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Evidence Guide: PMBPROD360B - Produce centrifugally cast polyurethane 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

 

PMBPROD360B - Produce centrifugally cast polyurethane products

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

Prepare to centrifugally cast polyurethane materials.

  1. Interpret materials specifications.
  2. Identify required materials, including additives and curatives.
  3. Identify required equipment, including handling, control and material preparation equipment.
  4. Identify materials and process hazards and plan for their elimination.
  5. Locate and make ready appropriate safety equipment.
Interpret materials specifications.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify required materials, including additives and curatives.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify required equipment, including handling, control and material preparation equipment.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify materials and process hazards and plan for their elimination.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Locate and make ready appropriate safety equipment.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Plan centrifugal casting operations.

  1. Confirm product and process parameters.
  2. Ensure environmental controls are valid and in place according to operational procedures.
  3. Identify product to be made and calculate quantity of material required to produce product of correct shape and physical dimensions.
  4. Determine product colour and obtain appropriate agents.
  5. Plan the sequence of events from availability of the material to stripping of the final product.
  6. Obtain appropriate mould coating and releasing agents.
Confirm product and process parameters.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure environmental controls are valid and in place according to operational procedures.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify product to be made and calculate quantity of material required to produce product of correct shape and physical dimensions.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine product colour and obtain appropriate agents.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Plan the sequence of events from availability of the material to stripping of the final product.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Obtain appropriate mould coating and releasing agents.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set up and check centrifugal casting equipment.

  1. Inspect and set up centrifugal casting equipment.
  2. Ensure that mould is secured or adequately restrained to prevent separation of mould and rotational equipment.
  3. Test run horizontal cylindrical moulds to ensure vibration free running.
  4. Ensure work area is clean and free from hazards, and check operational sequence and procedures, particularly OHS procedures, codes and practices.
  5. Test and confirm that equipment control settings, stop and emergency stop functions are operational.
  6. Test run rotational equipment to assess equipment conformance to specification.
Inspect and set up centrifugal casting equipment.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure that mould is secured or adequately restrained to prevent separation of mould and rotational equipment.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Test run horizontal cylindrical moulds to ensure vibration free running.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure work area is clean and free from hazards, and check operational sequence and procedures, particularly OHS procedures, codes and practices.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Test and confirm that equipment control settings, stop and emergency stop functions are operational.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Test run rotational equipment to assess equipment conformance to specification.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Centrifugally cast polyurethane products.

  1. Following the planned sequence, identify and operate equipment according to temperature, time, rotational speed and emergency procedures.
  2. Pour materials at the appropriate rate per minute, angle and quantity using necessary aids and assistance to ensure pour is completed within required times and distribution requirements and using techniques to prevent excessive aeration.
  3. Check product quality including thickness, weight and product integrity, against specifications.
  4. Deal with material waste and scrap in accordance with workplace procedures.
  5. Store unused materials, clean up equipment, apply lubricants, make adjustments and manage waste in accordance with workplace procedures.
Following the planned sequence, identify and operate equipment according to temperature, time, rotational speed and emergency procedures.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Pour materials at the appropriate rate per minute, angle and quantity using necessary aids and assistance to ensure pour is completed within required times and distribution requirements and using techniques to prevent excessive aeration.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check product quality including thickness, weight and product integrity, against specifications.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Deal with material waste and scrap in accordance with workplace procedures.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Store unused materials, clean up equipment, apply lubricants, make adjustments and manage waste in accordance with workplace 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 centrifugal casting process characteristics in relation to the process requirements and the end product

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

the process runs consistently and smoothly.

Assessment method and context

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

Competence in this unit may be assessed:

on an operating 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 of 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 organisation 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:

impact of incorrect or faulty materials

production workflow sequences and materials demand

focus of operation of work systems and equipment

correct selection and use of equipment, materials, processes and procedures

hazards of the materials and process and appropriate hazard control procedures

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 centrifugal casting equipment and ancillary equipment

impact of machine speed, temperature, pressure, time during cycles on product quality and production output

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

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

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.

Competency also includes the ability to

plan own work, including predicting consequences and identifying improvements

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

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.

Basic numeracy is also required, eg to determine that one 30 kg batch of material and one 15 kg batch of material are required to produce a 45 kg product.

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 production of cast polyurethane products within the plastics and rubber industries. It includes the operation of all relevant additional equipment where that equipment is integral to the polyurethane products casting 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:

lifting equipment such as cranes an hoists not requiring licensed operators

spanners, hammers, wrenches and other hand tools

vertical or horizontal axis centrifugal rotational equipment

cylindrical and other moulds

relevant personal protective equipment

hand tools used in the casting process

material loading equipment used for loading of raw materials

This competency does not include the use of powered equipment/aids.

Hazards

Typical hazards include:

spills

noxious fumes or vapours

hazardous materials

manual handling hazards

rotational equipment hazards

temperature hazards

mechanical lifting hazards.

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:

variations in materials

contamination of materials

mechanical failures or disruptions

incorrect casting temperatures

physical anomalies such as variations to wall thickness

inappropriate setting up of the mould for spinning

machine malfunction

mould/tooling problems

processing problems.

Fault causes

Fault causes include:

wrong raw materials/additives/catalyst

incorrect quantity of materials/additives/catalyst

contaminated materials/additives/catalyst

variations in section thickness

difficult product removal

material 'shuts' and other material problems

incorrectly or improperly prepared materials

inadequately mixed materials.

Variables

Key variables to be monitored include:

operating temperatures

speed of rotation or cure

colour

location of pouring basin

cycle time

use of separating agents

product weight

product integrity and general conformance to specification/sample.