Modification History
Not applicable.
Unit Descriptor
Unit descriptor
This competency covers the operation and adjustment of composite sheet production processes and the solving of routine and non-routine problems
Application of the Unit
Application of this unit
This competency is typically performed by advanced operators applying knowledge of materials, product purpose and processes to the operation of composite sheeting equipment. It also requires using a range of well developed skills requiring some discretion and judgement to recognise and resolve a range problems.
The operator will:
- start up the composite sheeting machine
- check settings and adjustments of the equipment line, including formers
- monitor equipment operation
- make appropriate adjustments to correct materials, equipment or process variations
- solve composite sheeting equipment, material and process problems, seeking guidance where necessary or appropriate.
Licensing/Regulatory Information
Not applicable.
Pre-Requisites
Prerequisites
This unit has the prerequisite of PMBPROD295A Operate composite sheeting equipment .
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. Plan own work requirements. |
1.1 Identify the most appropriate equipment to be used for production and upstream and downstream operations from production plan or request. 1.2 Identify and check materials required including additives. 1.3 Implement measures to control identified hazards in line with procedures and duty of care. 1.4 Identify requirements for materials, quality, and production and equipment checks. |
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2. Start up composite sheeting process to procedures. |
2.1 Identify process settings required for product. 2.2 Set process to required settings. 2.3 Check materials, resins and fibres are correct. 2.4 Take appropriate action for non-conforming materials. 2.5 Set up date, batch and materials markings to specifications, as required. 2.6 Complete pre-start checks. 2.7 Start up composite sheeting process. |
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3. Operate and make adjustments as required to the composite sheet process to procedures. |
3.1 Operate composite sheeting process, noting key variables. 3.2 Monitor controls/displays/terminals for production/process data. 3.3 Take samples as required and identify product out of specification. 3.4 Monitor product/process quality. 3.5. Make adjustments to remedy faults and non-conformity to standard as required. 3.5 Establish a stable composite sheet production process. 3.6 Adjust process to minimise scrap and trim. 3.7 Clean, adjust and lubricate equipment as required. |
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4. Shut down machine to procedures. |
4.1 Determine type of shutdown. 4.2 Select appropriate purging method. 4.3 Purge efficiently and adequately as required. 4.4 Leave machine in appropriate condition and with appropriate locks, tags, or notices. 4.5 Complete relevant documentation. 4.6 Ensure area is clean and clear after the shutdown, in readiness for the next start-up. |
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5. Anticipate and solve problems. |
5. 1 Recognise a problem or a potential problem. 5.2 Determine problems needing priority action. 5.3 Refer problems outside area of responsibility to appropriate person, with possible causes. 5.4 Seek information and assistance as required to solve problems. 5.5 Solve problems within area of responsibility 5.6 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 and ability to implement organization procedures, quality requirements at each production stage and relevant regulatory requirements within appropriate time constraints and work standards.
Skills to identify and take appropriate action on the range of possible causes of product faults.
Application of the knowledge of managing risks using the hierarchy of controls applied to the composite sheeting 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 process and material problems, including:
- characteristics of materials and behaviour in relation to heat, pressure, flow rate and time
- function and operating principles of composite sheeting equipment, machine components and ancillary equipment including the mechanical, hydraulic, pneumatic, electrical and electronic principles which effect machine operation
- impact of machine speed, temperature, pressure, time during cycles on product quality and production output
- phases of the composite sheet production cycle and the effect of the key variables on product quality, in order to make appropriate adjustments to machine settings
- processing behaviour of those polymers used for composite sheets
- changes to materials at various stages of production
- impact of variations in raw materials and equipment operation in relation to final product
- 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
- maintain output and product quality using appropriate instruments, controls, test information and readings
- identify and describe own role and role of others involved directly in the process
- identify factors which may affect product quality or production output and appropriate remedies
- identify when assistance is required to solve problems.
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.
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 (eg catalyst, pigment) 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.
Where the assessee does not currently possess evidence of competence in PMBPROD295A Operate composite sheeting equipment , it may be co-assessed with this unit.
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 composite sheet process variables in relation to the process requirements and the end product
- make adjustments to the process as required
- identify and take appropriate action on problems and potential problems.
Consistent performance should be demonstrated. For example, look to see that:
- the process runs consistently and smoothly, with the minimum need for intervention
- all safety procedures are always followed.
Assessment method and context
Assessment will occur on industrial composite sheeting equipment and will be undertaken in a work-like environment.
Competence in this unit may be assessed:
- using an appropriate industrial composite sheeting machine requiring demonstration of start-up, operation and shutdown procedures
- in a situation allowing for the generation of evidence of the ability to recognise, anticipate and 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 production of composite sheets (typically wall and roof sheeting) within the plastics and rubber industries. It includes the operation of all relevant additional equipment where that equipment is integral to the composites sheeting 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:
- composite sheeting machine
- components of composite sheeting machine such as profiling and compaction rollers, formers
- additional equipment (eg curing equipment)
- controller, such as PLC, if fitted
- material loading equipment
- hand tools, eg knives, cutters
- relevant personal protective equipment.
Hazards
Typical hazards include:
- spills
- dusts/vapours
- slip and fall
- moving equipment
- hazardous materials
- manual handling hazards
- moving machinery hazards
- temperature.
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/s recorded in the procedures.
Typical process and product problems may include:
- cracks, dents or imperfections of the formers and rollers
- variations in materials, colour, consistency or mix
- equipment malfunction
- variations in curing conditions
- variations in materials and/or contamination of materials
- variations in process conditions.
Variables
Key variables to be monitored include:
- operating temperatures
- speed
- colour
- thickness
- cycle time
- output rate
- product weight
- product integrity and general conformance to specification/sample.
Unit Sector(s)
Not applicable.
