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Evidence Guide: PMC553070 - Design and construct moulds for fibrous plaster 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

 

PMC553070 - Design and construct moulds for fibrous plaster products

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

Develop mould design

  1. Establish original product concept or design from drawings, originals or consultation with the customer
  2. Sketch out product prototype design and establish product sizes making appropriate allowance for material shrinkage
  3. Identify areas where undercuts, cutbacks or other special features are required
  4. Determine parting line
  5. Determine material from which mould is to be made
Establish original product concept or design from drawings, originals or consultation with the customer

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Sketch out product prototype design and establish product sizes making appropriate allowance for material shrinkage

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify areas where undercuts, cutbacks or other special features are required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine parting line

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine material from which mould is to be made

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Select mould material and prepare for mould production

  1. Set up material for mould making, ensuring that the mould can be handled or moved without damage
  2. Establish datum point and mark out design dimensions using geometric and lineal calculations
  3. Determine correct cavity depths and contours
  4. Ensure there is adequate ventilation and light to facilitate an appropriate work environment
Set up material for mould making, ensuring that the mould can be handled or moved without damage

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Establish datum point and mark out design dimensions using geometric and lineal calculations

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine correct cavity depths and contours

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure there is adequate ventilation and light to facilitate an appropriate work environment

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Produce working mould

  1. Fit appropriate protective equipment to prevent inhalation or irritation of by-products of the mould making process
  2. Use appropriate tools to carve out mould cavity and detail
  3. Accurately follow the design detail to produce a mould cavity to specification
  4. Avoid undercuts which will prevent removal of the plaster product from the mould
  5. Ensure appropriate degrees of taper are provided to facilitate product removal
  6. Carve reliefs according to design and remove debris as the work proceeds
Fit appropriate protective equipment to prevent inhalation or irritation of by-products of the mould making process

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Use appropriate tools to carve out mould cavity and detail

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Accurately follow the design detail to produce a mould cavity to specification

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Avoid undercuts which will prevent removal of the plaster product from the mould

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure appropriate degrees of taper are provided to facilitate product removal

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Carve reliefs according to design and remove debris as the work proceeds

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete mould

  1. Clean down completed mould and clean up work area
  2. Inspect mould surface for defects or irregularities
  3. Compare design details with mould cavity to confirm accuracy of translation
  4. Coat mould surface to preserve finish and allow to dry
Clean down completed mould and clean up work area

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Inspect mould surface for defects or irregularities

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Compare design details with mould cavity to confirm accuracy of translation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Coat mould surface to preserve finish and allow to dry

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Produce product prototype

  1. Apply slipping agent to mould surface
  2. Prepare and insert anchors or ties
  3. Prepare plaster mixture and appropriate amount of glass fibre
  4. Cast plaster mix and fibre into mould cavity, strike off and allow to set
  5. Remove prototype from mould or mould from prototype
  6. Check prototype for dimensional and detail accuracy
  7. Compare prototype and mould to identify any faults or mould inaccuracies
  8. Adjust or dress mould to remove imperfections and clean mould surface
  9. Cast second prototype and recheck product and mould
  10. Clean up mould and mark in accordance with organisation identification practice
Apply slipping agent to mould surface

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare and insert anchors or ties

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare plaster mixture and appropriate amount of glass fibre

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Cast plaster mix and fibre into mould cavity, strike off and allow to set

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Remove prototype from mould or mould from prototype

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check prototype for dimensional and detail accuracy

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Compare prototype and mould to identify any faults or mould inaccuracies

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Adjust or dress mould to remove imperfections and clean mould surface

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Cast second prototype and recheck product and mould

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Clean up mould and mark in accordance with organisation identification practice

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Control hazards

  1. Identify hazards in modelling work area
  2. Assess the risks arising from those hazards
  3. Implement measures to control those risks in line with procedures and duty of care
Identify hazards in modelling work area

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assess the risks arising from those hazards

