Modification History
Not applicable.
Unit Descriptor
Unit descriptor
This competency covers the production of sheet feed vacuum forming products using sheet feed vacuum forming equipment.
This competency is typically performed by operators working either independently or as part of a work team.
Application of the Unit
Application of this unit
This competency applies to operators who are involved in the operation of sheet feed fabrication vacuum forming equipment, monitoring production, maintaining person safety and the safety of others within the context of required production output and product quality standards. The key factors are the setting up of sheet feed fabrication vacuum forming equipment, monitoring production and the recognition and resolving of a range of routine and non-routine problems.
It includes:
- identifying and planning own work requirements from production requests
- identifying and minimising any hazards connected with materials and process from materials safety data sheets, labels and workplace procedures
- checking settings and adjustments of equipment
- checking materials for conformity to job requirements
- monitoring equipment operation and correcting process variations
- correcting materials, equipment or process variations and making appropriate adjustments
- discarding non-conforming products ensuring discarded materials are reused where possible and waste and scrap is disposed of in accordance with workplace instructions
- solving routine and non-routine vacuum forming equipment and process problems, seeking guidance where necessary or appropriate
- completing logs and reports.
Licensing/Regulatory Information
Not applicable.
Pre-Requisites
Prerequisites
This unit has no prerequisites.
Employability Skills Information
Employability Skills
The required outcomes described in this unit contain applicable Employability Skills. The Employability Skills Summary of the qualification(s) in which this unit is packaged will assist in identifying Employability Skill requirements.
Elements and Performance Criteria Pre-Content
ELEMENT Elements describe the essential outcomes of a unit of competency |
PERFORMANCE CRITERIA Performance criteria describe the required performance needed to demonstrate achievement of the element. Assessment of performance is to be consistent with the evidence guide. |
Elements and Performance Criteria
ELEMENT ELEMENT |
PERFORMANCE CRITERIA Performance criteria describe the required performance needed to demonstrate achievement of the element. Assessment of performance is to be consistent with the evidence guide. |
1. Plan own work requirements. |
1.1 Identify equipment and processes used for production process and upstream and downstream operations from production plan or request. 1.2 Identify materials required including additives. 1.3 Recognise hazards and follow appropriate hazard control/minimisation methods. 1.4 Identify and check emergency stops, guards and controls. 1.5 Identify requirements for materials, quality, production and equipment checks. 1.6 Identify materials, waste management and housekeeping needs. 1.7 Plan vacuum forming operations within scope of authority. |
2. Check process setup. |
2.1 Determine equipment requirements. 2.2 Check vacuum forming settings and adjustments for conformity to documented procedures. 2.3 Check materials for conformity. 2.4 Set process to specifications as required. 2.5 Discard non-conforming materials or adjust processing operations in accordance with procedures/ workplace instructions. 2.6 Set up (where applicable) date and/or batch markings, materials identification for the appropriate information. 2.7 Undertake other pre-start checks in accordance with procedures. |
3. Operate and make adjustments to the process as required. |
3.1 Start machine safely and correctly in accordance with procedures/work instructions. 3.2 Monitor sheet feed vacuum forming operations in accordance with procedures/work instructions, noting key variables. 3.3 Monitor controls/displays/terminals for production/process data. 3.4 Monitor product/process quality in accordance with procedures. 3.5 Make adjustments to remedy faults and non-conformity to standard as required. 3.5 Maintain continuity of process. 3.6 Collect and reprocess/discard scrap/trim and other materials in accordance with procedures. 3.7 Clean, adjust and lubricate equipment as required. 3.8 Pause equipment or stop equipment in an emergency, following workplace and emergency procedures. |
4. Anticipate and solve problems |
4.1 Recognise a problem or a potential problem. 4.2 Determine problems needing priority action. 4.3 Refer problems outside area of responsibility to appropriate person, with possible causes. 4.4 Seek information and assistance as required to solve problems. 4.5 Solve problems within area of responsibility. 4.6 Follow through items initiated until final resolution has occurred. |
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 vacuum forming 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:
- the impact of chemical reactions/mechanical processes on the condition of materials
- products, materials and material characteristics
- quality requirements at each production stage
- function and operating principles of sheet feed vacuum forming equipment, machine components and ancillary equipment
- sheet feed vacuum forming cycle and 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.
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 vacuum forming 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.
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.
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 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 vacuum forming machine(s) equipment and will be undertaken in a work-like environment.
Competence in this unit may be assessed:
- by using an appropriate, industrial vacuum forming machine requiring demonstration of operation and emergency stop procedures
- 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.
Range Statement
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 unit includes the use of sheet feed fabrication vacuum forming equipment. It includes the operation of all relevant additional equipment where that equipment is integral to the vacuum 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:
- hand tools as required
- relevant personal protective equipment.
Hazards
Typical hazards include:
- manual handling
- fumes/vapours
- 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 variations in sheet feeding, in the material, temperature or pressure, or in line speed.
Unit Sector(s)
Not applicable.