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Evidence Guide: PMBPROD301C - Draw wire

Student: __________________________________________________

Signature: _________________________________________________

Tips for gathering evidence to demonstrate your skills

The important thing to remember when gathering evidence is that the more evidence the better - that is, the more evidence you gather to demonstrate your skills, the more confident an assessor can be that you have learned the skills not just at one point in time, but are continuing to apply and develop those skills (as opposed to just learning for the test!). Furthermore, one piece of evidence that you collect will not usualy demonstrate all the required criteria for a unit of competency, whereas multiple overlapping pieces of evidence will usually do the trick!

From the Wiki University

 

PMBPROD301C - Draw wire

What evidence can you provide to prove your understanding of each of the following citeria?

Plan own work requirements.

  1. Identify equipment and processes used for production process, upstream and downstream operations from production plan or request.
  2. Identify materials required including additives.
  3. Recognise hazards and take appropriate action.
  4. Identify and check emergency stops, guards and controls.
  5. Identify requirements for materials, quality, production and equipment checks.
  6. Identify materials, waste management and housekeeping needs.
Identify equipment and processes used for production process, upstream and downstream operations from production plan or request.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify materials required including additives.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Recognise hazards and take appropriate action.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify and check emergency stops, guards and controls.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify requirements for materials, quality, production and equipment checks.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify materials, waste management and housekeeping needs.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check wire drawing process set-up.

  1. Determine equipment requirements.
  2. Check equipment settings and adjustments are as required.
  3. Select appropriate dies (number and sizes) and arrange in correct production sequence.
  4. Identify and check dies, capstans, head, wire reel pack and gears, replacing or maintaining as required.
  5. Coat wire drawing capstan with lubricant to procedures.
  6. Check materials are correct.
  7. Check material spool sizes for conformity with requirements.
  8. Discard, or make adjustments to the process for, non-conforming materials.
  9. Thread new materials checking free operation through dies and secure fixing to reels or spools.
  10. Conduct equipment and component checks to ensure safe and efficient operation to procedures.
  11. Set up date, batch and materials markings as required.
  12. Complete other pre-start checks to procedures.
Determine equipment requirements.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check equipment settings and adjustments are as required.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Select appropriate dies (number and sizes) and arrange in correct production sequence.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify and check dies, capstans, head, wire reel pack and gears, replacing or maintaining as required.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Coat wire drawing capstan with lubricant to procedures.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check materials are correct.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check material spool sizes for conformity with requirements.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Thread new materials checking free operation through dies and secure fixing to reels or spools.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Conduct equipment and component checks to ensure safe and efficient operation to procedures.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set up date, batch and materials markings as required.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete other pre-start checks to procedures.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Operate wire drawing process to procedures.

  1. Operate wire drawing equipment, noting key variables.
  2. Monitor controls/displays/terminals for production/process data.
  3. Monitor product/process quality.
  4. Make adjustments to remedy faults and nonconformity as required.
  5. Maintain continuity of process.
  6. Collect and reprocess/discard scrap/trim and other materials.
  7. Clean, adjust and lubricate equipment as required.
  8. Complete required workplace documentation/records.
  9. Pause equipment, or stop equipment in an emergency, as required.
Operate wire drawing equipment, noting key variables.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor product/process quality.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Make adjustments to remedy faults and nonconformity as required.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Maintain continuity of process.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Collect and reprocess/discard scrap/trim and other materials.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Clean, adjust and lubricate equipment as required.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete required workplace documentation/records.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Pause equipment, or stop equipment in an emergency, as required.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down equipment to procedures.

  1. Shut down equipment as required.
  2. Complete equipment cleanup, adjustments and waste management.
  3. Place suitable guards, locks and notices to prevent inadvertent start-up.
Shut down equipment as required.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete equipment cleanup, adjustments and waste management.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Place suitable guards, locks and notices to prevent inadvertent start-up.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Anticipate and solve problems.

  1. Recognise a problem or a potential problem.
  2. Determine problems needing priority action.
  3. Refer problems outside area of responsibility to appropriate person, with possible causes.
  4. Seek information and assistance as required to solve problems.
  5. Solve problems within area of responsibility.
  6. Follow through items initiated until final resolution has occurred.
Recognise a problem or a potential problem.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine problems needing priority action.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Seek information and assistance as required to solve problems.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Solve problems within area of responsibility.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Follow through items initiated until final resolution has occurred.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

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 wire drawing 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 wire drawing machine in a work-like environment.

Competence in this unit may be assessed:

by using an appropriate, industrial wire drawing machine

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.

Required Skills and Knowledge

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 the enterprise's procedures 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 wire drawing process. Application of approved hazard control, safety procedures, the use of PPE in relation to handling materials, equipment operation and clean-up.

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

products, materials and material characteristics

function of wire drawing equipment, equipment components and ancillary equipment

impact of die wear and build up, faulty capstan and wire welds on product quality and production output

wire drawing manufacturing processes

behaviour of materials in relation to speed, temperature and tension

waste management and importance of non-conforming materials

wire properties and their interactions with process conditions

relationships between wire properties and process conditions

changes to wire properties to better suit process requirements

product problems related to wire properties

product problems related to process conditions

adjustments to process conditions to meet wire 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

identify and describe own role and role of others involved directly in the wire drawing 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.

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.

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 the operation of all wire drawing equipment within the plastics, rubber and cablemaking industries. It includes the operation of all relevant additional equipment where that equipment is integral to the wire drawing process.

Procedures

All operations are performed in accordance with procedures.

Procedures include all relevant workplace procedures, work instructions, temporary instructions, manufacturer operating instructions and relevant industry and government codes and standards.

Tools and equipment

This competency includes use of equipment and tools such as:

wire drawing equipment and components, including die box, payoff, capstan, internal cooling system, annealer, tinner, accumulator, spooler, main drive, control unit, wire drawing dies (diamond, tungsten, carbide, compax)

associated equipment, including manual handling equipment, pointers, taggers, welders, lubrication system, packaging

measuring equipment

hand tools used in production process

relevant personal protective equipment.

Hazards

Typical hazards include:

temperature

hazardous materials

manual handling hazards

equipment operations.

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:

equipment malfunctions (eg wire breaks - raw material contamination, die wear, die build-up, faulty capstan bands, faulty wire welds)

materials problems (eg incorrect quantity of materials, raw material contamination)

processing problems (eg incorrect diameter, ovality, surface appearance, colour, inclusions, elongation, tensile strength, weight, wrap)

Variables

Key variables to be monitored include:

machine speed

lubrication

wire quality.