Elements and Performance Criteria

This competency applies to the removal and replacement of conveyor belts. It includes the operation of all relevant additional equipment where that equipment is integral to the belt removal and replacement process. The competency unit includes the use of manual handling aids such hand winches and portable lifting gear, and of powered equipment/aids for some aspects.

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:
portable power generators and vulcanising equipment
knives and other cutting instruments
portable hoists/lifting equipment not requiring any special permits or licences
spanners, wrenches, hammers, etc.
power operated hand tools such as drills, cutting disks, sanders
relevant personal protective equipment.

Typical hazards include:
unpredicted belt movements
equipment malfunctions
manual handling hazards
lifting, tracking and securing hazards
equipment operation hazards
damaged material hazards.

Respond to/rectify 'non-routine problems' means 'apply known solutions to a variety of predictable problems'.

Typical process and product problems include:
weight of the belting to be removed and replaced
obstructions and impediments to removal and fitting on new belt
worn or malfunctioning rollers, drums or propulsion equipment
lack of accessibility
lack of required human resources
tool problems
variations in materials and/or contamination of materials
processing problems.

Key variables to be monitored include:
belt condition
belt location
degree of damage
weight of the belt
forces acting on the conveyor belt
environmental conditions
lock-out of equipment.

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 material and equipment conditions which may lead to out of specification production.
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:
impact of incorrect or faulty joining processes
production workflow sequences and inherent hazards with conveyors
stresses and tensions on working belts and the common failure causes
correct selection and use of equipment, materials, processes and procedures
hazards of the materials and process and appropriate hazard control procedures
distinguish between causes of faults such as:
mechanical equipment failures versus wear failure in belts
product damage and internal belt damage
wear and impact damage
belt alignment and running problems
apply and/or explain function and operating principles of conveyor systems and ancillary equipment
plan own work including predicting consequences and identifying improvements
interpret from production requests the correct selection and use of equipment, materials, processes and procedures
make adjustments to equipment operation to rectify variations in equipment operation or product quality
check conveyor equipment for correct set-up to job specifications and implement adjustments or report deviations immediately
start up equipment and make appropriate adjustments to bring conveyor on line
take samples when required and identify product out of specification
safely shut down equipment in normal or abnormal circumstances
identify factors which may affect product quality or production output and appropriate remedies
identify when the operator is able to rectify faults and when assistance is required
identify hazards of the conveyor system and take appropriate hazard control measures
use PPE, safely handle products and materials, read relevant safety information and apply safety precautions appropriate to the task.

Critical aspects
It is essential that competence is demonstrated in the ability to:
identify critical materials properties and belt removal and replacement process characteristics
plan own work process within workplace procedures and explain the reasons for the steps in the process
take appropriate action to observe equipment, materials and products for out of specification results, make adjustments and identify problems to be reported.

Consistent performance should be demonstrated. In particular look to see that:
production quality and output standards are met consistently
problems are anticipated from process observations
problems are efficiently resolved
the removal and replacement process runs consistently and smoothly.

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.
Numeracy is also required, e.g. to determine the number of belt sections required to form a continuous belt for a given length of that conveyor.

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 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.