Application of this unit

This competency applies to operators who are required to apply knowledge of materials, product purpose and processes to the operation of rotational moulding equipment. The key factors are the production of material meeting quality standards and product requirements and the recognition and resolving of a range of routine and non-routine problems.

It includes:

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

monitoring equipment operation and correcting process variations

correcting materials, equipment or process variations and making appropriate adjustments

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

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

completing logs and reports.

Prerequisites

This unit of competency has the prerequisite of PMBPROD221A Operate rotational moulding equipment.

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 for the practical completion of the job toapply and/or explain:

products, materials and material characteristics

behaviour of materials in relation to heat, rotation and time

quality requirements at each production stage

function and operating principles of rotational moulding equipment, machine components and ancillary equipment

impact of machine speed, temperature, time during heating and cooling cycles on product quality and production output

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

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

safety procedures and the use of PPE in relation to handling materials, equipment operation and clean up

the hierarchy of control including engineering controls

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

interpret from production requests the correct selection and use of equipment, materials, processes and procedures

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

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

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

distinguish between causes of faults.

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 and production reports.

Basic numeracy is required, eg to determine how many 2 kg, 3 kg and 5 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

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 rotational moulding process characteristics in relation to the process requirements and the end product.

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

production quality and output standards are met consistently

the process runs consistently and smoothly.

Assessment method and context

Assessment will occur on an industrial rotational 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.

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 rotomoulding systems, including fixed spindle, single spindle, multiple spindle and shuttle, swing and carousel type machines. It includes the operation of all relevant additional equipment where that equipment is integral to the rotational moulding process.

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 competency includes use of equipment and tools such as:

hand tools used in the rotational moulding process

material loading equipment used for loading of raw materials

relevant personal protective equipment.

Hazards

Typical hazards include:

noise, light, energy sources

manual handling

humidity, air temperatures, radiant heat, hot moulds

stationary and moving machinery, parts and components.

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:

routine and non-routine product rotational moulding faults

machine malfunction

mould/tooling problems

variations in materials and/or contamination of materials

processing problems.

Causes of faults

Causes of faults include:

short mouldings

sink marks

voids

burn marks

mica

splash marks

warping

silver streaking

blistering

flow marks

poor surface finish

windows

erratic cycles

poor colour dispersion

rotation damage

colour contamination

black spots

incorrect quantity of materials

contaminated materials.

Variables

Key variables to be monitored include:

cycle time according to external temperatures and humidity

operating temperatures

type of heating used

cooling time

speed of rotation/movement

pattern of movement

colour of product

product integrity and general conformance to specification/sample.

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.