Elements and Performance Criteria

This competency applies to all thermoforming operations within the plastics and rubber sectors. It includes the operation of all relevant additional equipment where that equipment is integral to the thermoforming process.

This unit of competency relates to primary equipment only and if the role includes the operation of major stand alone ancillary equipment then PMBPROD206A - Operate ancillary equipment should also be chosen. If the role includes finishing, then PMBFIN201B - Finish products and components should be chosen.

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

This competency includes operations such as:
clearing rubbish from tool
packaging and labelling
adjusting heaters, forming air, stackers and blow off air
monitoring sheet quality
inching the sheet and opening the tool/mould cavity.

This competency includes equipment and tools such as:
heaters, mould, stacker, winder and granulator
conveyors and chutes
hand tools used in the thermoforming process
relevant personal protective equipment.

Typical hazards include:
spills
dusts/vapours
slip and fall, particularly due to leaks
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
variations in temperature, pressure, speed
variations in sheet or contamination of sheet or product
tool damage.

Typical product problems include:
routine thermoforming faults - wall thinning, pin holes, poor surface finish, poor colour dispersion, stacking damage, colour contamination, black spots and other defects
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 thermoforming equipment and components
forming process and parts of the thermoforming machine
reasons for checking process control panels and reporting readings which do not conform to the work instructions
principles behind tool/mould cavity for thermoforming
approved hazard control and safety procedures and the use of PPE in relation to handling materials, equipment operation and cleanup
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 thermoforming 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 thermoforming faults such as:
contaminated materials/additives
equipment faults
mould/tool damage
incorrect sheet
incorrect sheet feeding
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 :
thermoforming production standards are met consistently
upstream and downstream 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.
Basic numeracy is required, e.g. to read and interpret temperature and pressure gauges, add weights and interpret graphs.

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 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.