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Evidence Guide: PMBPROD315 - Produce polyurethane foam

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

 

PMBPROD315 - Produce polyurethane foam

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

Plan process stages for polyurethane foam production

  1. Plan the stages in the polyurethane foaming process and ensure these comply with the quality requirements for production
  2. Identify and allow for changes in materials at each stage of the polyurethane foaming process
  3. Plan the availability of the equipment and components for each production stage
  4. Anticipate the impact of the process on product characteristics and product quality and useability
  5. Plan work requirements based on procedures
Plan the stages in the polyurethane foaming process and ensure these comply with the quality requirements for production

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify and allow for changes in materials at each stage of the polyurethane foaming process

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Plan the availability of the equipment and components for each production stage

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Anticipate the impact of the process on product characteristics and product quality and useability

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Plan work requirements based on procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify work requirements for polyurethane foaming operations

  1. Prepare materials, including base raw materials and additives
  2. Recognise hazards and follow appropriate hazard control/minimisation methods
  3. Check materials, ancillary supplies and equipment are correct
  4. Check equipment and processes used for materials preparation, production process and for the downstream operations are available
  5. Check product quality requirements for the relevant process stage
  6. Identify and check emergency stops, gauges, guards and controls
  7. Plan the task sequences, including times and locations for product quality checks, equipment operation and required production outputs
  8. Provide for ongoing materials input, waste management and work area housekeeping requirements
  9. Arrange any required supplementary equipment for product quality testing or routine equipment maintenance and/or adjustments
Prepare materials, including base raw materials and additives

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Recognise hazards and follow appropriate hazard control/minimisation methods

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check materials, ancillary supplies and equipment are correct

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check equipment and processes used for materials preparation, production process and for the downstream operations are available

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check product quality requirements for the relevant process stage

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify and check emergency stops, gauges, guards and controls

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Plan the task sequences, including times and locations for product quality checks, equipment operation and required production outputs

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Provide for ongoing materials input, waste management and work area housekeeping requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Arrange any required supplementary equipment for product quality testing or routine equipment maintenance and/or adjustments

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check polyurethane foaming process set-up

  1. Comply with equipment information, required quality specifications and set-up procedures
  2. Set up equipment in accordance with required quality specifications and standard operating procedures (SOPs)
  3. Check polyurethane foaming equipment settings and adjustments and conformity to documented procedures
  4. Inspect materials for conformity with requirements, including surface condition and materials thickness
  5. Discard non-conforming materials or make adjustments to processing operations in accordance with procedures
Comply with equipment information, required quality specifications and set-up procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set up equipment in accordance with required quality specifications and standard operating procedures (SOPs)

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check polyurethane foaming equipment settings and adjustments and conformity to documented procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Inspect materials for conformity with requirements, including surface condition and materials thickness

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Discard non-conforming materials or make adjustments to processing operations in accordance with procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Operate and make adjustments as required to the foam process

  1. Start up, operate and shut down foam equipment as required by procedures
  2. Monitor polyurethane foaming operations noting product quality, production outputs, equipment operating temperature, amperage, pressures, colour, thickness and product integrity
  3. Make adjustments to remedy faults and non-conformity to production standards where applicable
  4. Collect material which is able to be reprocessed and reused, and dispose of waste and scrap in accordance with workplace procedures
  5. Clean up equipment, lubricate and adjust in accordance with procedures
Start up, operate and shut down foam equipment as required by procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor polyurethane foaming operations noting product quality, production outputs, equipment operating temperature, amperage, pressures, colour, thickness and product integrity

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Make adjustments to remedy faults and non-conformity to production standards where applicable

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Collect material which is able to be reprocessed and reused, and dispose of waste and scrap in accordance with workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Clean up equipment, lubricate and adjust in accordance with procedures

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

Plan process stages for polyurethane foam production

1.1

Plan the stages in the polyurethane foaming process and ensure these comply with the quality requirements for production

1.2

Identify and allow for changes in materials at each stage of the polyurethane foaming process

1.3

Plan the availability of the equipment and components for each production stage

1.4

Anticipate the impact of the process on product characteristics and product quality and useability

1.5

Plan work requirements based on procedures

2

Identify work requirements for polyurethane foaming operations

2.1

Prepare materials, including base raw materials and additives

2.2

Recognise hazards and follow appropriate hazard control/minimisation methods

2.3

Check materials, ancillary supplies and equipment are correct

2.4

Check equipment and processes used for materials preparation, production process and for the downstream operations are available

