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Evidence Guide: PMBPROD323C - Produce powder coated products

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

 

PMBPROD323C - Produce powder coated products

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.
  2. Identify materials colour, grade and quantity required.
  3. Recognise hazards and follow appropriate hazard control/minimisation methods.
  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 and upstream and downstream operations from production plan or request.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify materials colour, grade and quantity required.

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.

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:

 

 

 

 

 

 

 

Start up powder coating process.

  1. Determine equipment requirements.
  2. Set up and adjust powder coating equipment, racks, overhead tracks, spray equipment, oven.
  3. Check equipment, powder coat material and settings all match requirements.
  4. Discard, or make adjustments to the process for, non-conforming materials.
  5. Set up date, batch and materials markings to specifications, as required.
  6. Complete other pre-start checks in accordance with procedures.
  7. Start up powder coating process.
Determine equipment requirements.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set up and adjust powder coating equipment, racks, overhead tracks, spray equipment, oven.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check equipment, powder coat material and settings all match requirements.

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 in accordance with procedures.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Start up powder coating process.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Operate and make adjustments as required to the powder coating process.

  1. Start equipment safely and correctly in accordance with standard procedures.
  2. Operate equipment, noting key variables.
  3. Compare measures of powder build, colour and final coat match requirements.
  4. Monitor controls including speeds, operating temperatures and spray conditions, as required.
  5. Monitor controls/displays/terminals for production/process data.
  6. Make adjustments to remedy faults and non-conformity to standard as required.
  7. Maintain continuity of process.
  8. Collect and reprocess/discard scrap/trim and other materials in accordance with procedures.
  9. Clean, adjust and lubricate equipment as required.
  10. Pause or stop equipment in an emergency, following procedures.
Start equipment safely and correctly in accordance with standard procedures.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Operate equipment, noting key variables.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Compare measures of powder build, colour and final coat match requirements.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor controls including speeds, operating temperatures and spray conditions, as required.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

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 or stop equipment in an emergency, following 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.

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 powder coating 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 powder coating machine(s) equipment and will be undertaken in a work-like environment.

Competence in this unit may be assessed:

on a processing plant, allowing for operation under all normal and a range of abnormal conditions

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 toapply and/or explain:

coatings, materials and material characteristics

behaviour of materials in relation to heat, pressure and time

quality requirements at each production stage

different types of powders

use and purpose of pre-treatment

suitability of powders for range of substrate materials in components

affect of heat on powders

function and operating principles of powder coating equipment, machine components and ancillary equipment

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 coating

changes to materials at various stages of production

waste management and importance of non-conforming materials

polymer properties and their interactions with process conditions

relationships between polymer properties and process conditions

changes to polymer properties to better suit process requirements.

product problems related to polymer properties

product problems related to process conditions

adjustments to process conditions to meet polymer and product requirements.

Competence also includes the ability to:

plan own work, including predicting consequences and identifying improvements

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

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

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

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

distinguish between causes of faults.

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 all powder coating processes within the plastics and rubber industries. It includes the operation of all relevant additional equipment where that equipment is integral to the powder coating process.

Procedures

All operations are performed in accordance with procedures.

Procedures include 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:

powder coating spray equipment and ancillaries

racks, baskets and supports, including overhead tracks and drives

curing ovens and controls

hand tools used in the powder coating process

powder handling equipment

relevant personal protective equipment.

Hazards

Typical hazards include:

hazardous chemicals, pre-treatment chemicals and powder coating material

humidity, air temperatures, radiant heat, hot surfaces

stationary and moving machinery, parts and components

temperature

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:

poor pre-treatment coverage, drainage or compatibility

colour variation

blemishes

uneven coating

over/under cured coating

variations in materials and/or contamination of materials

processing problems.

Fault causes

Fault causes include:

substrate surface condition

pre-treatment effectiveness

spray application

powder

oven conditions

incorrect quantity of materials

contaminated materials.

Variables

Key variables to be monitored include:

spray application and coverage

operating temperatures

speed

colour

cycle time

coating integrity and general conformance to specification/sample.