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Implement measures to control those risks in line with procedures and duty of care

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Respond to problems

  1. Identify possible routine and non-routine problems in the equipment or process
  2. Determine problems needing action
  3. Determine possible fault causes
  4. Rectify problem using appropriate solution within area of responsibility
  5. Report problems outside area of responsibility to designated person
Identify possible routine and non-routine problems in the equipment or process

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine problems needing action

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine possible fault causes

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Rectify problem using appropriate solution within area of responsibility

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Report problems outside area of responsibility to designated person

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

Develop mould design

1.1

Establish original product concept or design from drawings, originals or consultation with the customer

1.2

Sketch out product prototype design and establish product sizes making appropriate allowance for material shrinkage

1.3

Identify areas where undercuts, cutbacks or other special features are required

1.4

Determine parting line

1.5

Determine material from which mould is to be made

2

Select mould material and prepare for mould production

2.1

Set up material for mould making, ensuring that the mould can be handled or moved without damage

2.2

Establish datum point and mark out design dimensions using geometric and lineal calculations

2.3

Determine correct cavity depths and contours

2.4

Ensure there is adequate ventilation and light to facilitate an appropriate work environment

3

Produce working mould

3.1

Fit appropriate protective equipment to prevent inhalation or irritation of by-products of the mould making process

3.2

Use appropriate tools to carve out mould cavity and detail

3.3

Accurately follow the design detail to produce a mould cavity to specification

3.4

Avoid undercuts which will prevent removal of the plaster product from the mould

3.5

Ensure appropriate degrees of taper are provided to facilitate product removal

3.6

Carve reliefs according to design and remove debris as the work proceeds

4

Complete mould

4.1

Clean down completed mould and clean up work area

4.2

Inspect mould surface for defects or irregularities

4.3

Compare design details with mould cavity to confirm accuracy of translation

4.4

Coat mould surface to preserve finish and allow to dry

5

Produce product prototype

5.1

Apply slipping agent to mould surface

5.2

Prepare and insert anchors or ties

5.3

Prepare plaster mixture and appropriate amount of glass fibre

5.4

Cast plaster mix and fibre into mould cavity, strike off and allow to set

5.5

Remove prototype from mould or mould from prototype

5.6

Check prototype for dimensional and detail accuracy

5.7

Compare prototype and mould to identify any faults or mould inaccuracies

5.8

Adjust or dress mould to remove imperfections and clean mould surface

5.9

Cast second prototype and recheck product and mould

5.10

Clean up mould and mark in accordance with organisation identification practice

6

Control hazards

6.1

Identify hazards in modelling work area

6.2

Assess the risks arising from those hazards

6.3

Implement measures to control those risks in line with procedures and duty of care

7

Respond to problems

7.1

Identify possible routine and non-routine problems in the equipment or process

7.2

Determine problems needing action

7.3

Determine possible fault causes

7.4

Rectify problem using appropriate solution within area of responsibility

7.5

Report problems outside area of responsibility to designated person

Required Skills and Knowledge

Elements describe the essential outcomes.

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

1

Develop mould design

1.1

Establish original product concept or design from drawings, originals or consultation with the customer

1.2

Sketch out product prototype design and establish product sizes making appropriate allowance for material shrinkage

1.3

Identify areas where undercuts, cutbacks or other special features are required

1.4

Determine parting line

1.5

Determine material from which mould is to be made

2

Select mould material and prepare for mould production

2.1

Set up material for mould making, ensuring that the mould can be handled or moved without damage

2.2

Establish datum point and mark out design dimensions using geometric and lineal calculations

2.3

Determine correct cavity depths and contours

2.4

Ensure there is adequate ventilation and light to facilitate an appropriate work environment

3

Produce working mould

3.1

Fit appropriate protective equipment to prevent inhalation or irritation of by-products of the mould making process

