Application of this unit

This competency applies to operators who are required to undertake the routine operation of blown film equipment in the production process. The key factors are the making of products to meet quality standards and workplace requirements. This competency is typically performed by operators working either independently or as part of a work team.

It includes

checking job sheets for work requirements

following approved hazard minimisation procedures for any hazards connected with materials and process, using work instructions, labels and materials safety data sheets, and in accordance with occupational health and safety legislative responsibilities

monitoring equipment operation and reporting process variations checking product for quality and conformity to specifications discarding non-conforming products ensuring discarded materials are reused where possible and waste and scrap is disposed of in accordance with workplace instructions

identifying and taking action on routine process problems

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 out of specification products, process problems and materials faults.

Knowledge of the enterprise's procedures and relevant regulatory requirements along with the ability to implement them within appropriate time constraints and work standards.

Knowledge of and skills in the operation of blown film equipment and main components sufficient for consistent production of quality products including:

operation of blown film equipment and components;

production workflow sequences and materials demand;

reasons for checking process control panels and reporting readings which do not conform to the work instructions;

approved hazard control and safety procedures and the use of PPE in relation to handling materials,

equipment operation and cleanup;

potential effects of variations in raw materials and equipment operation in relation to quality of product; waste management and importance of reusing non-conforming products wherever possible;

correct selection and use of equipment, materials, processes and procedures

plan own work including predicting consequences and identifying improvements

monitor equipment operation and product quality

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 process

identify factors which may affect product quality or production output and appropriate remedies

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

pause equipment, or shut down equipment in abnormal circumstances

explain the effect of unauthorised or emergency shutdown in relation to safety and production requirements

distinguish between possible causes of routine faults such as: incorrect quantity of materials; contaminated materials/additives; equipment faults; die/tool damage; wrong raw materials/additives; incorrect quantity of materials/additives; machine failure.

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.

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

Assessment will occur on an industrial blown film machine(s) and will be undertaken in a work like environment.

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

It is essential that competence is demonstrated in the ability to

identify critical materials properties and blown film process characteristics in relation to the process requirements and the end product

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. In particular look to see that

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

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. A holistic approach should be taken to the assessment.

Competence in this unit may be assessed

on an operating plant allowing for operation under all normal and a range of abnormal conditions

in a situation allowing the generation of evidence of the ability to respond to problems

by use of a suitable simulation and/or a range of case studies/scenarios

by 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 of variables 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 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

extruder

bubble guides and rollers

film rollers, slitting, trimming and winding gear

coolers, heaters and ancillary equipment

hand tools, knives, adjustment tools

relevant personal protective equipment

treatment unit.

Hazards:

Typical hazards include

high air velocities

high voltage corona treatment systems

sharp knives

high towers manual handling

fumes, humidity, air temperatures, radiant heat, hot dies

stationary and moving machinery, parts and components.

Problems:

'Respond to routine problems' means 'apply known solutions to a limited range of predictable problems'.

Typical process and product problems may include

extruder control

contamination

alignment and control of trimming and winding gear

raw material contamination, wrong grade, variations of polymer properties.

Variables:

Key variables to be monitored include

equipment pressures and temperatures

material specifications

ambient temperature

Not applicable.

This unit contains employability skills.

Not applicable.