Application
This unit of competency covers the skills and knowledge required to operate and adjust an autoclave to vulcanise/cure rubber products.
This unit of competency applies to experienced operators who are required to load product, bring the autoclave online, monitor operations, maintain continuity of process, make adjustments to remedy faults and non-conformity and solve problems within area of responsibility.
This unit of competency applies to an experienced operator demonstrating theoretical and technical knowledge and well developed skills in situations that require some discretion and judgement. The 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 work requirements from workplace procedures |
1.2 | Identify equipment and processes used for materials preparation, vulcanising and any related production process and for the downstream operations | ||
1.3 | Identify hazards connected with materials and process from workplace reference materials, including safety data sheets (SDS) and equipment instructions | ||
1.4 | Implement measures to control identified hazards in line with procedures and duty of care | ||
1.5 | Identify requirements for materials, quality, production and equipment checks | ||
2 | Set up autoclave vulcanising process | 2.1 | Identify and read equipment information, quality specifications and standard operating procedures (SOPs) |
2.2 | Check heat and pressure settings and process adjustments for conformity to procedures | ||
2.3 | Compare equipment and material condition to known optimum condition and take appropriate action in accordance with procedures (including, where authorised, making adjustments within overall specifications to process settings to ensure product output quality is appropriate). | ||
2.4 | Check that all gauges are operating, safety features are activated or fitted, locks and guards are in place | ||
3 | Operate and make adjustments to the autoclave process to procedures | 3.1 | Load and close autoclave and bring on line |
3.2 | Monitor production outputs, equipment operating temperatures and pressures | ||
3.3 | Make adjustments to remedy faults and non-conformity as required | ||
3.4 | Shut down, vent and unload autoclave | ||
3.5 | Take samples as required and identify product out of specification | ||
3.6 | Note and report non-conformity to required workplace specifications, following workplace procedures | ||
3.7 | Clean, adjust and lubricate equipment as required | ||
3.8 | Pause or stop equipment in an emergency, following procedures | ||
4 | Respond to product quality improvement requests | 4.1 | Monitor vulcanising process and note conditions which may affect product quality standards |
4.2 | Report process variations | ||
4.3 | Note and implement changes in standard operating procedures and specifications | ||
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, instruments/control panels, material labels and safety data sheets (SDS)
set up autoclave vulcanising process and materials to meet specifications
operate the equipment
monitor key variables, including:
operating temperatures
stacking and loading off product for autoclaving
material composition
operating pressure
cycle time
output rate product integrity and general conformance to specification
make adjustments to remedy faults and non-conformity
load and unload products
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
materials properties
process variables
raw material variations/contamination
process abnormalities
procedural errors
recognise and prioritise problems requiring action
resolve routine and 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:
function and operating principles of vulcanising equipment, machine components and ancillary equipment
impact of variations in machine process conditions and raw materials on product quality and production output
factors which may affect product quality or production output and appropriate remedies
vulcanising process and phases of the cycle
characteristics of materials and their behaviour in relation process conditions and stages of production
quality requirements at each production stage
common adjustments in process variables and their impact on product quality and production output
impact of variations in raw materials and equipment operation in relation to final product
possible changes to materials properties to better suit specific process requirements
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, focussing 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: autoclave ancillary equipment that is integral to the process other than boiler operation. Additional tools and equipment will be selected as required from: hand tools used in this process knives and other bag opening 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: confined spaces weight, shape, volume of materials to be handled hazardous products and materials rotational equipment or vibration knives and cutting blades sharp edges, protrusions or obstructions slippery surfaces, spills or leaks smoke, dust 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 intermittent faults. Operational knowledge includes one or more of: procedures training technical information, such as journals and engineering specifications remembered experience relevant knowledge obtained from appropriate people. Routine problems are predictable and have known solutions and include one or more of: processing problems equipment malfunctions out of specification equipment operation variations in materials wrong cure cycle changed product cure systems/section steam problems. |
Sectors
Not applicable
Competency Field
Production