Elements and Performance Criteria

This unit of competence applies to engine reconditioning
Engine components include camshaft lobes/journals, crankshaft journals/thrust surfaces, cylinder heads (alloy and cast iron), piston and connecting rod assemblies, and crankshaft and camshaft bearing faces
Methods are to include:
building up of lobes/journals by welding, metal spraying, hard chroming
repairing cracks in alloy cylinder heads, repairing cast iron cylinder heads

Work requires individuals to demonstrate judgement and problem-solving skills in managing own work activities and contributing to a productive team environment
Work is carried out in accordance with award provisions

OH&S requirements are to be in accordance with legislation/regulations/codes of practice and enterprise safety policies and procedures. This may include protective clothing and equipment, use of tooling and equipment, workplace environment and safety, handling of material, use of fire fighting equipment, enterprise first aid, hazard control and hazardous materials and substances
Personal protective equipment is to include that prescribed under legislation/regulation/codes of practice and workplace policies and practices
Safe operating procedures are to include, but are not limited to operational risk assessment and treatments associated with vehicular movement, toxic substances, electrical safety, machinery movement and operation, manual and mechanical lifting and shifting, working in proximity to others and site visitors
Emergency procedures related to this unit are to include but may not be limited to emergency shutdown and stopping of equipment, extinguishing fires, enterprise first aid requirements and site evacuation

Environmental requirements are to include but are not limited to waste management, noise, dust and clean-up management

Quality requirements are to include, but are not limited to regulations, including Australian Standards, internal company quality policy and standards and enterprise operations and procedures

Statutory/regulatory authorities may include Federal, State/Territory and local authorities administering acts, regulations and codes of practice

Tooling and equipment are to include hand tooling, power tooling, lifting equipment, measuring equipment, finishing equipment, and may include roll welders, short arc welding equipment, gas metal arc welders, gas tungsten arc welders, metal spraying equipment and hard chroming equipment

Materials may include metal treatments, welding consumables and cleaning materials

Communications are to include, but are not limited to verbal and visual instructions and fault documenting and may include site specific instructions, written instructions, plans or instructions related to job/task, telephones and pagers

Information sources may include, but are not limited to verbal or written and graphical instructions, signage, work schedules/plans/specifications, work bulletins, memos, material safety data sheets, diagrams or sketches
Safe work procedures related to rebuilding engine components
Regulatory/legislative requirements pertaining to automotive industry, including Australian Design Rules
Engineer's design specifications and instructions
Organisation work specifications and requirements
Instructions issued by authorised enterprise or external persons
Australian Standards

Critical aspects of evidence

It is essential that competence is fully observed and there is ability to transfer competence to changing circumstances and to respond to unusual situations in the critical aspects of:

observing safety procedures and requirements
communicating effectively with others involved in or affected by the work
selecting methods and techniques appropriate to the circumstances
completing preparatory activity in a systematic manner
rebuilding a range of engine components in accordance with workplace and manufacturer/component supplier requirements
completing work to manufacturer/component supplier requirements
completing work without damage to tooling and equipment or injury to persons

Relationship to other units
Competence in this unit may be assessed in conjunction with other functional units which together form part of the holistic work role

Underpinning knowledge

A working knowledge of:

OH&S regulations/requirements, equipment, material and personal safety requirements
technical information
engine and engine component structures
effects of heat on various metals and heating procedures
specific welding procedures (e.g. MMAW, GMAW, GTAW, flux core, metal spraying)
hard chrome application
work organisation and planning processes
enterprise quality processes

Specific key competencies, underpinning and employability skills required to achieve the performance criteria
These include a number of processes that are learned throughout work and life, which are required in most jobs. Some of these are covered by the national key competencies, although others may be added. The details below highlight how these competencies are to be applied in the attainment of this unit.

Application of the key competencies in this unit are to satisfy the nominated level in which:

Level 1 - relates to working effectively within set conditions and processes;
Level 2 - relates to management or facilitation of conditions or processes; and
Level 3 - relates to design, development and evaluation of conditions or process.
How will the candidate apply the following key competency in this unit? The candidate will need to:

Collect, analyse and organise information
Apply research and interpretive skills sufficient to locate, interpret and apply manufacturer/component supplier procedures, workplace policies and procedures
Apply analytical skills for identification and analysis of technical information
(Level 1)

Communicate ideas and information
Apply plain English literacy and communication skills in relation to dealing with customers and team members
Apply questioning and active listening skills for example when obtaining information from customers
Apply oral communication skills sufficient to convey information and concepts to customers
(Level 1)

Plan and organise activities
Apply planning and organising skills to own work activities, including making good use of time and resources, sorting out priorities and monitoring own performance
(Level 1)

Work with others and in a team
Interact effectively with other persons both on a one-to-one basis and in groups, including understanding and responding to the needs of a customer and working effectively as a member of a team to achieve a shared goal
(Level 1)

Solve problems
Establish safe and effective work processes which anticipate and/or resolve problems and downtime, to systematically develop solutions to avoid or minimise reworking and avoid wastage
(Level 1)

Use mathematical ideas and techniques
Use mathematical ideas and techniques to correctly calculate time, assess tolerances, apply accurate measurements, calculate material requirements and establish quality checks
(Level 1)

Use technology
Use workplace technology related to rebuilding engine components, including the use of welding and chroming systems, measuring equipment, computerised technology and communication devices and the documenting/recording of results
(Level 1)

Context of assessment
Application of competence is to be assessed in the workplace or simulated worksite
Assessment is to occur using standard and authorised work practices, safety requirements and environmental constraints
Assessment is to comply with regulatory requirements, including Australian Standards

Method of assessment
Assessment must satisfy the endorsed assessment guidelines of the automotive industry's RS&R Training Package
Assessment methods must confirm consistency and accuracy of performance together with application of underpinning knowledge
Assessment must be by direct observation of tasks, with questioning on underpinning knowledge and it must also reinforce the integration of key competencies
Assessment may be applied under project related conditions and require evidence of process
Assessment must confirm a reasonable inference that competence is able not only to be satisfied under the particular circumstance, but is able to be transferred to other circumstances
It is preferable that assessment reflects a process rather than an event and occurs over a period of time to cover varying quality circumstances. Evidence of performance may be provided by customers, team leaders/members or other persons subject to agreed authentication arrangements

Specific resource requirements for this unit

The following resources should be made available:

workplace location or simulated workplace
material relevant to rebuilding engine components
equipment, hand and power tooling appropriate to rebuilding engine components
activities covering mandatory task requirements
specifications and work instructions