Unit of competency details

Unit descriptor 

This unit describes the application of the required skills and knowledge to use cutting equipment to safely and efficiently cut blanks, fabricate formed parts and maintain the dies.

No licensing, legislative, regulatory or certification requirements apply to this unit at the time of publication.

Application of the unit 

The unit applies to the automotive and related component manufacturing environment and involves application of skills and knowledge at a production worker level. These skills and knowledge are to be used within the scope of the person's job and authority.

Employability skills 

This unit contains Employability Skills.

Elements describe the essential outcomes of a unit of competency.

Performance criteria describe the required performance needed to demonstrate achievement of the element. Where bold italicised text is used, further information is detailed in the required skills and knowledge and/or the range statement. Assessment of performance is to be consistent with the evidence guide.

ELEMENT 

PERFORMANCE CRITERIA 

1. Cut blanks to size

1.1. Materials  list is read and interpreted, and the correct material for the job selected in accordance with organisation requirements 

1.2. Materials are cleaned to remove surface impurities

1.3. Cutting equipment  is set and adjusted to specifications to minimize waste

1.4. Blanks are cut  to specification using appropriate tools and cutting equipment

1.5. Blanks are sorted and recorded for identified press production purposes

1.6. Blanks are stacked in/on the appropriate containers/pallets for transportation 

2. Fabricate formed parts

2.1. Materials list is read and interpreted to select and load blanks

2.2. Specified amount of the correct lubricant is applied to the blank

2.3. Waste is minimised by aligning the blank to specified press points on the die bed

2.4. Formed parts are pressed to specification using the appropriate press equipment

2.5. Formed parts are unloaded from press equipment and checked for specification and quality

2.6. Faulty parts are marked and recorded according to organisation procedures

2.7. Workflow and production schedule are recorded and maintained

3. Maintain/changeover dies

3.1. Die surfaces are steam cleaned  and inspected for defects and conformity 

3.2. Damaged dies are marked for repair or disposal and appropriate personnel  notified

3.3. Undamaged dies are coated/covered to protect their surfaces and stored in designated areas

3.4. Dies are pre-built on outside bolsters fitted to organisation specifications

3.5. Die is removed/fitted in the sequence shown in the press set up specifications and aligned

3.6. Press is tested by producing part samples which are checked against specification

REQUIRED SKILLS AND KNOWLEDGE 

This describes the essential skills and knowledge and their level, required for this unit.

Required skills 

• speak clearly and directly in order to inform appropriate personnel of damaged dies
• apply teamwork to a range of situations, including the transportation of blanks
• solve problems particularly in teams in order to meet performance indicators
• show initiative in adapting to changing work conditions or contexts particularly when working across a variety of work areas
• access, interpret and apply information on relevant organisation policies, procedures and instructions, particularly to ensure appropriate materials are selected for the job
• manage time when planning, preparing and organising work priorities
• take responsibility for organising own work priorities.

Required knowledge 

• relevant Occupational Health and Safety and Environmental regulations and enterprise policies and procedures needed to carry out work in a manner which ensures the safety of people, equipment and the environment. The specific regulations will vary according to the area of operation
• organisation technical work documentation covering procedures, specifications, schedules and work plans or equivalent
• organisation quality system documentation covering instructions, procedures, performance indicators and review processes or equivalent
• organisation cost minimisation/waste avoidance policies, procedures and practices
• environmental protection requirements relating to the disposal of waste material
• established communication channels and protocols
• problem identification and resolution techniques
• types of cutting equipment and application
• procedures for the safe and efficient production of blanks with minimum waste
• organisation production schedules
• quality standards and faulty parts
• company of work flow records - written / electronic
• identification of faulty parts
• maintenance procedures for dies

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 

Critical aspects for assessment and evidence required to demonstrate competency in this unit 

Evidence of the following is essential:

• compliance with relevant legislative, regulations, standards, codes of practice and establish safe practices and enterprise policies and procedures for managing personal work priorities
• maintaining a working knowledge of current work systems and practices
• working and communicating effectively and positively with others involved in the work
• applying, within authority, the requirements of the job or work role in relation to:

• achieving production goals
• achieving work quality goals
• responding positively to changing work requirements
• contributing effectively to cost reduction initiatives
• effectively applying problem solving techniques

• modify activities to cater for variations in workplace context and environment
• use cutting equipment safely and efficiently to produce blanks with minimum waste
• produce formed parts to meet the production schedule
• limit the number of faulty parts to less than quality standards
• produce work flow records
• identify and mark faulty parts
• maintain dies in effective condition
• identify and deal with faulty dies
• apply company OH&S policy and procedures.

Context of and specific resources for assessment 

• assessment of the competency should take place in a safe working environment in a passenger motor vehicle manufacturing plant or simulated environment using tools/equipment/machinery required for the production process without undue disruption to the production process
• assessment is to occur under standard and authorised work practices, safety requirements and environmental constraints.

Method of assessment 

A range of assessment methods should be used to assess practical skills and knowledge. The following examples are appropriate for this unit:

• assessment methods must confirm consistency and accuracy of performance (over time and in a range of workplace relevant contexts) together with application of underpinning knowledge
• assessment methods must be by direct observation of tasks and include questioning on underpinning knowledge to ensure its correct interpretation and application
• assessment may be applied under project related conditions (real or simulated) and require evidence of process
• assessment must confirm a reasonable inference that competency is able not only to be satisfied under the particular circumstance, but is able to be transferred to other circumstances.

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. Bold italicised wording in the Performance Criteria is detailed below. 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.

Materials  may include:

• coils of steel
• sheets of steel
• uncut blanks.

Organisation requirements  may include:

• access and equity principles and practices
• environmental management (waste disposal, recycling and re-use guidelines)
• emergency and evacuation procedures
• equipment use procedures
• ethical standards
• legal obligations
• maintenance and storage procedures
• OHS requirements
• organisational and site guidelines
• policies and procedures relating to own role and responsibility
• procedural manuals
• quality assurance guidelines
• quality and continuous improvement processes and standards
• recording and reporting guidelines.

Cutting equipment  may include:

• guillotines
• shear presses
• metal punches.

Blanks may be cut  by::

• hitch
• roller feed
• guillotine.

Transportation  may include:

• use of cranes
• hoists
• tow motors
• trolleys.

Steam cleaned  may include the use of:

• solvent
• washes
• detergents
• steam cleaners.

Conformity  may include:

• size
• shape
• tolerances
• critical measurements.

Appropriate personnel  may include:

• clients and managers
• supervisors
• suppliers
• team leaders
• team members.

Unit sector 

Technical - Fabrication

Competency field 

Manufacturing - Common