Elements and Performance Criteria

This competency applies to all polyurethane gravity casting within the plastics and rubber industries. It includes the operation of all relevant additional equipment where that equipment is integral to the polyurethane gravity casting process. This competency unit includes the use of both manually operated equipment and moulds and mechanised processes for longer production runs.

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

This competency includes tools and equipment such as:
moulds and dies
surface coatings and stripping agents
hoists/lifting equipment not requiring any special permits or licences
hand tools such as spanners, wrenches and hammers
temperature sensing equipment
relevant personal protective equipment
hand tools used in the gravity casting process
material loading equipment used for loading of raw materials.

Typical hazards include:
spills/splashes
noxious fumes/vapours
hazardous materials
manual handling hazards
temperature hazards
equipment operations.

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

Typical process and product problems include:
variations in materials
contamination of materials
mould or die problems
temperature related difficulties
product release difficulties
machine malfunction
mould/tooling problems
processing problems.
excessive aeration of materials
inadequately mixed materials.

Key variables to be monitored include:
operating temperatures
speed of cure
colour
location of pouring basin
cycle time
use of separating agents
product weight
product integrity and general conformance to specification/sample.

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 materials
production workflow sequences and materials demand
focus of operation of work systems and equipment
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:
wrong raw materials/additives/curative
incorrect quantity of materials/additives/curative
contaminated materials/additives/curative
variations in section thickness
difficult product removal
material 'shuts' and other material problems
excessive aeration
voids
apply and/or explain:
products, materials and material characteristics
behaviour of materials in relation to heat, pressure and time
quality requirements at each production stage
function and operating principles of centrifugal casting equipment and ancillary equipment
impact of machine speed, temperature, pressure, time during cycles on product quality and production output
the importance of machine set-up and warm-up for effective processing of materials
safety procedures and the use of PPE in relation to handling materials, equipment operation and clean up
the hierarchy of control including engineering controls
impact of variations in raw materials and equipment operation in relation to final product
changes to materials at various stages of production
waste management and importance of non-conforming materials
plan own work including predicting consequences and identifying improvements
interpret from production requests the correct selection and use of equipment, materials, processes and procedures
maintain output and product quality using appropriate instruments, controls, test information and readings
make adjustments to equipment operation to rectify variations in equipment operation or product quality
check centrifugal casting equipment for correct set-up to job specifications and implement adjustments or report deviations immediately
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 materials and process
implement appropriate procedures for hazard control
use PPE, safely handle products and materials, read relevant safety information and apply safety precautions appropriate to the task
distinguish between causes of faults such as:
incorrect quantity of materials
contaminated materials.

Critical aspects
It is essential that competence is demonstrated in the ability to:
identify critical materials properties and gravity casting process characteristics in relation to the process requirements and the end product
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 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.
Basic numeracy is also required, e.g. to determine the percentage of rejects if 16 out of 65 products are failed at inspection.

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.