Application of this unit

This competency is typically performed by advanced operators applying knowledge of materials, product purpose and processes to the operation of calendering equipment to convert plastic or rubber compound into intermediate or final film/sheet products. It also requires using a range of well developed skills requiring some discretion and judgement to recognise and resolve problems.

The operator will:

start up the calendering equipment

check settings and adjustments of equipment

monitor equipment operation

make appropriate adjustments to correct materials, equipment or process variations

solve calendering equipment, material and process problems, seeking guidance where necessary or appropriate.

This unit does not include milling - PMBPROD354A Compound materials using an open mill blender.

Prerequisites

This unit of competency has the prerequisite of PMBPROD207A Operate calender.

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 and ability to implement organisation procedures, quality requirements at each production stage and relevant regulatory requirements; within appropriate time constraints and work standards.

Application of the knowledge of managing risks using the hierarchy of controls applied in the calendering process. Application of approved hazard control and safety procedures and the use of PPE in relation to handling materials, equipment operation and cleanup.

Knowledge and ability to identify and take appropriate action on the range of possible causes of product faults

Knowledge as a basis for solving process and material problems including:

characteristics of materials and behaviour in relation to heat, pressure, flow rate and time

function and operating principles of calendering equipment, machine components and ancillary equipment, including the mechanical , hydraulic, pneumatic, electrical and electronic principles which affect machine operation

impact of machine settings such as nip setting, speed, temperature, tension etc. on product quality and production output

processing behaviour of those polymers which are moulded at the workplace

characteristics of different types of coated materials

impact of variations in raw materials and equipment operation in relation to final product

changes to materials at various stages of production

waste management and importance of non-conforming materials

polymer properties and their interactions with process conditions

relationships between polymer properties and process conditions

changes to polymer properties to better suit process requirements.

product problems related to polymer properties

product problems related to process conditions

adjustments to process conditions to meet polymer and product requirements.

Competence also includes the ability to:

plan own work including predicting consequences and identifying improvements

maintain output and product quality using appropriate instruments, controls, test information and readings

identify and describe own role and role of others involved directly in the calendering process

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

identify when assistance is required to solve problems.

Language, literacy and numeracy requirements

This unit requires the ability to read and interpret typical product specifications, job sheets, machine control panels, and material labels as provided to operators.

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

Basic numeracy is required, eg to determine time required to produce product at a give production rate, amount of compound required to produce the required amount of product.

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.

Where the assessee does not currently possess evidence of competency in PMBPROD207A Operate calender, it may be co-assessed with this unit.

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:

identify critical materials properties and calendering process variables in relation to the process requirements and the end product

make adjustments to the process as required

identify and take appropriate action on problems and potential problems.

Consistent performance should be demonstrated. For example, look to see that:

the process runs consistently and smoothly, with the minimum need for intervention

all safety procedures are followed.

Assessment method and context

Assessment will occur on a calendering equipment and will be undertaken in a work-like environment.

Competence in this unit may be assessed:

by using an appropriate calendering machine requiring demonstration of start-up, operation and shutdown procedures

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.

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 the operation of all calendering within the plastics and rubber industries. It also includes the operation of all relevant additional equipment, where that equipment is integral to the calendering process.

It includes the calendering of 'solid' polymers as well as the coating/impregnating of fabric, wire and other webs.

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 unit of competency includes use of equipment and tools such as:

calenders

additional equipment (such as mill knives, thickness gauges, profiling gauges/tools/jigs, nip adjusting bars, strainers and metal detector)

manual handling equipment

product take up equipment

material feeding equipment

hoists/lifting equipment not requiring any special permits or licences

basic hand tools

relevant personal protective equipment.

Hazards

Typical hazards include:

restricted spaces

heat

hazardous chemicals

dust/fumes

manual handling hazards

knife hazards

nip hazards

creel and spooling hazards.

Problems

Anticipate and solve problems means resolve a wide range of routine and non-routine problems, using product and process knowledge to develop solutions to problems which do not have a known solution/a solution recorded in the procedures.

Typical process and product problems may include:

contamination of materials

incorrect machine set-up, especially the nip setting tensions

temperatures

uniformity of product.

Appropriate action for problems outside area of responsibility may be reporting to an appropriate person.

Appropriate action for solving problems within area of responsibility includes asking questions and seeking assistance from appropriate persons/ sources.

Variables

Key variables to be monitored include:

operating temperatures

speed

nip settings

materials consistency

surface finish

product integrity and general conformance to specifications.

Not applicable.

The required outcomes described in this unit contain applicable Employability Skills. The Employability Skills Summary of the qualification(s) in which this unit is packaged will assist in identifying Employability Skill requirements.

Not applicable.