Modification History
Not applicable.
Unit Descriptor
Unit descriptor
This competency covers the operation of thermoforming equipment and the resolving of routine problems to procedure.
Application of the Unit
Application of this unit
This competency applies to operators who are required to undertake the routine operation of thermoforming equipment. This competency is typically performed by operators working either independently or as part of a work team.
The operator:
- takes product off the machine
- checks product for quality and conformity to specifications
- checks raw material feed
- notices any problems and takes required action (eg reporting)
- deals with non-conforming products, waste and scrap
- completes logs and reports.
They may record key variables such as machine conditions and production rate and reasons for interruptions.
This unit does not include:
- packing of product - see MSASUP204A Pack products or materials
- finishing of product - see PMBFIN201B Finish products and components .
- start up and adjustment.
Licensing/Regulatory Information
Not applicable.
Pre-Requisites
Prerequisites
This unit has no prerequisites.
Employability Skills Information
Employability Skills
This unit contains employability skills.
Elements and Performance Criteria Pre-Content
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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
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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. |
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1. Check work requirements. |
1.1 Identify work requirements from production plan or request. 1.2 Check product, materials and equipment meet requirements for job(s). 1.3 Recognise requirements which may not be in accordance with usual practice. 1.4 Ask questions of appropriate person to confirm unusual practice. 1.5 Identify hazards associated with the job and take appropriate action. 1.6 Perform other pre-operational checks in accordance with procedures. |
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2. Start up thermoforming equipment to procedures |
2.1 Conduct pre-start checks. 2.2 Start up thermoforming equipment |
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3. Operate equipment to procedures. |
3.1 Check process is operating within required limits. 3.2 Check product is in specification and to required quality standard. 3.3 Ensure product is consistently ready for next operation. 3.4 Maintain supply of material(s) as required. 3.5 Complete logs and records as required. 3.6 Keep equipment and work area clean. 3.7 Collect and segregate scrap, trim and other materials as required. 3.8 Pause machine cycle and perform emergency stop as required. |
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4. Respond to routine problems in accordance with procedures. |
4.1 Recognise known faults that occur during the operation. 4.2 Identify and take action on causes of routine faults. 4.3 Log problems as required. 4.4 Identify non-routine problems and report to designated person. |
Required Skills and Knowledge
This describes the essential skills and knowledge and their level required for this unit.
Application of an operational knowledge of the materials, equipment and process sufficient to recognise out of specification products, process problems and materials faults. For example, clamp frames are commonly used to hold heated sheet in place around the perimeter of each individual mould cavity creatingTherefore, clamp pressure should be monitored so that uniform parts are created and variation between cavities is reduced.
Knowledge of organisation procedures and relevant regulatory requirements along with the ability to implement them within appropriate time constraints and work standards. For example, when monitoring process conditions, action should be taken when there is more than 10% shrinkage of the sheet during heating.
Application of the knowledge of managing risks using the hierarchy of controls applied to the thermoforming process. Application of approved hazard control and safety procedures and the use of PPE in relation to handling materials, equipment operation and cleanup.
Knowledge of, and skills in the operation of, thermoforming equipment and main components sufficient for consistent production of quality products, including:
- production workflow sequences and materials demand
- reasons for checking process control panels and reporting readings which are outside of normal range of process variability
- accurately monitoring equipment operation and product quality
- the potential effects of variations in raw materials and equipment operation in relation to quality of product
- processing behaviour of polymers and the role of additives
- waste management and importance of reusing non-conforming products wherever possible
- explain the effect of unauthorised or emergency shutdown in relation to safety and production requirements
- correct selection and use of equipment, materials, processes and procedures
- identify factors which may affect product quality or production output and appropriate remedies.
Competence also includes the ability to:
- plan own work, including predicting consequences and identifying improvements
- identify when the operator is able to rectify faults, when assistance is required and who is the appropriate source for assistance
- identify and describe own role and role of others involved directly in the thermoforming process.
Language , literacy and numeracy requirements
This unit requires the ability to read and interpret typical product specifications, job sheets, procedures, material labels and safety information as provided to operators.
Writing is required to the level of completing workplace forms.
Basic numeracy is required, eg to read and interpret temperature and pressure gauges, add weights and interpret graphs.
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:
- apply the required skills and knowledge to operate an thermoforming machine
- apply approved procedures.
Consistent performance should be demonstrated. For example, look to see that:
- thermoforming production standards are met consistently.
- all safety procedures are followed.
Assessment method and context
Assessment will occur on an industrial thermoforming machine(s) equipment and will be undertaken in a work-like environment.
Competence in this unit may be assessed:
- by use of an appropriate, industrial thermoforming 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 applies to all thermoforming operations within the plastics and rubber sectors. It includes the operation of all relevant additional equipment where that equipment is integral to the thermoforming 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:
- heaters
- mould
- stacker
- winder
- granulator
- conveyors and chutes
- hand tools used in the thermoforming process
- relevant personal protective equipment.
Hazards
Typical hazards include:
- spills
- dusts/vapours
- slip and fall (such as due to leaks)
- temperature (such as from ovens)
- hazardous substances
- moving equipment (such as opening the tool/mould cavity)
- manual handling hazards.
Problems
'Respond to routine problems' means 'apply known solutions to a limited range of predictable problems'. Typical process problems may include:
- equipment malfunction
- variations in temperature (such as uneven oven temperatures)
- pressure
- speed (such as cycle times)
- variations in sheet or contamination of sheet
- product tool damage
- machine malfunction
- mould /tooling problems
- variations in materials and/or contamination of materials.
Typical product problems may include routine thermoforming faults such as:
- wall thinning
- pin holes
- poor surface finish
- poor colour dispersion
- stacking damage
- colour contamination
- black spots
- scorching
- shrinkage
- uneven stretching.
Unit Sector(s)
Not applicable.
