1

Prepare for work

1.1

Work requirements are determined from work instructions

1.2

Occupational health and safety (OHS) requirements relevant to operating insulating glass equipment, including personal protective equipment, are observed throughout the work

1.3

Work sequence is planned in a logical order to suit the job requirements and workplace procedures

1.4

Tools, equipment and materials are selected and checked prior to use to ensure they are appropriate for the work, of the required quality, serviceable and in a safe condition

1.5

IGU machines, tools and equipment are identified and checked for safe and effective operation, including emergency stops, gauges, guards and controls

1.6

Procedures for checking quality of materials and items produced, rating system compliance, working condition of equipment, and quality requirements for each stage of the IGU manufacturing process are identified

1.7

Communication with others involved with the work is established and maintained to ensure efficient workflow coordination, personnel cooperation and safety throughout the insulated glass manufacturing process

2

Set up equipment

2.1

Machine settings and adjustments are made in accordance with job requirements and machine and tool manufacturer instructions

2.2

IGU spacers are cut and sorted into order of run in accordance with workplace procedures

2.3

Desiccant to be used in process is tested in accordance with industry standards and workplace practices

2.4

Trial runs are conducted to check machine operation, accuracy and quality of finished work, and any necessary adjustments made to machine settings

3

Conduct IGU manufacturing operations

3.1

Glass sheets are loaded into IGU machine using the appropriate mechanical handling equipment

3.2

IGU spacers are assembled in accordance with specification/order and workplace procedures

3.3

IGU machine is operated to wash and dry glass and to press the unit

3.4

Unit is unloaded from IGU machine and relocated for sealing using appropriate mechanical handling equipment in accordance with workplace practices

3.5

Primary and secondary seal equipment is operated in accordance with workplace procedures

3.6

Testing for water vapour (dewpoint) and integrity of sealing (moisture) is conducted in accordance with workplace procedures

3.7

Serviceable units are labelled and stored in accordance with industry standards and workplace procedures, with items not meeting quality requirements being discarded or returned for reprocessing in accordance with workplace procedures

4

Complete work and maintain equipment

4.1

Work area is cleaned and rubbish disposed of, as appropriate

4.2

IGU machine is cleaned and inspected for serviceability in accordance with workplace procedures

4.3

Unserviceable equipment is tagged and faults identified in accordance with workplace procedures

4.4

Equipment and tooling is maintained in accordance with workplace procedures

4.5

Tools, equipment and unused materials are removed and stored appropriately

4.6

Documentation is completed in accordance with workplace requirements

Required skills include:

collecting, organising and understanding information related to work orders, basic plans and safety procedures

using communication skills to the level required to confirm work requirements and specifications; communicate effectively regarding work requirements with supervisors, other workers and customers; report work outcomes and problems; and relate to people from a range of social, cultural and ethnic backgrounds, and of varying physical and mental abilities

using literacy skills to the level required to understand information related to work orders, including common industry terminology, plans and safety procedures; prepare reports; and interpret technical information and specifications

planning and organising activities, including the preparation and layout of the work area, and the obtaining of equipment and materials to avoid any backtracking, workflow interruptions or wastage

working with others and in a team by recognising dependencies and using cooperative approaches to optimise workflow and productivity

using mathematical ideas and techniques to correctly complete measurements, calculate work requirements, optimise glass sizes for handling and processing, and assemble required materials

using pre-checking and inspection techniques to plan work, and avoid re-working and wastage

using workplace technology related to the operation of IGU manufacturing equipment

modifying activities to cater for variations in workplace contexts and environment

Required knowledge includes:

correct procedures for the set-up, operation and operator maintenance of IGU manufacturing equipment

glass and window rating systems for insulation applications

workflow requirements relating to the operation of IGU manufacturing equipment

characteristics of materials used and uses of products produced in the IGU manufacturing process

relevant workplace procedures for the reporting of material, product or equipment faults

workplace safety system requirements related to the operation of IGU manufacturing equipment

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment

Assessment processes and techniques must be culturally appropriate and appropriate to the language, literacy and numeracy capacity of the candidate and the work being performed.

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

Assessors must be satisfied that the candidate can competently and consistently:

interpret work order/job instruction and locate and apply relevant information, including relevant glass and window rating systems to the operation of IGU manufacturing equipment

plan the conduct of IGU manufacturing operations

set up, operate and monitor IGU manufacturing equipment and the quality testing of IGU

apply safe handling requirements for equipment, products and materials, including use of personal protective equipment

follow work instructions, operating procedures and inspection practices to:

minimise the risk of injury to self and others

prevent damage to goods, equipment and products

maintain required production output and product quality

as a minimum:

prepare, set up, manufacture and conduct the appropriate quality testing of five (5) differing IGU patterns to the capacity of the IGU machine

work effectively with others.

Context of and specific resources for assessment

The application of competency is to be assessed in the workplace or realistically simulated workplace.

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

Assessment of essential underpinning knowledge, other than confirmatory questions, will usually be conducted in an off-site context.

Assessment is to comply with relevant regulatory or Australian Standard requirements.

The following resources should be made available:

insulated glass unit manufacturing equipment

workplace operating procedures

unprocessed materials

personal protective equipment

an appropriate work area.

Method of assessment

Assessment must satisfy the endorsed Assessment Guidelines of the LMF02 Furnishing Industry Training Package.

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 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.

Assessment may be in conjunction with assessment of other units of competency.

Guidance information for assessment

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, if used in the performance criteria, is detailed below. 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) may also be included.

Work requirements may include:

material to be used

process required to complete work tasks

the required size of the units

number of IGUs required and holding area for completed items

IGUs are:

two sheets of glass that are separated by a spacer, sealed to form an airtight unit

Personal protective equipment includes:

that prescribed under legislation, regulations and enterprise practices and procedures, and may include:

gauntlets

gloves

safety glasses

hard hats

safety footwear

aprons

hearing protection

overalls

Workplace procedures include:

workplace procedures relating to the setting up and operation of IGU manufacturing machinery

machine manufacturer specifications and operational procedures

workplace procedures relating to the handling and movement of glass

work instructions, including job sheets, cutting lists, plans, drawings and designs

safety standards, including personal protective equipment, OHS regulations and enterprise requirements

Australian Standards:

AS 1288:2006 Glass in buildings - Selection and installation.

AS/NZS 2208:1996 Safety glazing materials in buildings

AS/NZS 4666:2000 Insulating glass units

AS/NZS 4667:2000 Quality requirements for cut-to-size and processed glass

Tools and equipment are to include:

cutting equipment (e.g. saws)

spacer preparation equipment (appropriate size)

sieve machine and desiccant equipment

primary seal equipment

secondary seal equipment

basic hand tools (e.g. screwdrivers and scrapers)

mechanical handling equipment

Materials are to include, but are not limited to:

customer requirements for glass (annealed, toughened or laminated)

corner keys for spacers

appropriate primary (polyisobutylene) and secondary sealant (polysulphide) and separation paper

Desiccant is:

a hygroscopic substance that induces or sustains a state of dryness (desiccation)