Elements and Performance Criteria

This competency applies to all work environments and sectors within the plastics, rubber and cablemaking sectors. It includes the operation of all relevant ancillary equipment where that equipment is integral to the extrusion 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.

The processes covered by this unit include, but are not limited to:
rod
sheet
film
profile
tread profile
cable.

Competence under this competency unit is only required in one process.

This competency includes equipment and tools such as:
extruder equipment and components such as main drive, gearbox, thrust assembly, adapter, gate, breaker plate, screen pack, doser, screw/s, barrel, heaters, thermocouples
extrusion dies - rod, sheet, film, pipe, profile, tread profile and cable
auxiliary equipment - water pump, feeders, hopper loader, pelletiser, dehumidifiers, etc.
tools for taking samples
relevant personal protective equipment.

Typical hazards include:
vapours
burns
moving equipment
hazardous materials
manual handling hazards.

Typical problems include:
equipment malfunction
variations in materials
contamination of materials
temperature/speed variations.

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:
function of extruder components, extrusion dies and auxiliary equipment
function of downstream equipment - stackers, haul off, saw/cutter, printing, embossing, coil winder, packaging, etc
impact of temperature, pressure and time on product quality and production output
safety procedures and the use of PPE in relation to handling materials, equipment operation and cleanup
impact of variations in raw materials and equipment operation in relation to final product
waste management and importance of reusing non conforming materials
planning own work including predicting consequences and identifying improvements
correct selection and use of equipment, materials, processes and procedures
monitor equipment operation and product quality
check extrusion equipment for correct set up to job specifications
identify when the operator is able to rectify faults and when assistance is required
make adjustments within scope of role/level of authorisation
shut down equipment in normal or abnormal circumstances
identify and describe own role and role of others involved directly in the extrusion process
identify factors which may affect product quality or production output and appropriate remedies
identify hazards of the materials and process and follow appropriate hazard control procedures
use PPE, safely handle products and materials, read relevant safety information and apply safety precautions appropriate to the task
explain the effect of unauthorised or emergency shutdown in relation to safety and production requirements
distinguish between possible causes of routine faults such as:
routine product extrusion faults - dimensions, surface appearance, colour, deformations
incorrect quantity of materials
contaminated materials/additives
equipment faults.

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 :
extrusion 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 determine that two 25 kg bags are needed to make up a requirement for 50 kg.

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.