This unit applies to the setting up of tufting machines and related equipment for production and the maintenance repair, adjustment and testing of tufting looms and related equipment to ensure efficient working order. Discretion and judgement may be required, for both self and others, in planning and selecting processes, procedures or outcomes

This unit does not cover all repair and adjustment functions associated with tufting looms. In particular skills associated with general engineering (fitting), electrical and electronic systems, and fluid power systems may be required according to the nature of the set up, repair or adjustment, and the workplace practices of a particular enterprise.

Work may be conducted in a variety of environments, such as operational workplace activities, restricted space, hazardous, controlled or exposed conditions.

The application of this unit is according to OHS practices of the enterprise and workplace practices, which may include:

requirements prescribed by legislation, awards, agreements and conditions of employment

standard operating procedures

work instructions

oral, written and visual communication

quality practices, including responsibility for maintenance of own work quality and contribution to quality improvement of team or section output

housekeeping

tasks related to environmental protection, waste disposal, pollution control and recycling

This unit requires the application of skills associated with planning and organising of resources and machinery for the required work, as well as applying skills and knowledge of machines and equipment to ensure production outcomes are met. Initiative and enterprise, and problem solving are key skills required to ensure operational efficiency of machines. This unit also requires and ability to communicate in writing and verbally with others.

Prerequisites

ELEMENT

PERFORMANCE CRITERIA

1 Set up machines for tufting operations

1.1 Specificationsandproduction requirements are interpreted to determine machine settings

1.2 Documentation relating to machine settings, operation and maintenance is interpreted, referenced and applied according to the needs of the task

1.3 Tools appropriate for the loom or machine are selected, prepared and used in a safe and effective manner to set up machine for operation

1.4 Loom is set up for operation according to required specifications, including fixing of required attachments, in order to run at optimum quality and efficiency levels

1.5 Loom settings are checked to meet production requirements

1.6 Tufting yarn beams are identified, checked and joined into the loom according to manufacturer specifications

1.7 Tufting operators are instructed of any special operating requirements

2 Test machine settings

2.1 Tufting machine is operated in accordance with manufacturer and workplace instructions to test settings against specifications and operational standards

2.2 Yarn sample is produced and examined to identify required adjustments to machine settings or pattern specifications

2.3 Quality tests are conducted or organised as required to ensure optimal production outcomes are achieved

2.4 Required adjustments are identified and documented and machine settings adjusted accordingly

2.5 Operation is monitored in all production stages

3 Diagnose and fix tufting problems

3.1 Tufting machine operations are monitored to assess operational efficiency in accordance with OHS procedures

3.2 Yarn is assessed to identify faults and to assess impact on operational problems

3.3 Problems and faults are identified and analysed to determine root cause

3.4 Diagnosis is established and strategy for repair or replacement of machine components is developed

3.5 Tufting machine is returned to optimal performance through repair of faulty operation

3.6 Tufting machine is operated to ensure problems have been fixed

4 Communicate operational information

4.3 Records are maintained and reports prepared where necessary

4.3 Adjustments to machines and patterns are documented and discussed with appropriate personnel

4.3 Operational instructions are documented

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

Demonstrates knowledge of:

tufting methods and the various types of yarn outcomes

yarn twist and application

fibre types and their method of production

fibre parameters

yarn counts

factors affecting machine performance: yarn strength, sizing, ambient conditions

yarn quality indicators

machine manufacturer specifications

safety and environmental aspects of relevant enterprise activities

OHS practices, including hazard identification and control measures

quality practices

workplace practices

recording and reporting practices

Demonstrates skills to:

set and operate tufting machines

test, analyse and prepare samples

read, interpret and follow information on work specifications, standard operating procedures and work instructions and other reference material

maintain accurate records

communicate within the workplace

sequence operations

meet specifications

clarify and check task-related information

carry out work according to OHS practices

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 the Training Package.

Critical aspects of evidence to be considered

Demonstrates skills and knowledge to:

interpret production specifications accurately

set and operate tufting machine safely and correctly

perform sample runs and analyse results

identify and make appropriate readjustments

determine root cause of operational problems

solve operational problems

apply workplace health and safety policies in production operations

maintain accurate records

Consistency in performance

Consistently applies skills and knowledge when:

organising work

completing tasks

identifying improvements

using workplace practices

using OHS practices

recording and reporting accidents and incidents

assessing operational readiness of equipment used and work processes

recognising and adapting to cultural differences in the workplace, including modes of behaviour and interactions

completing work systematically with attention to detail without damage to goods and equipment

Resource implications

Access is required to real or appropriately simulated situations, including work areas, materials and equipment, and to information on workplace practices and OHS practices.

Context for assessment

Assessment may occur on the job or in an appropriately simulated environment.

Interdependent Assessment

This unit may be assessed independently or in combination with other relevant units.

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. Add any essential operating conditions that may be present with training and assessment depending on the work situation, needs if the candidate, accessibility of the item, and local industry and regional contexts.

Legislative/regulatory requirements

All work must comply with relevant Federal and State or Territory legislative or regulatory requirements.

Specifications and production requirements may include

beaming

primary backing

backing type and specifications

yarn type and specifications

pile height

beat up

level loop

cut pile

cut and pile

loop pile

colour

pattern

size

stitch rate

tension

hard twist pile

blends

frieze (textured/bulk)

Saxony (plush)

Berber (thick yarns)

sisal/cord (textured)

Machines may include

winding machines

finishing equipment

other ancillary equipment

Yarn may be

wool

nylon

acrylic

polypropylene

polyester

blends

Joined may include

splicing

weavers knot

double weavers knot

Loom settings may include

electronic settings

automated setting

mechanical settings

OHS practices

OHS practices must include hazard identification and control, risk assessment and implementation of risk reduction measures specific to the tasks described by this unit, and may include:

manual handling techniques

standard operating procedures

personal protective equipment

safe materials handling

taking of rest breaks

ergonomic arrangement of workplaces

following marked walkways

safe storage of equipment

housekeeping

reporting accidents and incidents

other OHS practices relevant to the job and enterprise

Faults may include

holes

j-cutting

low-cut yarn

incorrect yarn height

foreign matter

creasing of primary backing or carpet

lines in carpet

marks

broken looper

choppy face

Sector

Textile Production

This unit contains employability skills.