Elements and Performance Criteria

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 continuous thermoforming processes and includes the use of air pressure or vacuum processes. 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
moulds
stacker
winder
granulator
conveyors and chutes
relevant personal protective equipment.
hand tools as required
additional equipment (including programmable limit controllers)
relevant personal protective equipment.
Hazards
Typical hazards include:
spills
dust/vapours
slip and fall (eg due to leaks)
temperature (eg from ovens)
hazardous substances
moving equipment (eg changing heater rods)
manual handling hazards.
stationary and moving machinery, parts and components.
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/a solution recorded in the procedures.
Typical routine faults include:
sheet sag
non-uniform pre-stretching
non-uniform wall thickness
sheet pulling out
bubbles, blisters or pits
scorching
whitening of formed part
blushing
loss of embossing detail
chill marks, drag-off lines
pinholes/pimples
shiny streaks
shrink marks
plug sticking
sheet tearing during forming.
Non-routine faults, which may have multiple causes include:
warpage or shrinkage after moulding
cracking
surface marks
webbing or wrinkling
mould sticking.
Typical process and product problems may include:
equipment malfunction
variations in temperature (eg uneven oven temperatures)
pressure
speed (eg 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.
Variables
Key variables to be monitored include:
temperature
speeds (eg rollers, mould opening and closing)
times (including cycle times)
surface finish/appearance
product weight and output rate
product integrity and general conformance to specification and quality sample.

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
Assessment will occur on an industrial thermoforming machine(s) equipment and will be undertaken in a work like environment.
Where the assessee does not currently possess evidence of competency in PMBPROD212 Operate thermoforming 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 continuous thermoforming process characteristics in relation to the process requirements and the end product
make adjustments and identify problems to be reported
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 human intervention
all safety procedures are always followed.
Assessment method and context
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. A holistic approach should be taken to the assessment.
Competence in this unit may be assessed:
by use of an appropriate, thermoforming machine requiring demonstration of start up, operation and shut down procedures
in a situation allowing the generation of evidence of the ability to recognise, anticipate and solve problems
by use of a suitable simulation and/or a range of case studies/scenarios
by 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 of variables 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.