AUM8057B
Perform gas metal arc welding operations (GMAW)

This unit describes the application of the required skills and knowledge to perform gas metal arc welding operations within the truck, bus and trailer manufacturing industry.No licensing, legislative, regulatory or certification requirements apply to this unit at the time of publication.

Application

This unit applies to the automotive and related component manufacturing environment and involves application of skills and knowledge at a specialist level. These skills and knowledge are to be used within the scope of the person's job and authority.


Prerequisites

Nil


Elements and Performance Criteria

ELEMENT

PERFORMANCE CRITERIA

1. Determine job requirements

1.1. Job specifications and requirements are interpreted and determined from job sheets and / or work instructions

1.2. Appropriate OH&S practices are identified in accordance with OHS, legislative and organisation requirements

2. Plan and prepare to undertake the work

2.1. Resources required to satisfy the work plan are identified, obtained and inspected for compliance with the job specifications

2.2. Relevant plans, drawings and texts are selected and interpreted in accordance with the work plan

2.3. Correct size, type and quantity of materials/components are determined, obtained and inspected for compliance with the job specifications

2.4. Work is planned in detail including sequencing and prioritising considerations

2.5. Work area is prepared in accordance with work requirements and organisation procedures

2.6. Potential hazards are identified and prevention and/or control measures are selected in accordance with the work plan and site procedures

2.7. Safety clothing and protective equipment are used according to OHS and organisation requirements

3. Weld materials/job

3.1. Materials for welding are prepared and aligned in accordance with the work plan and specifications

3.2. Distortion prevention measures are identified and applied in accordance with job requirements

3.3. Equipment start-up procedures follow company standard operating procedures

3.4. Test runs are undertaken in accordance with the work plan and job requirements

3.5. Materials are welded using GMAW process to Australian Standards or equivalent, in accordance with the work plan and specifications

3.6. Welds are cleaned using appropriate tools and techniques in accordance with the work plan

4. Check completed work for conformation to specification

4.1. Weld specifications are confirmed by non-destructive testing and inspection, in accordance with standard work practices

4.2. Defects are identified and repaired using appropriate techniques and in accordance with the work plan

4.3. Work is completed and appropriate personnel notified in accordance with company requirements

4.4. Work area is cleared of waste, cleaned, restored and secured in accordance with organisation procedures

4.5. Plant, tools and equipment are maintained and stored in accordance with organisation procedures

4.6. Work completion details are finalised in accordance with organisation procedures

Required Skills

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

Required skills

speak clearly and directly in order to inform appropriate personnel of work completed

apply teamwork to a range of situations, including the undertaking of test runs

solve problems particularly in teams in order to meet performance indicators

show initiative in adapting to changing work conditions or contexts particularly when working across a variety of work areas

access, interpret and apply information on relevant organisation policies, procedures and instructions, particularly to ensure plant, tools and equipment are maintained and stored appropriately

manage time when planning, preparing and organising work priorities

take responsibility for organising own work priorities.

Required knowledge

relevant Occupational Health and Safety and Environmental regulations and enterprise policies and procedures needed to carry out work in a manner which ensures the safety of people, equipment and the environment. The specific regulations will vary according to the area of operation

organisation technical work documentation covering procedures, specifications, schedules and work plans or equivalent

organisation quality system documentation covering instructions, procedures, performance indicators and review processes or equivalent

organisation cost minimisation/waste avoidance policies, procedures and practices

environmental protection requirements relating to the disposal of waste material

established communication channels and protocols

problem identification and resolution techniques

welding and heating techniques

organisation OHS policies and procedures

welding and material preparation techniques

distortion control techniques

weld testing techniques (non destructive)

welding equipment maintenance procedures.

