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Unit of competency details

PMBPROD323 - Produce powder coated products (Release 1)

Summary

Usage recommendation:
Deleted
The Deleted usage recommendation was implemented on 13 June 2017 to describe training components that have no replacement. Enrolments in training components and statements of attainment or qualifications issued before 13 June 2017 are valid. For any components marked as deleted after 13 June 2017, the applicable transition/teach-out periods apply. For specific questions regarding the enrolment, delivery or issuance of a statement of attainment/qualification, please contact your training regulator.
Mapping:
MappingNotesDate
DeletedDeleted from PMB Plastics, Rubber and Cablemaking17/Feb/2021
Supersedes and is equivalent to PMBPROD323C - Produce powder coated productsSupersedes and is equivalent to PMBPROD323C Produce powder coated products21/Jun/2016

Releases:
ReleaseRelease date
1 1 (this release) 22/Jun/2016


Classifications

SchemeCodeClassification value
ASCED Module/Unit of Competency Field of Education Identifier 030305 Materials Engineering  

Classification history

SchemeCodeClassification valueStart dateEnd date
ASCED Module/Unit of Competency Field of Education Identifier 030305 Materials Engineering  14/Oct/2016 
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Unit Of competency

Modification History

Release 1. Supersedes and is equivalent to PMBPROD323C Produce powder coated products

Application

This unit of competency covers the skills and knowledge required to operate and adjust powder (dry) coating equipment to produce powder coated products.

This unit of competency applies to experienced operators who are required to start up and stop powder (dry) coating equipment, monitor equipment operation, maintain continuity of process, make adjustments to remedy faults and non-conformity and solve problems within area of responsibility.

This unit of competency applies to an experienced operator demonstrating theoretical and technical knowledge and well developed skills in situations that require some discretion and judgement. The experienced operator may work alone or as a member of a team or group and will work in liaison with other shift team members, team leader and supervisor, as appropriate.

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

Pre-requisite Unit

Nil

Competency Field

Production

Unit Sector

Not applicable

Elements and Performance Criteria

Elements describe the essential outcomes.

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

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 colour, grade and quantity required

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

2

Start up powder coating process 

2.1

Determine equipment requirements

2.2

Set up and adjust powder coating equipment, racks, overhead tracks, spray equipment and oven

2.3

Check equipment, powder coat material and settings all match requirements

2.4

Discard, or make adjustments to the process for, non-conforming materials

2.5

Set up date, batch and materials markings to specifications, as required

2.6

Complete other pre-start checks in accordance with procedures

2.7

Start up powder coating process

3

Operate and make adjustments as required to the powder coating process 

3.1

Start equipment safely and correctly in accordance with standard procedures

3.2

Operate equipment, noting key variables

3.3

Compare measures of powder build, colour and final coat match requirements

3.4

Monitor controls, including speeds, operating temperatures and spray conditions, as required

3.5

Monitor controls/displays/terminals for production/process data

3.6

Make adjustments to remedy faults and non-conformity to standard as required

3.7

Maintain continuity of process

3.8

Collect and reprocess/discard scrap/trim and other materials in accordance with procedures

3.9

Clean, adjust and lubricate equipment as required

3.10

Pause or stop equipment in an emergency, following 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

Foundation Skills

This section describes those required skills (language, literacy and numeracy) that are essential to performance.

Foundation skills essential to performance are explicit in the performance criteria of this unit of competency.

Range of Conditions

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, manual handling 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:

  • 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.

Tools and equipment 

Tools and equipment include:

  • powder coating spray equipment
  • ancillary equipment that is integral to the process
  • racks, baskets and supports, including overhead tracks and drives
  • curing ovens and controls.

Additional tools and equipment will be selected as required from:

  • powder handling equipment
  • hand tools used in the process
  • hoists/lifting equipment not requiring any special permits or licences
  • manual handling aids, such as hand carts and trolleys
  • relevant personal protective equipment (PPE).

Hazards 

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

  • weight, shape, volume of materials to be handled
  • hazardous products and materials
  • rotational equipment or vibration
  • sharp edges, protrusions or obstructions
  • slippery surfaces, spills or leaks
  • smoke, dust, vapours or other atmospheric hazards
  • high temperatures
  • electricity
  • gas
  • gases and liquids under pressure
  • structural hazards
  • equipment failures
  • machinery, equipment and product mass
  • other hazards that might arise.

Problems 

Routine and non-routine problems must be resolved.

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.

Non-routine problems are unexpected problems or variations of previous problems and include one or more of:

  • unstable process variables
  • sub-optimal operation
  • variations in feed rates
  • variations in quality
  • emergency situations
  • intermittent faults.

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.

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

  • processing problems
  • equipment malfunctions
  • out of specification equipment operation
  • variations in materials
  • raw material contamination
  • incorrect quantity of materials
  • poor pre-treatment coverage, drainage or compatibility
  • colour variation
  • blemishes
  • uneven coating
  • over/under cured coating
  • contamination of materials.

