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Evidence Guide: PMBPROD308 - Take a machine out of production

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

 

PMBPROD308 - Take a machine out of production

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

Take over operation of the machine

  1. Arrange handover from the operator (if necessary)
  2. Determine type and reason for shutdown
  3. Implement measures to control identified hazards in line with procedures and duty of care
  4. Notify relevant associated personnel
Arrange handover from the operator (if necessary)

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine type and reason for shutdown

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Implement measures to control identified hazards in line with procedures and duty of care

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Notify relevant associated personnel

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Perform long-term shutdown

  1. Stop material feed
  2. Purge, using appropriate materials as required
  3. Switch off ancillaries as required
  4. Make required adjustments to ensure the safety of machine and materials
  5. Isolate, lock out and make machine safe for personnel, and leave with appropriate tags or notices
  6. Complete relevant documentation
Stop material feed

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Purge, using appropriate materials as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Switch off ancillaries as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Make required adjustments to ensure the safety of machine and materials

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Isolate, lock out and make machine safe for personnel, and leave with appropriate tags or notices

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete relevant documentation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Perform post-shutdown preventive maintenance and cleanup after long-term shutdown

  1. Clean all components as required
  2. Apply required surfaces treatments
  3. Leave all parts in required condition
  4. Confirm all isolations have been done
  5. Pack/process any remaining goods/ product and label as required
  6. Sort material that can be salvaged from waste and arrange reprocessing/disposal to procedures
  7. Ensure area is clean and clear, ready for restarting of the machine
Clean all components as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Apply required surfaces treatments

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Leave all parts in required condition

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Confirm all isolations have been done

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Pack/process any remaining goods/ product and label as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Sort material that can be salvaged from waste and arrange reprocessing/disposal to procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure area is clean and clear, ready for restarting of the machine

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

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Take over operation of the machine

1.1

Arrange handover from the operator (if necessary)

1.2

Determine type and reason for shutdown

1.3

Implement measures to control identified hazards in line with procedures and duty of care

1.4

Notify relevant associated personnel

2

Perform long-term shutdown

2.1

Stop material feed

2.2

Purge, using appropriate materials as required

2.3

Switch off ancillaries as required

2.4

Make required adjustments to ensure the safety of machine and materials

2.5

Isolate, lock out and make machine safe for personnel, and leave with appropriate tags or notices

2.6

Complete relevant documentation

3

Perform post-shutdown preventive maintenance and cleanup after long-term shutdown

3.1

Clean all components as required

3.2

Apply required surfaces treatments

3.3

Leave all parts in required condition

3.4

Confirm all isolations have been done

3.5

Pack/process any remaining goods/ product and label as required

3.6

Sort material that can be salvaged from waste and arrange reprocessing/disposal to procedures

3.7

Ensure area is clean and clear, ready for restarting of the machine

4

Anticipate and solve problems

4.1

Recognise a problem or a potential problem

4.2

Determine problems needing priority action

4.3

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

4.4

Seek information and assistance as required to solve problems

4.5

Solve problems within area of responsibility

4.6

Follow through items initiated until final resolution has occurred

Required Skills and Knowledge

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Take over operation of the machine

1.1

Arrange handover from the operator (if necessary)

1.2

Determine type and reason for shutdown

1.3

Implement measures to control identified hazards in line with procedures and duty of care

1.4

Notify relevant associated personnel

2

Perform long-term shutdown

2.1

Stop material feed

2.2

Purge, using appropriate materials as required

2.3

Switch off ancillaries as required

2.4

Make required adjustments to ensure the safety of machine and materials

2.5

Isolate, lock out and make machine safe for personnel, and leave with appropriate tags or notices

2.6

Complete relevant documentation

3

Perform post-shutdown preventive maintenance and cleanup after long-term shutdown

3.1

Clean all components as required

3.2

Apply required surfaces treatments

3.3

Leave all parts in required condition

3.4

Confirm all isolations have been done

3.5

Pack/process any remaining goods/ product and label as required

3.6

Sort material that can be salvaged from waste and arrange reprocessing/disposal to procedures

3.7

Ensure area is clean and clear, ready for restarting of the machine

4

Anticipate and solve problems

4.1

Recognise a problem or a potential problem

4.2

Determine problems needing priority action

4.3

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

4.4

Seek information and assistance as required to solve problems

4.5

Solve problems within area of responsibility

4.6

Follow through items initiated until final resolution has occurred

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)

safely shutdown the machine, feed and ancillary equipment by adjusting machine control system, including one or more of:

basic controls

open loop

closed loop

shot size and correction capacity

speed/cycle time

screw position

equipment/process pressure

clamp pressure

time

screw speed

screw back pressure

screw back time

melt decompress position

sprue break

monitor key variables, including:

temperature

fill rate

screw RPM

speed

brakes

stopping distance

safely shut down equipment in normal and abnormal circumstances

isolate, lock out and make machine safe

apply preventive maintenance, clean up and housekeeping procedures

identify hazards and apply relevant hazard controls

apply safety 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

polymer properties

process variables

raw material variations/contamination

process abnormalities

procedural errors

recognise and prioritise problems requiring action

resolve 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.

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:

structure, functions and principles of operation of equipment, machine components and ancillary equipment

impact of variations in production cycle/process/sequence on shutdown of equipment systems

functions and applications of analogue controls, digital controls, and microprocessor based process controls

function of and readings from measuring instruments, including one or more of:

levelling

thermocouples

pyrometers

transducers

thermometers

pressure gauges

vacuum gauges

flow meters

purpose and operation of safety interlocks and systems, including one or more of:

limit switches

normally open/normally closed

overstroke control systems

hydraulic temperature control

material temperature control

machine guards

nozzle purge guard

mould protection systems

ejection limit switches

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

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.

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:

production plant/equipment

machine control systems

safety interlocks and systems

measuring instruments

ancillary equipment that is integral to the process.

Additional tools and equipment will be selected as required from:

hand tools used in the process

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:

weight, shape, volume of materials to be handled

hazardous products and materials

sharp edges, protrusions or obstructions

slippery surfaces, spills or leaks

smoke, dust, vapours 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.

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:

cycle interruptions

degradation of materials

cooling and solidification of compounds

rusting and corrosion of moulds put in storage

clearing jams

damage to equipment.