Application
This unit of competency covers the skills and knowledge required to operate an open mill blender/mixer and ancillary equipment that is integral to the process. Open mill blenders, such as Banbury dump mills, are typically used to compound rubber. The mixing/blending may be incidental to other processes, such as slabbing off or stripping.
This unit of competency applies to operators who are required to prepare the rubber and other materials, mix the materials to procedures, remove mixed rubber from the mill and recognise routine and non-routine problems and take appropriate action.
This unit of competency applies to an individual working alone or as part of a team or group and working in liaison with other shift team members, team leader and supervisor, as appropriate.
No licensing, legislative or certification requirements apply to this unit at the time of publication.
Elements and Performance Criteria
Elements describe the essential outcomes. | Performance criteria describe the performance needed to demonstrate achievement of the element. | ||
1 | Check work requirements | 1.1 | Identify work requirements from production plans of workplace procedures |
1.2 | Check product, materials and equipment meet requirements for job | ||
1.3 | Recognise hazards and implement necessary steps to ensure safety | ||
1.4 | Ask questions of appropriate person to confirm usual 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 workplace procedures | ||
2 | Check process set-up | 2.1 | Check safety gates and guards are in position and working |
2.2 | Check materials are correct | ||
2.3 | Complete pre-start checks | ||
3 | Operate open mill blender to procedures | 3.1 | Start, operate and stop mill as required by procedures |
3.2 | Band, cut, fold and work rubber as needed | ||
3.3 | Add materials evenly at correct rate and time and blend in | ||
3.4 | Check open mill blender operations | ||
3.5 | Make adjustments to remedy faults and non-conformity to product blend standards where applicable | ||
3.6 | Collect and reuse material which is able to be reprocessed | ||
3.7 | Deal with waste and scrap in accordance with procedures | ||
3.8 | Clean, adjust and lubricate equipment as required | ||
4 | Respond to routine problems in accordance with 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 problems and quality problems and take appropriate action |
Evidence of Performance
Evidence required to demonstrate competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria and demonstrate the ability to:
read and interpret procedures, job specifications, basic machine control panels, material labels and safety data sheets (SDS)
select and use materials, procedures, tools and equipment to meet job specifications
monitor open mill blending equipment and ancillary equipment using measured/indicated data and smell, sight, sound and feel as appropriate
monitor and interpret key variables, including:
speed
pressure
temperature
duration
output rate
product integrity and general conformance to specification/sample
operate and adjust the equipment to meet product quality and production output specifications
pause the equipment or shut down equipment in normal and abnormal circumstances
identify hazards and apply relevant hazard controls
apply safety procedures
apply housekeeping procedures
apply waste management procedures
recognise early warning signs of equipment/processes needing attention or with potential problems
recognise routine and non-routine problems
identify when the operator is able to rectify faults, when assistance is required and who is the appropriate source for assistance
take action to resolve faults or report faults to appropriate personnel
distinguish between possible causes of routine faults, including:
raw material variations/contamination
process abnormalities
procedural errors
mechanical abnormalities
communicate effectively with team/work group and supervisors
complete workplace records
do basic arithmetical manipulations, including additions, subtractions, divisions, fractions and percentages.
Evidence of Knowledge
Must provide evidence that demonstrates knowledge relevant to their job sufficient to operate under routine only supervision and to solve routine problems, including knowledge of:
the function of open mill blending equipment, machine components and guides
principles of operation of the equipment
the impact of common chemical reactions/mechanical processes the state, form and condition of the materials
purpose of developing elasticity and controlling temperatures
effects of mastication, differential speed, overheating
the potential effects of variations in raw materials and equipment operation in relation to quality of product
reasons for checking process control panels and reporting readings which are outside of normal range of process variability
processing behaviour of polymers and the role of additives
production workflow sequences and materials demand
factors which may affect product quality or production output and appropriate remedies
routine problems, their probable causes and relevant corrective actions
organisation procedures relevant to the work environment/job role
hierarchy of control
hazards that may arise in the job/work environment and:
their possible causes
potential consequences
appropriate risk controls.
Assessment Conditions
The unit should be assessed holistically and the judgement of competence shall be based on a holistic assessment of the evidence.
In all plants it may be appropriate to assess this unit concurrently with units such as:
teamwork
communication.
The collection of performance evidence:
should occur over a range of situations which include typical disruptions to normal, smooth operation of an operating plant
will typically include a supervisor/third-party report or other evidence, focusing on consistent performance and problem recognition and solving. A supervisor/third-party report must be prepared by someone who has a direct, relevant, current relationship with the person being assessed and who is in a position to form a judgement on workplace performance relevant to the unit of competency
must include the use of an appropriate industrial item of equipment requiring demonstration of operation, start and stop procedures and responding to problems
may use industry-based simulation for all or part of the unit particularly where safety, lack of opportunity or significant cost is an issue.