Unit Mapping Information

Release 1. Supersedes and is equivalent to PMBPROD323C Produce powder coated products

Links

Companion Volume implementation guides are found in VETNet - https://vetnet.gov.au/Pages/TrainingDocs.aspx?q=932aacef-7947-4c80-acc6-593719fe4090

 

Assessment requirements

Modification History

Release 1. Supersedes and is equivalent to PMBPROD323C Produce powder coated products

Performance Evidence

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 procedures, job specifications, instruments/control panels, material labels and safety data sheets (SDS)
  • set up powder coating equipment and materials to meet specifications
  • start up and operate the equipment
  • monitor key variables, including:
  • spray application and coverage
  • operating temperatures
  • speed
  • colour
  • cycle time
  • product integrity and general conformance to specification
  • make adjustments to remedy faults and non-conformity
  • maintain output and product quality using appropriate instruments, controls, test information and readings
  • safely shut down equipment in normal and abnormal circumstances
  • leave machine in appropriate condition with any required locks, tags or notices
  • identify hazards and apply relevant hazard controls
  • apply safety procedures
  • apply housekeeping procedures
  • apply waste management procedures
  • recognise early warning signs of equipment/processes needing attention or with potential problems
  • distinguish between causes of problems, including:
  • operational problems
  • instrument failure/malfunction
  • electrical failure/malfunction
  • mechanical failure/malfunction
  • wrong readings
  • equipment design deficiencies
  • materials properties
  • surface conditions
  • oven conditions
  • process variables
  • raw material variations/contamination
  • process abnormalities
  • procedural errors
  • recognise and prioritise problems requiring action
  • resolve routine and non-routine problems
  • communicate effectively with team/work group and supervisors
  • complete workplace records
  • do basic arithmetical manipulations, including additions, subtractions, divisions, fractions and percentages.

Knowledge Evidence

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:

  • common types of powders and applications for range of substrate materials
  • common types and purpose of pre-treatment
  • function and operating principles of powder coating equipment, machine components and ancillary equipment
  • impact of variations in machine process conditions and raw materials on product quality and production output
  • factors which may affect product quality or production output and appropriate remedies
  • powder coating manufacturing process and stages of production
  • characteristics of materials and their behaviour in relation process conditions and stages of production
  • quality requirements at each production stage
  • mechanical, hydraulic, pneumatic, electrical and electronic principles which effect machine operation
  • common adjustments in process variables and their impact on product quality and production output
  • impact of variations in raw materials and equipment operation in relation to final product
  • impact of variations in raw materials and equipment operation in relation to final product
  • possible changes to materials properties to better suit specific process requirements
  • routine and 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.

Assessment Conditions

  • The unit should be assessed holistically and the judgement of competence shall be based on a holistic assessment of the evidence.
  • In all plants it may be appropriate to assess this unit concurrently with units such as:
  • teamwork
  • communication.
  • The collection of performance evidence:
  • should occur over a range of situations which include typical disruptions to normal, smooth operation of an operating plant
  • will typically include a supervisor/third-party report or other evidence, focusing on consistent performance and problem recognition and solving. A supervisor/third-party report must be prepared by someone who has a direct, relevant, current relationship with the person being assessed and who is in a position to form a judgement on workplace performance relevant to the unit of competency
  • must include the use of an appropriate industrial item of equipment requiring demonstration of operation, start and stop procedures and responding to problems
  • may use industry-based simulation for all or part of the unit particularly where safety, lack of opportunity or significant cost is an issue.
  • Assessment should occur in operational workplace situations. Where this is not possible or where personal safety or environmental damage are limiting factors assessment must occur in a sufficiently rigorous simulated environment that reflects realistic operational workplace conditions. This must cover all aspects of workplace performance, including environment, task skills, task management skills, contingency management skills and job role environment skills.
  • Assessment in a simulated environment should use evidence collected from demonstration of skills and one or more of:
  • walk-throughs
  • pilot plant operation
  • industry-based case studies/scenarios
  • ‘what ifs’.
  • Knowledge evidence may be collected concurrently with performance evidence or through an independent process, such as workbooks, written assessments or interviews.
  • Assessment processes and techniques must be appropriate to the language, literacy and numeracy requirements of the work being performed and the needs of the candidate.
  • Conditions for assessment must include access to all tools, equipment, materials and documentation required, including relevant workplace procedures, product and manufacturing specifications associated with this unit.
  • The regulatory framework will be reflected in workplace policies and procedures and is not required to be independently assessed.
  • Foundation skills are integral to competent performance of the unit and should not be assessed separately.
  • Assessors must satisfy the assessor competency requirements that are in place at the time of the assessment as set by the VET regulator.
  • In addition the assessor or anyone acting in subject matter expert role in assessment shall demonstrate both technical competency and currency. If the assessor cannot demonstrate technical competency and currency they shall assess with a subject matter expert who does meet these requirements.
  • Technical competence can be demonstrated through one or more of:
  • relevant VET or other qualification/Statement of Attainment
  • appropriate workplace experience undertaking the type of work being assessed under routine and non-routine conditions
  • appropriate workplace experience supervising/evaluating the type of work being assessed under routine and non-routine conditions
  • Currency can be demonstrated through one or more of:
  • being currently employed undertaking the type of work being assessed
  • being employed by the organisation undertaking the type of work being assessed and having maintained currency in accordance with that organisation’s policies and procedures
  • having consulted/had contact with an organisation undertaking the type of work being assessed within the last twelve months, the consultation/contact being related to assessment
  • conducting on the job training/assessments of the type of work being assessed
  • being an active member of a relevant professional body and participating in activities relevant to the assessment of this type of work.

Links

Companion Volume implementation guides are found in VETNet - https://vetnet.gov.au/Pages/TrainingDocs.aspx?q=932aacef-7947-4c80-acc6-593719fe4090