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 the operation of open mill equipment in the plastics and rubber sectors. It includes the operation of all relevant additional equipment where that equipment is integral to the process.
While primarily intended for the mixing of rubber compounds using an open mill it may also apply to the mixing of plastics or other materials and may apply where mixing and blending is incidental to the operation such as slabbing of striping.
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:
open mill and its major components
hand tools used in the process, eg mill knives
material loading equipment used for loading of raw materials, eg stock loaders and conveyors, overhead crane arms and hooks
relevant personal protective equipment.
Hazards
Typical hazards include:
nip hazards
cut hazards
dusts/vapours
slip and fall (such as caused by scrap of spilled materials)
temperature(such as hot rubber)
hazardous materials (including curatives and accelerators, plasticisers, fillers)
manual handling hazards.
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 process problems may include:
power failures
incorrect machine adjustments
incorrect quantities of materials
incorrect blending times
equipment breakdowns
worn rolls
short scorch products
forming the initial band
adjusting bank size for efficient mixing.
Typical product problems many include:
variations in materials
contamination of materials
lack of a homogeneous product.
Appropriate action for problems outside of area of responsibility may be reporting to an appropriate person.
Appropriate action for solving problems within area of responsibility includes asking questions and seeking assistance from appropriate persons/sources.
Variables
Key variables to be monitored include:
temperatures
speed (including difference in speed between rolls)
nip pressures
colour
cycle time/process timing
product/stock/material flow and quality
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
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 competency in PMBPROD254 Operate an open mill blender, 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 process characteristics 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 human intervention.
all safety procedures are always followed.
Assessment method and context
Assessment will occur on an industrial mill and will be undertaken in a work-like environment.
Competence in this unit may be assessed:
using an appropriate industrial mill 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.