Application of this unit

This competency is typically performed by advanced operators applying knowledge of materials, product purpose and processes to the operation of vacuum bagging equipment for the production of composites. It also requires using a range of well developed skills requiring some discretion and judgement to recognise and resolve a range of problems.

The operator will:

identify and plan own work requirements from production requests

check settings and adjustments of equipment

monitor equipment operation

make appropriate adjustments to correct materials, equipment or process variations and

solve routine and non-routine composites production equipment and process problems, seeking guidance where necessary or appropriate

complete logs and reports.

Prerequisites

This unit has the prerequisite of PMBPROD293A Operate vacuum bagging 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 organisation procedures, quality requirements at each production stage and relevant regulatory requirements along with the ability to implement them within appropriate time constraints and work standards.

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

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

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

products, materials and material characteristics

function and operating principles of vacuum bagging equipment, machine components and ancillary equipment

impact of temperature, pressure, time during cycles on product quality and production output

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

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

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

make measurements when required and identify product out of specification

identify and describe own role and role of others involved directly in the 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 and material labels as provided to operators.

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

Numeracy is required to the level of determining required weights/volumes of materials in a resin mix for different circumstances (say using a data sheet), number of layers of impregnated matrix required to yield the required product laminate thickness, and similar activities.

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 PMBPROD293 Produce composites using vacuum bagging, 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 composites moulding process characteristics 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 human intervention.

all safety procedures are always followed.

Assessment method and context

Assessment will occur on an industrial vacuum bagging machine(s) and will be undertaken in a work-like environment.

Competence in this unit may be assessed:

on an appropriate processing plant

in a situation allowing for the generation of evidence of the ability to recognise, anticipate and 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 manufacture of composite products using vacuum bagging equipment within the plastics and rubber industries.

It includes all moulds, pumps and programmable logic controllers (PLCs) if fitted and all relevant ancillary equipment integral to the composites forming 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:

moulds, closures and fittings

vacuum pumps and fittings such as couplings, hoses, breathers, bleeders

controller, such as PLC if fitted

relevant personal protective equipment (PPE)

hand tools used in the production process

material loading equipment used for loading of raw materials.

Hazards

Typical hazards include:

hazardous vapours and materials

fibres, airborne and handled

humidity, air temperatures, radiant heat, hot moulds

stationary and moving machinery, parts and components

manual handling 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 routine faults include:

heat

loss of vacuum

equipment - adjustments/set-up

equipment - maintenance requirements incorrect quantity of materials

contaminated materials.

Typical process and product problems may include:

resin, over or undersupplied to mould

release agents performance

contamination

temperature variations, affecting resin cure-rate

vacuum variation/leakage in vacuum system/bag

blemishes

missing detail

warped, worn or damaged mould parts or fittings

variations in materials and/or contamination of materials

processing problems.

Appropriate action for problems outside of 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:

cycle time

output rate

surface finish and condition

product weight

product integrity and general conformance to specification/sample.

Not applicable.

This unit contains employability skills.

Not applicable.