This unit of competency applies to operators who are responsible for using equipment to load and prepare clays and other materials for ceramic production.

Operators must be able to determine requirements and quantities of materials from the production schedule and product specifications, and determine the adjustments required to meet the production needs.

This competency does NOT include bulk raw materials blending and forming processes.

This competency is typically performed by operators working either independently or as part of a team.

ELEMENT

PERFORMANCE CRITERIA

1. Mix raw materials

1.1. Receive, sample and store raw materials as required

1.2. Load and start mixing equipment to procedures

1.3. Operate mixing equipment to produce materials as specified

1.4. Operate mixing equipment within specifications

1.5. Carry out routine maintenance to specifications

1.6. Unload and shut down mixing equipment to specifications

1.7. Store materials as required

2. Settle mixtures as required

2.1. Operate pumps and valves to move materials as required

2.2. Load materials into tank as required

2.3. Produce a properly settled mixture

2.4. Pump mixture to appropriate storage after treatment

2.5. Carry out routine maintenance to settling equipment to specifications

2.6. Report sediment status to designated person

3. Control moisture of mixtures

3.1. Operate equipment to produce clay with the correct moisture content

3.2. Carry out routine maintenance to moisture control equipment to specifications

3.3. Unload and shut down moisture control equipment as required

3.4. Store materials as required

4. Rectify routine problems

4.1. Identify the range of faults that can occur during the operation

4.2. Determine and rectify fault causes by procedures

4.3. Identify and rectify equipment failure causes to procedures

4.4. Maintain appropriate records and log books of equipment operations in accordance with procedures

4.5. Identify non-routine problems and report to designated person

5. Control hazards

5.1. Identify hazards from the job to be done

5.2. Identify other hazards in the work area

5.3. Assess the risks arising from those hazards

5.4. Implement measures to control those risks in line with procedures

Required skills

Required skills include:

recognising conditions which will lead to out of specification product and taking appropriate action

implementing enterprise's procedures and relevant regulatory requirements within time constraints and in a manner relevant to the operation of the equipment

reading and numeracy to interpret workplace documents and technical information

Required knowledge

Required knowledge includes:

source and properties of typical raw materials

operation of the preparation equipment

consistency of the prepared materials

distinguish between causes of faults such as:

material variations

specification or recipe tolerance

equipment malfunction

The Evidence Guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment

The unit will be assessed in as holistic a manner as is practical and may be integrated with the assessment of other relevant units of competency.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Competence must be demonstrated in the ability to recognise situations requiring action and then in implementing appropriate corrective action. Consistent performance should be demonstrated. In particular look to see that:

raw materials are correctly selected

preparation is as specified

completed products meet specifications

performance of materials is as required.

Context of and specific resources for assessment

Assessment will require access to an operating plant over an extended period of time, or a suitable method of gathering evidence of operating ability over a range of situations.

Assessment will occur over a range of situations which will include disruptions to normal, smooth operation.

Simulation or case studies/scenarios may be required to allow for timely assessment of parts of this unit of competency. Simulation should be based on the actual plant and will include 'walk-throughs' of the relevant competency components. A bank of scenarios/case studies/what ifs and questions will be required to probe the reasoning behind observable actions.

Method of assessment

This unit may be assessed in conjunction with:

PMC552002B Operate equipment to blend/mix materials.

Individual enterprises may choose to add prerequisites and co-requisites relevant to their processes.

Guidance information for assessment

Assessment processes and techniques must be culturally appropriate and appropriate to the language and literacy capacity of the candidate and the work being performed.

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. 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) may also be included.

Procedures

All operations are performed in accordance with standard procedures and work instructions

Materials

Materials may include:

additives

body materials

glaze pigments and stains

slip

waste

Equipment

Equipment may include:

ball mill

blunger

bobcat

box feeder

filter press and filters

fine rolls

fork lift truck

front end loader

hammer mill

hygrometer

magnet

mortar and pestle

power consumption gauge

pug mill

rotameter

sieves and screens

spray drying tower

storage room

tanks and silos

tempering machine

thermometer

timing equipment

weighing equipment

PLCs

scrapper

penetrometers

balances

infrared

microwave

Processes

Processes may include:

batch

continuous

dry materials

wet materials

Typical problems

Typical problems may include:

adjustments to allow for materials variations

equipment malfunction

contamination

Occupational health and safety (OHS)

All operations are subject to stringent OHS requirements and these must not be compromised at any time. Where there is an apparent conflict between performance criteria and OHS requirements, the OHS requirements take precedence

Unit sector

Operational/technical

This unit contains employability skills.