PMBPROD320C
Produce foam injected mouldings

This competency covers the application of knowledge of materials, product purpose and processes to the production of foam injected mouldings.

Application

Application of this unit

This competency applies to operators of foam injection moulding equipment. The key factors are the adequate planning of the process stages, preparation of the equipment, checking on performance of the equipment and making approved adjustments and equipment corrections. This competency is typically performed by operators working either independently or as part of a work team.

It includes:

checking job sheets for work to be done and identifying the priority in which jobs/product will be made/completed

ensuring the equipment and materials are appropriate for the job

producing the product

checking the product for conformance with specification

identifying and planning own work requirements from production requests

identifying and minimising any hazards connected with materials and process from materials safety data sheets, labels and workplace procedures

checking settings and adjustments of equipment

checking materials for conformity to job requirements

correcting materials, equipment or process variations and making appropriate adjustments

discarding non-conforming products ensuring discarded materials are re-used where possible and waste and scrap is disposed of in accordance with workplace instructions

solving routine and non-routine foam injection moulding equipment and process problems, seeking guidance where necessary or appropriate

completing logs and reports.


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. Plan own work requirements.

1.1 Identify equipment and processes used for production process and upstream and downstream operations from production plan or request.

1.2 Identify materials required including additives

1.3 Recognise hazards and follow appropriate hazard control/minimisation methods.

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 foam injection moulding process set-up.

2.1 Determine equipment requirements.

2.2 Set process to specifications as required.

2.3 Check foam injection moulding equipment settings and adjustments are as required.

2.4 Check materials are correct.

2.5 Discard, or make adjustments to the process for, non-conforming materials.

2.6 Set up date, batch and materials markings to specifications, as required.

2.7 Complete other pre-start checks in accordance with procedures.

3. Operate and make adjustments as required to the foam injection moulding process.

3.1 Operate foam injection moulding equipment, noting key variables.

3.2 Monitor controls/displays/terminals for production/process data.

3.3 Monitor product/process quality in accordance with procedures.

3.4 Make adjustments to remedy faults and nonconformity to standard as required.

3.5 Maintain continuity of process.

3.6 Collect and reprocess/discard scrap/trim and other materials in accordance with procedures.

3.7 Clean, adjust and lubricate equipment as required.

3.8 Pause equipment, or stop equipment in an emergency, following workplace and emergency procedures.

4. Anticipate and solve problems.

4.1 Recognise a problem or a potential problem.

4.2 Determine problems needing priority action.

4.3 Refer problems outside area of responsibility to appropriate person, with possible causes.

4.4 Seek information and assistance as required to solve problems.

4.5 Solve problems within area of responsibility.

4.6 Follow through items initiated until final resolution has occurred.

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 material and equipment conditions which may lead to out of specification production.

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

Competence includes the ability to apply and/or explain:

impact of incorrect or faulty materials

production workflow sequences and materials demand

focus of operation of work systems and equipment

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

hazards of the materials and process and appropriate hazard control procedures

quality requirements at each production stage

nature of mechanical, hydraulic, pneumatic, electrical and electronic principles which affect machine operation and product development

foam injection moulding cycle and the importance of machine set-up and warm-up for effective processing of materials

the hierarchy of control including engineering controls

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

distinguish between causes of faults

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

identify when the operator is able to rectify faults and when assistance is required.

Language, literacy and numeracy requirements

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

Writing is required to the level of completing workplace forms.

Basic numeracy is also required, eg to determine that 16 units and 46 units are equal to a total of 62 units.

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:

identify critical materials properties and foam injection moulding process characteristics in relation to the process requirements and the end product

plan own work process within workplace procedures and explain the reasons for the steps in the process

take appropriate action to observe equipment, materials and products for out of specification results, make adjustments and identify problems to be reported.

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

production quality and output standards are met consistently

problems are anticipated from process observations

problems are efficiently resolved

the process runs consistently and smoothly.

Assessment method and context

Assessment will occur on an industrial foam injection moulding machine(s) equipment and will be undertaken in a work-like environment.

Competence in this unit may be assessed:

on a processing plant, allowing for operation under all normal and a range of abnormal conditions

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 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:

hand carts and trolleys

knives and other bag opening equipment

hoists/lifting equipment not requiring any special permits or licences

basic hand tools required for opening of material packaging

relevant personal protective equipment

hand tools used in the foam injected product moulding process

material loading equipment used for loading of raw materials.

Hazards

Typical hazards include:

spills

dusts/vapours

hazardous materials

manual handling hazards

knife 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:

variations in materials

contamination of materials

out-of-specification machine operation

machine malfunction

mould/tooling problems

processing problems.

Variables

Key variables to be monitored include:

operating temperatures

speed

colour

cycle time

output rate

product integrity and general conformance to specification/sample.


Sectors

Not applicable.


Employability Skills

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.


Licensing Information

Not applicable.