Evidence Required

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

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Evidence of the following is essential:

compliance with relevant legislative, regulations, standards, codes of practice and establish safe practices and enterprise policies and procedures for managing personal work priorities

maintaining a working knowledge of current work systems and practices

working and communicating effectively and positively with others involved in the work

applying, within authority, the requirements of the job or work role in relation to:

achieving production goals

achieving work quality goals

responding positively to changing work requirements

contributing effectively to cost reduction initiatives

effectively applying problem solving techniques

modify activities to cater for variations in workplace context and environment

prepare and plan work

complete gas metal arc weld

complete work procedures

employ organisation OHS policies and procedures

maintain welding and heating equipment

control distortion of materials

inspect and identify defects in welds

inspect and finalise job.

Context of and specific resources for assessment

assessment of the competency should take place in a safe working environment in a passenger motor vehicle manufacturing plant or simulated environment using tools/equipment/machinery required for the production process without undue disruption to the production process

assessment is to occur under standard and authorised work practices, safety requirements and environmental constraints.

Method of assessment

A range of assessment methods should be used to assess practical skills and knowledge. The following examples are appropriate for this unit:

assessment methods must confirm consistency and accuracy of performance (over time and in a range of workplace relevant contexts) together with application of underpinning knowledge

assessment methods must be by direct observation of tasks and include questioning on underpinning knowledge to ensure its correct interpretation and application

assessment may be applied under project related conditions (real or simulated) and require evidence of process

assessment must confirm a reasonable inference that competency is able not only to be satisfied under the particular circumstance, but is able to be transferred to other circumstances.


Range Statement

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording in the Performance Criteria is detailed below. 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.

OHS requirements may include:

Legislation and regulations, organisational safety policies and procedures and may include: the use of personal protective equipment and clothing, rescue services, fire fighting organisation and equipment, first aid equipment, hazard and risk control and elimination, systems covering the use of hazardous materials and substances and manual handling procedures including lifting and carrying.

Legislative requirements may include:

Applicable legislation, regulations and codes of practice, including those related to:

anti-discrimination

award and enterprise agreements

confidentiality and privacy

duty of care

employee relations

environment protection

equal opportunity

industrial relations

relevant industry codes of practice.

Organisationrequirements may include:

access and equity principles and practices

environmental management (waste disposal, recycling and re-use guidelines)

emergency and evacuation procedures

equipment use procedures

ethical standards

legal obligations

maintenance and storage procedures

OHS requirements

organisational and site guidelines

policies and procedures relating to own role and responsibility

procedural manuals

quality assurance guidelines

quality and continuous improvement processes and standards

recording and reporting guidelines.

Resources may include:

welding equipment may include MIG welder, leads, argon shield, welding wire and welding shield

materials may include stainless steel, aluminum, high, mild and low carbon steels, high and low alloy steels in the appropriate profile eg plate, pipe, rolled steel sections

distortion prevention measures may include bracing, pre-setting, tacking, bolting and clamping, jigs and fixtures

appropriate tools may include wire brush and angle grinder

non-destructive testing may include visual inspection, dye check, magnetic particle, pressure tests and ultra sound

maintenance may refer to replacing tips and gas nozzles and cleaning tips, nozzles and welders

work completion details may include plant and maintenance records, job cards, check sheets, on device labelling updates and reporting and/or documenting equipment defects

OH&S standards (as per company and statutory requirements)

documentation and reporting systems (as per company requirements)- written / electronic

work specifications / work plan

qualified workplace assessor

workplace or simulated workplace.

Job context may include:

Work areas including:

body construction, aluminium die casting, iron foundry operations, engine machining, spray painting, automotive plastics, stamping & press operations, fabrication hardware, trim manufacture, vehicle assembly, warehousing, engine assembly, seat frame manufacture

Processes including:

welding sub-assemblies, fitting hang-on components, fittings dies to die boxes, pouring aluminium, machining parts, application of paint, cutting blanks, assembly of components to form sub-assemblies, fitting parts to bodies, assembly of parts, parts picking and replenishment.

Appropriatepersonnel may include:

clients and managers

supervisors

suppliers

team leaders

team members.


Sectors

Unit sector

Automotive Manufacturing


Competency Field

Truck/Bus/Trailer Manufacture and Assembly


Co-Requisites

Nil


Employability Skills

This unit contains Employability Skills.


Licensing Information

Not applicable.