Elements and Performance Criteria

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 means all relevant workplace procedures, work instructions, temporary instructions and relevant industry and government codes and standards.

This competency includes 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.

Typical hazards include:
spills
dusts/vapours
slip and fall
temperature
hazardous substances
moving equipment
manual handling hazards.

'Rectify routine problems' means 'apply known solutions to a limited range of predictable problems'.

Typical process problems include:
equipment malfunction
poor handling or storage of pre-preg materials
pre-preg incorrectly supplied to mould
variations in process conditions, especially temperature variations affecting cure rate
variations in materials or contamination of materials
equipment, tool or mould damage.

Typical product problems include:
routine product faults
machine malfunction
mould/tooling problems
variations in materials and/or contamination of materials.

All operations are performed in accordance with procedures.

Essential knowledge and enterprise requirements:
Application of knowledge of the materials, equipment and process sufficient to recognise out of specification products, process problems and materials faults.
Knowledge of the enterprise's procedures and relevant regulatory requirements along with the ability to implement them within appropriate time constraints and work standards.

Competence includes the ability for the practical completion of the job to:
apply and/or explain:
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
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
identify factors which may affect product quality or production output and appropriate remedies
use PPE, safely handle products and materials, read relevant safety information and apply safety precautions appropriate to the task
pause equipment, or shut down equipment in abnormal circumstances
explain the effect of unauthorised or emergency shutdown in relation to safety and production requirements
distinguish between possible causes of routine faults such as:
incorrect quantity of materials
contaminated materials/additives
equipment faults
mould damage
wrong raw materials/additives
incorrect quantity of materials/additives
machine failure.

Critical aspects
It is essential that competence is demonstrated in 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. In particular 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 (i.e. the problem is fixed or reported)
all safety procedures are followed.

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.

Assessment method and context
Competence in this unit may be assessed:
on an operating plant allowing for operation under all normal and a range of abnormal conditions
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 that the theoretical assessment will be combined with appropriate practical/simulation or similar assessment.

Resource implications
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.