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 -
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

Assessor name:

Signature:

Date:

Student signature:

Date: