process.
Operate equipment to form product to specification noting key variables.
Monitor controls/displays/terminals for production/process data.
Monitor product/process quality, thickness, colour and integrity.
Make adjustments to remedy faults and non-conformity to standard as required.
Maintain continuity of process.
Collect and reprocess/discard scrap/waste and other materials in accordance with procedures.
Clean, adjust and lubricate equipment as required.
Pause or stop equipment in an emergency, following workplace and emergency procedures.
Element: Shut down machine to procedures
Determine type of shut down
Select appropriate cleaning method
Clean efficiently and adequately as required
Leave machine in appropriate condition and with appropriate locks, tags or notices
Complete relevant documentation
Ensure area is clean and clear after the shut down, in readiness for the next start-up
Element: Anticipate and solve problems
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.
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.
Where the assessee does not currently possess evidence of competency in PMBPROD296A Operate centrifugal casting 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 centrifugal casting composites process characteristics in relation to the process requirements and the end product
plan own work process within workplace procedures and explain the reasons for the steps in the process
take appropriate action to observe equipment, materials and products for out of specification results, make adjustments and identify problems to be reported.
Consistent performance should be demonstrated. For example, look to see that:
production quality and output standards are met consistently
problems are anticipated from process observations
problems are efficiently resolved
the process runs consistently and smoothly.
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:
using an appropriate, industrial centrifugal casting machine
in a situation allowing for the generation of evidence of the ability to recognise, anticipate and 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 knowledge of the materials, equipment and process sufficient to recognise material and equipment conditions which may lead to out of specification production.
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 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:
products, materials and material characteristics
properties of the materials required to form a composite structure of the required strength and surface finish
pot life of the resins used
quality requirements at each production stage
function and operating principles of equipment, machine components and ancillary equipment
impact of machine speed, temperature, pressure, time during cycles on product quality and production output
nature of mechanical, hydraulic, pneumatic, electrical and electronic principles which effect machine operation and product development
safety procedures and the use of PPE in relation to handling materials, equipment operation and cleanup
the hierarchy of control, including engineering controls
impact of variations in raw materials and equipment operation in relation to final product
changes to materials at various stages of production
waste management and importance of non-conforming materials
operation or product quality
check centrifugal casting equipment for correct set-up to job specifications and implement adjustments or report deviations immediately
make measurements when required and identify product out-of-specification
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, including predicting consequences and identifying improvements
interpret from production requests the correct selection and use of equipment, materials, processes and procedures
maintain output and product quality using appropriate instruments, controls, test information and readings
make adjustments to equipment operation to rectify variations in equipment
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 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.
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 (typically pipes) by centrifugal casting 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 including:
dies, moulds, mandrels, formers
sprays and fibre lay up equipment
hand tools, eg knives, cutters
equipment for centrifugal casting and curing
relevant personal protective equipment.
Hazards
Typical hazards include:
hazardous vapours
hazardous materials
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 process and product problems may include:
cracks, dents or imperfections of the mould, mandrel, former, die
adjustment of resin and fibre applicators
variations in materials, colour, consistency or mix
adjustment and settings of the equipment
contamination of materials
curing conditions
variations in materials and/or contamination of materials
processing problems
wrong raw materials/additives/catalyst
incorrect equipment set-up, eg speed, material supply, temperature
curing problems, conditions or equipment
incorrect quantity of materials
contaminated materials.
Variables
Key variables to be monitored include:
operating temperatures
speed
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
Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice
Yes
No
Comments/feedback
Identify equipment and processes used for production process and upstream and downstream operations from production plan or request.
Identify materials required, including additives.
Recognise hazards and follow appropriate hazard control/minimisation methods.
Identify and check emergency stops, guards and controls.
Identify requirements for materials, quality, production and equipment checks.
Identify materials, waste management and housekeeping needs.
Determine equipment requirements.
Set process to specifications as required.
Check centrifugal casting equipment settings and adjustments are as required.
Check materials, resins and fibres are correct.
Discard, or make adjustments to the process for, non-conforming materials.
Set up date, batch and materials markings to specifications, as required.
Complete other pre-start checks in accordance with procedures.
Start up casting process.
Operate equipment to form product to specification noting key variables.
Monitor controls/displays/terminals for production/process data.
Monitor product/process quality, thickness, colour and integrity.
Make adjustments to remedy faults and non-conformity to standard as required.
Maintain continuity of process.
Collect and reprocess/discard scrap/waste and other materials in accordance with procedures.
Clean, adjust and lubricate equipment as required.
Pause or stop equipment in an emergency, following workplace and emergency procedures.
Determine type of shut down
Select appropriate cleaning method
Clean efficiently and adequately as required
Leave machine in appropriate condition and with appropriate locks, tags or notices
Complete relevant documentation
Ensure area is clean and clear after the shut down, in readiness for the next start-up
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
PMBPROD396B - Produce composites using centrifugal casting
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:
Signature:
Date:
Assessment Record Sheet
PMBPROD396B - Produce composites using centrifugal casting
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