2.5

Check product quality requirements for the relevant process stage

2.6

Identify and check emergency stops, gauges, guards and controls

2.7

Plan the task sequences, including times and locations for product quality checks, equipment operation and required production outputs

2.8

Provide for ongoing materials input, waste management and work area housekeeping requirements

2.9

Arrange any required supplementary equipment for product quality testing or routine equipment maintenance and/or adjustments

3

Check polyurethane foaming process set-up

3.1

Comply with equipment information, required quality specifications and set-up procedures

3.2

Set up equipment in accordance with required quality specifications and standard operating procedures (SOPs)

3.3

Check polyurethane foaming equipment settings and adjustments and conformity to documented procedures

3.4

Inspect materials for conformity with requirements, including surface condition and materials thickness

3.5

Discard non-conforming materials or make adjustments to processing operations in accordance with procedures

4

Operate and make adjustments as required to the foam process

4.1

Start up, operate and shut down foam equipment as required by procedures

4.2

Monitor polyurethane foaming operations noting product quality, production outputs, equipment operating temperature, amperage, pressures, colour, thickness and product integrity

4.3

Make adjustments to remedy faults and non-conformity to production standards where applicable

4.4

Collect material which is able to be reprocessed and reused, and dispose of waste and scrap in accordance with workplace procedures

4.5

Clean up equipment, lubricate and adjust in accordance with procedures

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

Required Skills and Knowledge

Elements describe the essential outcomes.

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

1

Plan process stages for polyurethane foam production

1.1

Plan the stages in the polyurethane foaming process and ensure these comply with the quality requirements for production

1.2

Identify and allow for changes in materials at each stage of the polyurethane foaming process

1.3

Plan the availability of the equipment and components for each production stage

1.4

Anticipate the impact of the process on product characteristics and product quality and useability

1.5

Plan work requirements based on procedures

2

Identify work requirements for polyurethane foaming operations

2.1

Prepare materials, including base raw materials and additives

2.2

Recognise hazards and follow appropriate hazard control/minimisation methods

2.3

Check materials, ancillary supplies and equipment are correct

2.4

Check equipment and processes used for materials preparation, production process and for the downstream operations are available

2.5

Check product quality requirements for the relevant process stage

2.6

Identify and check emergency stops, gauges, guards and controls

2.7

Plan the task sequences, including times and locations for product quality checks, equipment operation and required production outputs

2.8

Provide for ongoing materials input, waste management and work area housekeeping requirements

2.9

Arrange any required supplementary equipment for product quality testing or routine equipment maintenance and/or adjustments

3

Check polyurethane foaming process set-up

3.1

Comply with equipment information, required quality specifications and set-up procedures

3.2

Set up equipment in accordance with required quality specifications and standard operating procedures (SOPs)

3.3

Check polyurethane foaming equipment settings and adjustments and conformity to documented procedures

3.4

Inspect materials for conformity with requirements, including surface condition and materials thickness

3.5

Discard non-conforming materials or make adjustments to processing operations in accordance with procedures

4

Operate and make adjustments as required to the foam process

4.1

Start up, operate and shut down foam equipment as required by procedures

4.2

Monitor polyurethane foaming operations noting product quality, production outputs, equipment operating temperature, amperage, pressures, colour, thickness and product integrity

4.3

Make adjustments to remedy faults and non-conformity to production standards where applicable

4.4

Collect material which is able to be reprocessed and reused, and dispose of waste and scrap in accordance with workplace procedures

4.5

Clean up equipment, lubricate and adjust in accordance with procedures

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 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)

plan the foaming process and sequence tasks

set up foaming equipment and materials to meet specifications

start up and operate the equipment

monitor key variables, including:

operating temperatures

cycle time

colour

cushion specification

amperage

pressures

output rate

product weight

product integrity and general conformance to specification

make adjustments to remedy faults and non-conformity

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.

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 injection 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

injection moulding manufacturing process and phases of the cycle

importance of machine set-up and warm-up for effective processing of materials

characteristics of materials and their behaviour in relation to process conditions and stages of production

quality requirements at each production stage

mechanical, hydraulic, pneumatic, electrical and electronic principles which effect machine operation

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.

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

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:

polyurethane foaming equipment/machines

ancillary equipment that is integral to the process.

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:

fumes/vapours

weight, shape, volume of materials to be handled

hazardous products and materials

rotational equipment or vibration

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

raw material contamination

incorrect quantity of materials

contamination of materials.