Elements and Performance Criteria

This competency unit includes the use of equipment and materials to construct plugs/patterns from which composite moulds will be made. It includes the operation of all relevant additional equipment where that equipment is integral to the plug making process.

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:
construction of plugs or patterns
use of composites materials including gel coats, resins and fibres
use of other materials including timber and sheet metal, and fittings, fasteners, surface coatings and fillers.

This competency includes tools and equipment such as:
hand tools and power tools for use with composite and other materials such as sheet metal and timber
hand mixing equipment and stirrers
hand application tools, rollers, trowels, brushes, etc.
relevant personal protective equipment.

Typical hazards include:
hand and power tools
temperature
hazardous materials
manual handling hazards
equipment operations.

Typical process and product problems include:
structural strength, rigidity and stability of the tooling
dimensional accuracy of the tooling
allowances in the design for shrinkage, deformations and alterations in the process from tooling to mould to finished composite product
placement of flanges, closures, fitments, supports, struts and stiffeners
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 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:
selection of materials for construction of tooling
steps in the construction process
aspects of the plug construction to meet the dimensional and production requirements of the mould and final product
key requirements of the product which impact on the mould and the tooling construction
hazards of the materials and process and appropriate hazard control procedures
products, materials and material characteristics
quality requirements at each production stage
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
waste management and importance of non-conforming materials
cost considerations
construction procedures
specialist tools/equipment, e.g. filleting tools
use, care and maintenance of hand tools and portable equipment used for manufacturing plugs
surface textures and finishing: preparation, painting, advantages and disadvantages of polyurethane, shellac, gelcoat and acrylic finishes
safe use of wood working machinery
design of timber plugs
methods of fixing and joining timber
timber selection: timber types, sizes, timber based products, e.g. chipboard, craftwood
plug manufacture procedures
timber finishing techniques
paint finishes for use on plugs
application of paint finishes to plugs
definition and use of plugs
alternate materials for plug manufacture
plug design: increased stiffness, minimise shrinkage, shrinkage allowance, ease of laminating, part removal
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:
wrong materials
materials incorrectly used.

Critical aspects
It is essential that competence is demonstrated in the ability to produce a pattern/plug which will provide the most suitable model to enable the required mould to be made.

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 and production reports.
Numeracy is required to the level of determining required weights/volumes of materials in a resin mix for different circumstances (say using a data sheet), number of layers of impregnated matrix required to yield the required product laminate thickness, and similar activities.

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, lunchroom, etc. No other special resources are required.