Modification History
Not applicable.
Unit Descriptor
Unit descriptor
This competency covers the operation of equipment using pre-preg materials to produce composite products and the resolving of routine problems to procedure in the production process.
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 required to undertake the routine operation of equipment using pre-preg materials. The key factors are the making of products to meet quality standards and workplace requirements.
It includes:
- checking job sheets for work requirements
- following approved hazard minimisation procedures for any hazards connected with materials and process, using work instructions, labels and materials safety data sheets, and in accordance with occupational health and safety legislative responsibilities
- monitoring equipment operation and reporting process variations
- checking product for quality and conformity to specifications
- discarding non-conforming products ensuring discarded materials are reused where possible and waste and scrap is disposed of in accordance with workplace instructions
- identifying and taking action on routine process problems
- 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
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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 procedures. 1.2 Identify product, materials and equipment requirements for job(s). 1.3 Recognise hazards and adopt steps required to ensure safety. 1.4 Check with supervisor/appropriate person if requirements are not in accordance with usual practice. |
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2. Conduct pre-start checks as required. |
2.1 Check safety gates and guards are in position and working. 2.2 Check moulds, closures and fittings to procedures. 2.3 Check moulds for cracks, chips, marks and cleanliness. 2.4 Check pre-preg materials and other raw materials are correct. 2.5 Undertake other pre-start checks in accordance with procedures. |
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3. Operate equipment. |
3.1 Start equipment safely and correctly when required. 3.2 Check process is within required limits. 3.3 Collect products and store as required. 3.4 Check product/process is in specification/to required quality standard. 3.5 Maintain supply of material(s) as required. 3.6 Complete logs and records when required. 3.7 Collect and reprocess/discard scrap/trim, waste and other materials in accordance with procedures. 3.8 Clean up equipment and work area in accordance with procedures. 3.9 Pause or stop equipment in an emergency, following workplace and emergency procedures. |
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4. Respond to routine problems to 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 process and quality problems and take appropriate action. |
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 out of specification products, process problems and materials faults.
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 equipment using pre-preg materials. Application of approved hazard control, safety procedures and the use of PPE in relation to handling materials, equipment operation and cleanup.
Knowledge of and skills in the operation of equipment using pre-preg materials and main components sufficient for consistent production of quality products including:
- operation of moulding equipment and components
- production workflow sequences and materials demand
- reasons for checking process control panels and reporting readings which do not conform to the work instructions
- approved hazard control and safety procedures and the use of PPE in relation to handling materials, equipment operation and clean up
- potential effects of variations in raw materials and equipment operation in relation to quality of product
- waste management and importance of reusing non-conforming products wherever possible
- 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
- monitor equipment operation and product quality
- 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 process
- distinguish between possible causes of routine faults.
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.
Numeracy is required to the level of reading tables of figures and graphs (and applying the resultant information), using formula percentages/ratios to determine the required mass of an additive(catalyst, pigment etc.) for a given amount of resin, and similar manipulations and interpretation.
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:
- recognise the importance of material properties and qualities
- apply approved procedures
- take appropriate action to resolve faults or report faults to appropriate personnel
- explain and implement emergency shutdown procedures.
Consistent performance should be demonstrated. For example, look to see that:
- production standards are met consistently
- upstream and down stream communication is timely and effective
- operating procedures and work instructions are read and interpreted correctly
- problems are identified and appropriate action is taken (ie the problem is fixed or reported)
- all safety procedures are followed.
Assessment method and context
Assessment will occur using industrial pre-preg on industrial equipment and will be undertaken in a work like environment.
Competence in this unit may be assessed:
- by using an appropriate, industrial moulding machine
- 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 the operation of equipment using pre-preg materials to manufacture composite products. It includes moulds, equipment and programmable logic controllers (PLCs) if fitted.
Processes using pre-preg materials may include vacuum bagging or other closed mould processes.
It includes the operation of all relevant additional equipment where that equipment is integral to the 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
- moulding equipment and closures controllers, such as PLCs if fitted
- hand tools used in the this process
- material loading equipment used for loading of raw materials
- relevant personal protective equipment.
Hazards
Typical hazards include:
- spills
- dusts/vapours
- slip and fall
- temperature
- hazardous substances
- moving equipment
- 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
- poor handling or storage of pre-preg materials
- pre-preg incorrectly applied to mould
- variations in process conditions, especially temperature
- variations affecting cure rate
- variations in materials or contamination of materials
- equipment, tool or mould damage
- incorrect quantity of materials
- contaminated materials/additives
- equipment faults
- mould damage
- wrong raw materials/additives
- incorrect quantity of materials/additives
- machine failure.
Typical product problems may include:
- routine product faults
- machine malfunction
- mould/tooling problems
- variations in materials and/or contamination of materials.
Unit Sector(s)
Not applicable.
