Application
This unit of competency covers the skills and knowledge required to operate wire drawing equipment and ancillary equipment that is integral to the process.
This unit of competency applies to advanced operators who are required to start up and shut down wire drawing equipment, monitor equipment operation and make adjustments to remedy faults and nonconformity, maintain continuity of process and solve problems within area of responsibility.
This unit of competency applies to an advanced operator demonstrating theoretical and technical knowledge and well developed skills in situations that require some discretion and judgement. The advanced operator may work alone or as a member of a team or group and will work 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 | Plan own work requirements | 1.1 | Identify equipment and processes used for production process, upstream and downstream operations from production plan or request |
1.2 | Identify materials required including additives | ||
1.3 | Recognise hazards and take appropriate action | ||
1.4 | Identify and check emergency stops, guards and controls | ||
1.5 | Identify requirements for materials, quality, production and equipment checks | ||
1.6 | Identify materials, waste management and housekeeping needs | ||
2 | Check wire drawing process set-up | 2.1 | Determine equipment requirements |
2.2 | Check equipment settings and adjustments are as required | ||
2.3 | Select appropriate dies (number and sizes) and arrange in correct production sequence | ||
2.4 | Identify and check dies, capstans, head, wire reel pack and gears, replacing or maintaining as required | ||
2.5 | Coat wire drawing capstan with lubricant to procedures | ||
2.6 | Check materials are correct | ||
2.7 | Check material spool sizes for conformity with requirements | ||
2.8 | Discard, or make adjustments to the process for non-conforming materials | ||
2.9 | Thread new materials checking free operation through dies and secure fixing to reels or spools | ||
2.10 | Conduct equipment and component checks to ensure safe and efficient operation to procedures | ||
2.11 | Set up date, batch and materials markings as required | ||
2.12 | Complete other pre-start checks to procedures | ||
3 | Operate wire drawing process to procedures | 3.1 | Operate wire drawing equipment, noting key variables |
3.2 | Monitor controls/displays/terminals for production/process data | ||
3.3 | Monitor product/process quality | ||
3.4 | Make adjustments to remedy faults and nonconformity as required | ||
3.5 | Maintain continuity of process | ||
3.6 | Collect and reprocess/discard scrap/trim and other materials | ||
3.7 | Clean, adjust and lubricate equipment as required | ||
3.8 | Complete required workplace documentation/records | ||
3.9 | Pause equipment, or stop equipment in an emergency, as required | ||
4 | Shut down equipment to procedures | 4.1 | Shut down equipment as required |
4.2 | Complete equipment cleanup, adjustments and waste management. | ||
4.3 | Place suitable guards, locks and notices to prevent inadvertent start-up | ||
5 | Anticipate and solve problems | 5.1 | Recognise a problem or a potential problem |
5.2 | Determine problems needing priority action | ||
5.3 | Refer problems outside area of responsibility to appropriate person, with possible causes | ||
5.4 | Seek information and assistance as required to solve problems | ||
5.5 | Solve problems within area of responsibility | ||
5.6 | Follow through items initiated until final resolution has occurred | ||
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, material labels and safety data sheets (SDS)
set up wire drawing equipment to meet specifications
operate the equipment and monitor key variables, including:
machine speed
lubrication
wire quality
maintain output and product quality using appropriate instruments, controls, test information and readings
safely shut down equipment in normal and abnormal circumstances
leave machine in appropriate condition with any required locks, tags or notices
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
distinguish between causes of problems, including:
operational problems
instrument failure/malfunction
electrical failure/malfunction
mechanical failure/malfunction
wrong readings
equipment design deficiencies
wire properties
process variables
recognise and prioritise problems requiring action
resolve non-routine problems
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 independently and to solve routine and non-routine problems including knowledge of:
products, materials and material characteristics
behaviour of materials in relation to key process variables
quality requirements at each production stage
function and operating principles of wire drawing equipment, equipment components and ancillary equipment
impact of die wear and build up, faulty capstan and wire welds on product quality and production output
wire drawing manufacturing processes
behaviour of materials in relation to speed, temperature and tension
impact of machine operating parameters on product quality and production output
factors which may affect product quality or production output and appropriate remedies
wire properties and their interactions with process conditions
impact of variations in raw materials and equipment operation in relation to final product
routine and non-routine problems that may arise, the range of possible causes and appropriate 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, manual handling 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: wire drawing equipment and components wire drawing dies which may be diamond, tungsten, carbide, compax or similar ancillary equipment that is integral to the process. Additional tools and equipment will be selected as required from: hand tools used in the process pointers taggers welders lubrication system measuring equipment 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 sharp edges, protrusions or obstructions slippery surfaces, spills or leaks smoke, dust, vapours or other atmospheric hazards high temperatures electricity gas gases and liquids under pressure structural hazards equipment failures machinery, equipment and product mass other hazards that might arise. |
Problems | Routine and non-routine problems must be resolved. Non-routine problems must be resolved by applying operational knowledge to develop new solutions, either individually or in collaboration with relevant experts, to: determine problems needing action determine possible fault causes develop solutions to problems which do not have a known solution follow through items initiated until final resolution has occurred report problems outside area of responsibility to designated person. Non-routine problems are unexpected problems or variations of previous problems and include one or more of: unstable process variables sub-optimal operation variations in feed rates variations in quality emergency situations. Operational knowledge includes one or more of: procedures training technical information such as journals, engineering specifications remembered experience relevant knowledge obtained from appropriate people. Routine problems are predictable and have known solutions and include one or more of: routine and non-routine product faults machine malfunction mould/tooling/ die problems variations in materials and/or contamination of materials processing problems. |
Sectors
Not applicable
Competency Field
Production