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Evidence Guide: PMBPROD316C - Produce blown film

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

 

PMBPROD316C - Produce blown film

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 and upstream and downstream operations from production plan or request Identify materials required including additives.
  2. Recognise hazards and follow appropriate hazard control/minimisation methods.
  3. Identify and check emergency stops, guards and controls Identify requirements for materials, quality, production and equipment checks.
  4. Identify materials, waste management and housekeeping needs.
Identify equipment and processes used for production process and upstream and downstream operations from production plan or request Identify materials required including additives.

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Recognise hazards and follow appropriate hazard control/minimisation methods.

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Identify and check emergency stops, guards and controls 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 blown film process set-up.

  1. Determine equipment requirements.
  2. Set process to specifications as required.
  3. Set up and adjust blown film line for extruder temperature, back pressures and currents, nip and winding speeds, nip roller settings, corona treatment settings, winder settings, slitters, trimmers and die gap adjustments according to specifications.
  4. Check materials are correct.
  5. Discard, or make adjustments to the process for, non-conforming materials.
  6. Set up date, batch and materials markings to specifications, as required.
  7. Complete other pre-start checks to procedures.
Determine equipment requirements.

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Set process to specifications as required.

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Set up and adjust blown film line for extruder temperature, back pressures and currents, nip and winding speeds, nip roller settings, corona treatment settings, winder settings, slitters, trimmers and die gap adjustments according to specifications.

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Check materials are correct.

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Set up date, batch and materials markings to specifications, as required.

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Complete other pre-start checks to procedures.

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Operate and make adjustments as required to the blown film process.

  1. Start up blown film line as required.
  2. Operate blown film line, noting key variables.
  3. Monitor controls/displays/terminals for production/process data.
  4. Monitor product thickness and quality to procedures.
  5. Make adjustments to remedy faults and non-conformity to standard as required.
  6. Maintain continuity of process.
  7. Collect and reprocess/discard scrap/trim and other materials in accordance with procedures.
  8. Clean, adjust and lubricate equipment as required.
  9. Pause equipment, or stop equipment in an emergency, following workplace and emergency procedures.
Start up blown film line as required.

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Operate blown film line, noting key variables.

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Monitor product thickness and quality to procedures.

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Make adjustments to remedy faults and non-conformity to standard as required.

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Maintain continuity of process.

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Collect and reprocess/discard scrap/trim and other materials in accordance with procedures.

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Clean, adjust and lubricate equipment as required.

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Pause equipment, or stop equipment in an emergency, following workplace and emergency 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

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.

Overviewof assessment

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

Where the assessee does not currently possess evidence of competency in PMBPROD216A Operate blown film equipment, 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 blown film process characteristics in relation to the process requirements and the end product.

Consistent performance should be demonstrated. For example, look to see that

production quality and output standards are met consistently

the process runs consistently and smoothly.

Assessment method and context

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

Competence in this unit may be assessed

by using an appropriate, industrial blown film equipment

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 organization procedures and relevant regulatory requirements along with the ability to implement them within appropriate time constraints and work standards.

Competence includes the ability for the practical completion of the job to apply and/or explain:

products, materials and material characteristics

behaviour of materials in relation to heat, pressure and time

quality requirements at each production stage

function and operating principles of blown film equipment, machine components and ancillary equipment

impact of extruder speed, temperature, pressure on product quality and production output

impact of changes and adjustments to the winding gear on film properties

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

safety procedures and the use of PPE in relation to handling materials, equipment operation and cleanup

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

plan own work, including predicting consequences and identifying improvements

interpret from production requests the correct selection and use of equipment, materials, processes and procedures

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

make adjustments to equipment operation to rectify variations in equipment operation or product quality

check blown film line for correct setup to job specifications and implement adjustments or report deviations immediately

start up equipment and make appropriate adjustments to bring process on line

make measurements when required and identify product out of specification

safely shut down equipment in normal or abnormal circumstances

identify and describe own role and role of others involved directly in the film process

identify factors which may affect product quality or production output and appropriate remedies

identify when the operator is able to rectify faults and when assistance is required

identify hazards of the materials and process

implement appropriate procedures for hazard control

use PPE, safely handle products and materials, read relevant safety information and apply safety precautions appropriate to the task

distinguish between causes of faults such as materials, contaminants, equipment - adjustments/set-up, equipment - maintenance requirements.

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 operators demonstrating some relevant theoretical knowledge and using a range of well developed skills requiring some discretion and judgement.

Procedures

All operations are performed in accordance with procedures.

Procedures means 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:

extruder

die, air ring and blower

bubble guides and rollers

film rollers, slitting, trimming and winding gear

coolers, heaters and ancillary equipment

hand tools, knives, adjustment tools

relevant personal protective equipment.

Hazards

Typical hazards include:

high air velocities

high voltage corona treatment systems sharp knives

high towers manual handling

fumes, humidity, air temperatures, radiant heat, hot dies stationary and moving machinery, parts and components.

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:

extruder control, temperature, pressures, screw speed contamination

bubble control, size, stability

blemishes, voids, gels, die and weld lines, burn marks, poor surface finish, poor colour dispersion, partially decomposed products, uneven colour, contamination of colour

alignment and control of trimming and winding gear

materials variations

worn/damaged dies and extruder adjustments

raw material contamination, wrong grade, variations of polymer properties

hydraulic pressure variations, temperature variations, loss of power or drives

process sequencing problems

variations in component speeds.

Variables

Key variables to be monitored include:

extruder operating temperatures, melt temperatures, back pressures and current (amps)

nip and winding speeds, nip roller settings

corona treatment settings

winder settings, slitters, trimmers and die gap adjustments

colour

output rate

product thickness

product integrity and general conformance to specification/sample.