Application
Application of this unit
This competency applies to operators who are required to apply knowledge of materials, product purposes and processes to the operation of extrusion equipment. The key factors are the making of products to meet quality standards and workplace requirements.
The operator will:
check settings and adjustments of preset equipment
check extruder operation and report process variations
check materials for quality and conformity to product requirements
perform emergency shut down of equipment
purge line/cleaning line after product, grade or colour change.
This unit does not include
start-up or routine shutdown of extruders (see PMBPROD313B Produce extruded products)
die setting (see PMBPREP304C Change equipment dies)
start up or routine shutdown of twin screw extruders used for compounding and extruding PVC materials (see PMBPROD334A Produce products using twin screw extruders).
Prerequisites
Prerequisites
This unit has no prerequisites.
Elements and Performance Criteria
ELEMENT ELEMENT | PERFORMANCE CRITERIA Performance Criteria describe the required performance needed to demonstrate achievement of the Element. Assessment of performance is to be consistent with the Evidence Guide. |
1. Check work requirements. | 1.1 Identify work requirements from production plan or request. 1.2 Check product, materials and equipment meet requirements for job(s). 1.3 Recognise requirements which may not be in accordance with usual practice. 1.4 Ask questions of appropriate person to confirm unusual practice. 1.5 Ensure housekeeping is to requirements. 1.6 Identify hazards associated with the job and take appropriate action. 1.7 Perform other pre-operational checks in accordance with procedures. |
2. Operate extruder to procedures. | 2.1 Check process is operating within required limits. 2.2 Check product is in specification and to required quality standard. 2.3 Ensure product is consistently ready for next operation. 2.4 Maintain supply of material(s) as required. 2.5 Complete logs and records as required. 2.6 Collect and segregate scrap, trim and other materials as required. 2.7 Keep equipment and work area clean. 2.8 Pause machine cycle and perform emergency stop, as required. |
3. Change product/grade while operating as required. | 3.1 Run down/purge outgoing grade/product to procedures. 3.2 Make changes specified in procedures for oncoming product/grade. 3.3 Introduce oncoming materials/grade and check oncoming product. 3.4 Undertake other actions as specified in procedures. |
4. Respond to routine problems to procedures. | 4.1 Recognise known faults that occur during the operation. 4.2 Identify and take action on causes of routine faults. 4.3 Log problems as required. 4.4 Identify non-routine process and quality problems and take appropriate action. |
Required Skills
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 out of specification products, process problems and materials faults.
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 and the use of PPE in relation to handling materials, equipment operation and clean-up.
Knowledge of and skills in the operation of extrusion equipment and main components sufficient for consistent production of quality products, including:
production work-flow sequences and materials demand
the reasons for checking process control panels and reporting readings which are outside of normal range of process variability
accurately monitoring equipment operation and product quality
the potential effects of variations in raw materials and equipment operation in relation to quality of product
the relationship between the type of extruder and the materials being extruded
processing behaviour of polymers and the role of additives
waste management and knowing the importance of reusing non-conforming products wherever possible
correct selection and use of equipment, materials, processes and procedures
explain the effect of unauthorised or emergency shutdown in relation to safety and production requirements
identify factors which may affect product quality or production output and appropriate remedies.
Competence also includes the ability to:
plan own work, including predicting consequences and identifying improvements
identify when the operator is able to rectify faults, when assistance is required and who is the appropriate source for assistance
identify and describe own role and role of others involved directly in the extrusion process.
Language, literacy and numeracy requirements
This unit requires the ability to read and interpret typical product specifications, job sheets, procedures, material labels and safety information as provided to operators.
Writing is required to the level of completing workplace forms.
Basic numeracy is required, eg to determine that two 25 kg bags are needed to make up a requirement for 50 kg.
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
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:
recognise the importance of material properties and qualities
apply approved procedures
take appropriate action to resolve faults or report faults to appropriate personnel
explain and implement emergency shutdown procedures.
Consistent performance should be demonstrated. For example, look to see that:
extrusion production standards are met consistently
upstream and downstream communication is timely and effective operating procedures and work instructions are read and interpreted correctly
problems are identified and appropriate action is taken (ie the problem is fixed or reported)
all safety procedures are followed.
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:
by using an appropriate, industrialextruder
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.
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. 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 all work environments and sectors within the plastics, rubber and cablemaking sectors. It includes the operation of all relevant ancillary equipment where that equipment is integral to the extrusion process.
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.
Products
These may include:
rod
sheet
film
profile
tread profile
cable.
Competence under this competency unit is only required in one process.
Materials
This unit applies to most plastic and rubber materials, including compounded PVC fed to the extruder as pellets. It does not apply to dry blended PVC powder (refer to PMBPROD334A ).
Tools and equipment
This competency includes use of equipment and tools such as:
extruder equipment and components such as main drive, gearbox, thrust assembly, adapter, gate, breaker plate, screen pack, doser, screw/s, barrel, heaters, thermocouples
extruders, either single or twin screw
extrusion dies - rod, sheet, film, pipe, profile, tread profile and cable auxiliary equipment - water pump, feeders, hopper loader, pelletiser, dehumidifiers, etc
tools for taking samples
relevant personal protective equipment.
Hazards
Typical hazards include:
vapours
burns
moving equipment
hazardous materials
manual handling hazards.
Problems
Respond to 'routine problems' means 'apply known solutions to a variety of predictable problems'. Typical process and product problems may include:
equipment malfunction
variations in materials
contamination of materials or additives
temperature/speed variations
routine product extrusion faults - dimensions, surface appearance, colour, deformations
incorrect quantity of materials.
Variables
Key variables to be monitored include:
differences between actual and set temperatures
speeds, including screw speed and haul-off
colour and uniformity
surface finish and appearance
product finished thickness
output rate
product integrity and general conformance to specification/sample.
Sectors
Not applicable.
Employability Skills
This unit contains employability skills.
Licensing Information
Not applicable.