Application of this unit

This competency applies to advanced operators who set up and prepare for the production process. The key factors are checking equipment and materials for conformity to specification and working to a process plan. This competency is typically performed by experienced operators working either independently or as part of a work team.

It includes:

selecting and checking equipment and materials against specifications

identifying requirements for special tooling and set-up

drafting a work process plan, including objectives and timeframe

preparing tools, equipment and materials

setting up, checking and adjusting the production process

identifying and planning own work requirements from production requests

identifying and minimising any hazards connected with materials and process from materials safety data sheets, labels and workplace procedures

checking settings and adjustments of equipment

checking materials for conformity to job requirements

correcting materials, equipment or process variations and making appropriate adjustments

completing logs and reports.

Prerequisites

This unit has no prerequisites.

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.

Knowledge as a basis for solving processing and material problems including:

products, materials and material characteristics

behaviour of materials in relation to heat, pressure and time; quality requirements at each production stage

function and operating principles of equipment, machine components and ancillary equipment

impact of machine operating parameters on product quality and production output

nature of mechanical, hydraulic, pneumatic, electrical and electronic principles which may effect machine operation and product development

assessing operational capabilities of equipment

predict materials behaviour

adjust machine parameters

assess production workflow in relation to focus of operation of work systems and equipment

identify and correctly use equipment, processes and procedures

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 operation or product quality

check equipment for correct set-up to job specifications and implement adjustments or report deviations immediately

start up equipment and make appropriate adjustments to bring process on line

take samples when required and identify product out of specification

safely shut down equipment in normal or abnormal circumstances

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

identify hazards of the materials and process

implement appropriate procedures for hazard control

use PPE, safely handle products and materials, read relevantsafety information and apply safety precautions appropriate to the task.

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.

Numeracy is also required, eg to determine quantities required for production run/batch.

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.

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:

select, set up and adjust equipment

arrange materials supply

inspect results of checks for equipment and materials performance

locate, interpret and apply relevant information

maintain workplace records

identify and handle products and materials safely, applying safety precautions appropriate to the task

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:

set-up conforms to organisation requirements

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 using industrial equipment and materials and will be undertaken in a work-like environment.

Competence in this unit may be assessed:

on a processing plant, allowing for operation under all normal and a range of abnormal conditions

in a situation allowing for the generation of evidence of the ability to 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.

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 experienced operators working either independently or as part of a work team.

Procedures

All operations are performed in accordance with procedures.

Procedures means 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 such as:

hand carts and trolleys

hoists/lifting equipment not requiring any special permits or licences

relevant personal protective equipment.

Hazards

Typical hazards include:

moving heavy equipment/materials items

materials spills

fumes/dusts/vapours

hazardous materials in gaseous, liquid or solid form

manual handling hazards

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:

power or equipment failures

temperature variations

variations in materials

contamination of materials

faulty functioning of equipment.

Variables

Key variables to be monitored include:

variations in the timing of machine cycles

atmospheric variations

variations in the sequence of product availability

variations in the quality of the raw materials.

Not applicable.

The required outcomes described in this unit contain applicable Employability Skills. The Employability Skills Summary of the qualification(s) in which this unit is packaged will assist in identifying Employability Skill requirements.

Not applicable.