3.2

Use appropriate tools to carve out mould cavity and detail

3.3

Accurately follow the design detail to produce a mould cavity to specification

3.4

Avoid undercuts which will prevent removal of the plaster product from the mould

3.5

Ensure appropriate degrees of taper are provided to facilitate product removal

3.6

Carve reliefs according to design and remove debris as the work proceeds

4

Complete mould

4.1

Clean down completed mould and clean up work area

4.2

Inspect mould surface for defects or irregularities

4.3

Compare design details with mould cavity to confirm accuracy of translation

4.4

Coat mould surface to preserve finish and allow to dry

5

Produce product prototype

5.1

Apply slipping agent to mould surface

5.2

Prepare and insert anchors or ties

5.3

Prepare plaster mixture and appropriate amount of glass fibre

5.4

Cast plaster mix and fibre into mould cavity, strike off and allow to set

5.5

Remove prototype from mould or mould from prototype

5.6

Check prototype for dimensional and detail accuracy

5.7

Compare prototype and mould to identify any faults or mould inaccuracies

5.8

Adjust or dress mould to remove imperfections and clean mould surface

5.9

Cast second prototype and recheck product and mould

5.10

Clean up mould and mark in accordance with organisation identification practice

6

Control hazards

6.1

Identify hazards in modelling work area

6.2

Assess the risks arising from those hazards

6.3

Implement measures to control those risks in line with procedures and duty of care

7

Respond to problems

7.1

Identify possible routine and non-routine problems in the equipment or process

7.2

Determine problems needing action

7.3

Determine possible fault causes

7.4

Rectify problem using appropriate solution within area of responsibility

7.5

Report problems outside area of responsibility to designated person

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 product specifications, designs, drawings/plans, material labels and safety data sheets (SDS)

establish product concept and develop mould design to meet specifications

determine datum point and mark out dimensions, contours and cavity depths

carve out mould to meet specifications

prepare mould, produce and demould prototype product

review prototype for conformity to specifications

make adjustments to mould to remedy faults and non-conformity

identify hazards and apply relevant hazard controls

apply safety procedures

apply housekeeping procedures

distinguish between causes of problems, including:

equipment failure/malfunction

wrong readings/measurements

materials faults

dimensional inaccuracies

inappropriate allowance for material shrinkage

damage to components

recognise and prioritise problems requiring action

resolve routine and non-routine problems

communicate effectively with team/work group and supervisors

complete workplace records

perform geometric and lineal calculations.

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:

principles of fibrous plaster product moulding processes

types and application of mould making materials, including:

plaster

timber

rubber

metal

product specifications/materials properties that may affect mould design, materials and construction

quality requirements at each stage of construction

factors which may affect mould quality and appropriate remedies

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, equipment and production processes 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:

manufacturer's technical information

job cards

drawings

emergency procedures

work instructions

standard operating procedures (SOPs)

safe work method statements (SWMS)

formulas/recipes

batch sheets

temporary instructions

any similar instructions provided for the smooth running of the plant.

Hazards

Hazards must be identified and controlled. Identifying hazards requires consideration of:

heat, smoke, dust, vapours or other atmospheric hazards

weight, shape, volume of materials to be handled

hazardous products and materials

sharp edges, protrusions or obstructions

slippery surfaces, spills or leaks

electricity

gas

gases and liquids under pressure

noise

rotational equipment or vibration

plant services (steam, condensate, cooling water, etc)

structural hazards

equipment failures

machinery, equipment and product mass

limited head spaces or overhangs

working at heights

working in restricted or confined spaces

other hazards that might arise.

Problems

Routine and non-routine problems must be resolved.

Routine problems are predictable and have known solutions and include one or more of:

personal injuries

complexities of mould design and shape

lack of appropriate illumination

mould problems

product faults.

Non-routine problems are unexpected problems or variations of previous problems.

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.

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.

Tools and equipment

Tools and equipment include:

moulds/mould parts

chisels and hand held cutting tools

hand and power tools

jigs and fixtures

mixing equipment.