Application of this unit

This competency applies to advanced operators who are responsible for changing setups to meet the production schedule for an extrusion line process. Setup changes means the work involving the extrusion die and sizing equipment only. The key factors are the safe and precise removal and installation.

The operator will:

plan and prepare the change, including informing others selecting dies that match product/process specification removing, cleaning and storing the existing dies

fit the replacement die according to specification testing the changeover and fine tuning as needed.

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 organisation 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 extrusion process. Application of approved hazard control, safety procedures, the use of PPE in relation to handling materials, equipment operation and clean up.

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

impact of incorrect or faulty fitting

production work-flow sequences

correct selection and use of equipment and procedures

hazards of the removal and fitting process and appropriate hazard control procedures

the performance of die and cores

relevant information and workplace records

safety precautions appropriate to the task.

Competence also includes the ability to:

plan own work, including predicting consequences and identifying improvements

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 hazards of the materials and process

implement appropriate procedures for hazard control

use PPE

safely handle products and materials

read relevant safety 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 and production reports.

Writing is required to the level of completing workplace forms and production reports.

Basic numeracy is required, eg, to interpret and use dimensional and tolerance information relating to the die, design drawings and specifications.

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 ability to perform a die-change smoothly and methodically, which will put the extruder back into full production of in-specification product in standard time. In particular it is essential that the operator can:

select, install and check the performance of die and cores

locate, interpret and apply relevant information

maintain workplace records

identify and safely handle products and materials

apply safety precautions appropriate to the task

recognise potential situations requiring action and then implement appropriate action.

Consistent performance should be demonstrated. For example, look to see that production standards are met consistently.

Assessment method and context

It is preferred that assessment takes place on an industrial extruder in a work 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.

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 unit includes the selection and fitting of dies and cores.

This competency applies to all work environments and sectors within the plastics, rubber and cablemaking industry which use extrusion type dies and cores. It includes the operation of all relevant ancillary equipment.

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 such as:

hand carts and trolleys

hoists/lifting equipment not requiring any special permits or licences basic hand tools

hand tools

relevant personal protective equipment.

Hazards

Typical hazards include:

hazardous materials

manual handling hazards

hot surfaces.

Problems

Typical process and product problems may include:

lack of cleaning leading to corrosion

inadequate fitting

fine adjustments to optimise production.

Variables

Key variables to be monitored include:

fitting and adjustments to die

adjustments to extruder settings

quality of the product against product specifications.

Not applicable.

This unit contains employability skills.

Not applicable.