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Evidence Guide: PMBPROD398B - Produce composites using pre-pregs

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

 

PMBPROD398B - Produce composites using pre-pregs

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 required, including additives.
  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 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.

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 pre-preg process.

  1. Determine equipment requirements.
  2. Adjust control panel (eg cycle time, heating, cooling) as required for factors such as temperature, material etc.
  3. Check equipment, raw material and die/tool all match job requirements.
  4. Check materials, pre-pregs, release agents etc, 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 in accordance with procedures.
  8. Start up pre-preg process
Determine equipment requirements.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Adjust control panel (eg cycle time, heating, cooling) as required for factors such as temperature, material etc.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check equipment, raw material and die/tool all match job requirements.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check materials, pre-pregs, release agents etc, 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 in accordance with procedures.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Start up pre-preg process

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Operate and make adjustments as required to the process.

  1. Operate composites forming equipment, noting key variables.
  2. Monitor controls/displays/terminals for production/process data.
  3. Monitor product/process quality, thickness and integrity to procedures.
  4. Make adjustments to remedy faults and nonconformity to standard as required.
  5. Maintain continuity of process.
  6. Collect and reprocess/discard scrap/waste and other materials in accordance with procedures.
  7. Clean, adjust and lubricate equipment as required.
  8. Pause or stop equipment in an emergency, following procedures.
Operate composites forming equipment, noting key variables.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor product/process quality, thickness and integrity to procedures.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Make adjustments to remedy faults and nonconformity to standard as required.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Maintain continuity of process.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Collect and reprocess/discard scrap/waste 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:

 

 

 

 

 

 

 

Shut down machine to procedures

  1. Determine type of shut down
  2. Select appropriate cleaning method
  3. Clean efficiently and adequately as required
  4. Leave machine in appropriate condition and with appropriate locks, tags or notices
  5. Complete relevant documentation
  6. Ensure area is clean and clear after the shutdown, in readiness for the next start-up
Determine type of shut down

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Select appropriate cleaning method

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Clean efficiently and adequately as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Leave machine in appropriate condition and with appropriate locks, tags or notices

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete relevant documentation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure area is clean and clear after the shutdown, in readiness for the next start-up

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.

Where the assessee does not currently possess evidence of competency in PMBPROD298A Operate equipment using pre-pregs material, 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 composites moulding process characteristics in relation to the process requirements and the end product

plan own work process within workplace procedures and explain the reasons for the steps in the process

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

problems are anticipated from process observations

problems are efficiently resolved

the process runs consistently and smoothly.

Assessment method and context

Assessment will occur on an industrial pre-pregs and equipment and will be undertaken in a work-like environment.

Competence in this unit may be assessed:

using an appropriate, industrial pre-preg and equipment

in a situation allowing for the generation of evidence of the ability to recognise, anticipate and 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.

Application of the knowledge of managing risks using the hierarchy of controls applied to the pre-preg moulding process. Application of approved hazard control and safety procedures and the use of PPE in relation to handling materials, equipment operation and cleanup.

Knowledge as a basis for solving processing and material problems including:

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 composites forming equipment, machine components and ancillary equipment

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

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

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

check composites forming equipment for correct set-up to job specifications and implement adjustments or report deviations immediately

make measurements when required and identify product out of specification

distinguish between causes of faults

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

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

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

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.

Numeracy is required to the level of determining required weights/volumes of materials in a resin mix for different circumstances (say using a data sheet), number of layers of impregnated matrix required to yield the required product laminate thickness, and similar activities.

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 manufacture of composites products using pre-pregs within the plastics and rubber industries.

It includes all moulds, pumps and programmable logic controllers (PLCs) if fitted and all relevant ancillary equipment integral to the composites forming 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:

moulds, formers, closures and fittings

equipment including presses and ancillaries

controller, such as PLC if fitted

relevant personal protective equipment (PPE)

hand tools used in the production process

material loading equipment used for loading of raw materials

release films and fabrics

pre-pregs.

Hazards

Typical hazards include:

hazardous vapours and materials

fibres, airborne and handled

humidity, air temperatures, radiant heat, hot moulds

stationary and moving machinery, parts and components

manual handling hazards.

Problems

Respond to/rectify 'non-routine problems' means 'apply known solutions to a variety of predictable problems'.

Typical process and product problems may include:

pre-preg incorrectly applied to mould

release agents performance

contamination

temperature variations, affecting resin cure-rate

blemishes

missing detail

warped moulds or dies

worn or damaged mould parts or fittings

variations in materials and/or contamination of materials

processing

heat

poor handling or storage of pre-pregs

equipment - adjustments/set-up

equipment - maintenance requirements incorrect quantity of materials

contaminated materials.

Variables

Key variables to be monitored include:

operating temperatures

cycle time

output rate

surface finish and condition

product weight

product integrity and general conformance to specification/sample.