Assessment should occur in operational workplace situations. Where this is not possible or where personal safety or environmental damage are limiting factors assessment must occur in a sufficiently rigorous simulated environment that reflects realistic operational workplace conditions. This must cover all aspects of workplace performance, including environment, task skills, task management skills, contingency management skills and job role environment skills.
Assessment in a simulated environment should use evidence collected from demonstration of skills and one or more of:
walk-throughs
pilot plant operation
industry-based case studies/scenarios
‘what ifs’.
Knowledge evidence may be collected concurrently with performance evidence or through an independent process, such as workbooks, written assessments or interviews.
Assessment processes and techniques must be appropriate to the language, literacy and numeracy requirements of the work being performed and the needs of the candidate.
Conditions for assessment must include access to all tools, equipment, materials and documentation required, including relevant workplace procedures, product and manufacturing specifications associated with this unit.
The regulatory framework will be reflected in workplace policies and procedures and is not required to be independently assessed.
Foundation skills are integral to competent performance of the unit and should not be assessed separately.
Assessors must satisfy the assessor competency requirements that are in place at the time of the assessment as set by the VET regulator.
In addition the assessor or anyone acting in subject matter expert role in assessment shall demonstrate both technical competency and currency. If the assessor cannot demonstrate technical competency and currency they shall assess with a subject matter expert who does meet these requirements.
Technical competence can be demonstrated through one or more of:
relevant VET or other qualification/Statement of Attainment
appropriate workplace experience undertaking the type of work being assessed under routine and non-routine conditions
appropriate workplace experience supervising/evaluating the type of work being assessed under routine and non-routine conditions
Currency can be demonstrated through one or more of:
being currently employed undertaking the type of work being assessed
being employed by the organisation undertaking the type of work being assessed and having maintained currency in accordance with that organisation’s policies and procedures
having consulted/had contact with an organisation undertaking the type of work being assessed within the last twelve months, the consultation/contact being related to assessment
conducting on the job training/assessments of the type of work being assessed
being an active member of a relevant professional body and participating in activities relevant to the assessment of this type of work.
Foundation Skills
This section describes those required skills (language, literacy and numeracy) that are essential to performance.
Foundation skills essential to performance are explicit in the performance criteria of this unit of competency.
Range Statement
This field allows for different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included. | |
Regulatory framework | The latest version of all legislation, regulations, industry codes of practice and Australian/international standards, or the version specified by the local regulatory authority, must be used. Applicable legislation, regulations, standards and codes of practice include: health, safety and environmental (HSE) legislation, regulations and codes of practice relevant to the workplace, equipment and production processes and hazardous materials Australian/international standards relevant to the materials being used and products being made any relevant licence and certification requirements. All operations to which this unit applies are subject to stringent HSE requirements, which may be imposed through state/territory or federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between performance criteria and such requirements the legislative requirements take precedence. |
Procedures | All operations must be performed in accordance with relevant procedures. Procedures are written, verbal, visual, computer-based or in some other form, and include one or any combination of: emergency procedures work instructions standard operating procedures (SOPs) safe work method statements (SWMS) formulas/recipes batch sheets temporary instructions any similar instructions provided for the smooth running of the plant. |
Tools and equipment | Tools and equipment include: open mill blending equipment ancillary equipment that is integral to the process. Additional tools and equipment will be selected as required from: mill knifes nip adjusting bars bale hooks hoists/lifting equipment not requiring any special permits or licences manual handling aids, such as hand carts and trolleys relevant personal protective equipment (PPE). |
Hazards | Hazards must be identified and controlled. Identifying hazards requires consideration of: weight, shape, volume of materials to be handled hazardous products and materials knives, blades, cutting and nipping tools sharp edges, protrusions or obstructions slippery surfaces, spills or leaks rotational equipment or vibration high temperatures smoke, dust, vapours or other atmospheric hazards electricity gas gases and liquids under pressure structural hazards equipment failures machinery, equipment and product mass other hazards that might arise. |
Routine problems | Routine problems must be resolved by applying known solutions. Routine problems are predictable and include one or more of: power failures incorrect machine adjustments incorrect quantities of materials incorrect blending times equipment breakdowns short scorch products forming the initial band adjusting bank size for efficient mixing variations in materials contamination of materials lack of a homogeneous product. Known solutions are drawn from one or more of: procedures training remembered experience. Non-routine problems must be reported according to according to relevant procedures. |
Sectors
Not applicable
Competency Field
Production