Elements and Performance Criteria

This competency applies to all work environments and sectors within the plastics, rubber and cablemaking industry.

Standard 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:
movement of equipment and components.

This unit of competency may be designated for one of the following streams where workers use that unit substantially only in that stream area:
cablemaking
blow moulding
blown film
calendering
composites
compounding
extrusion
fabrication
injection moulding
polystyrene
expanded foam polyurethane
rotational moulding
thermoforming
belt splicing
rubber lining
tyre manufacture
tyre retreading
surface coating.

This competency includes equipment and tools such as:
hand carts and trolleys
hoists/lifting equipment not requiring any special permits or licences
basic hand tools required for opening of material packaging
relevant personal protective equipment
material loading equipment used for loading of raw materials
relevant personal protective equipment.

Typical hazards include:
inadequate use of guards and warning signs
manual handling hazards
hazardous materials
equipment operations.

Typical problems include:
variations in materials
faulty components
machine malfunction
variation in product
contamination of materials
processing problems.

Key variables to be monitored include:
variations in the timing of machine cycles
variations in the sequence of product availability
variations in the quality of the raw materials
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:
products, materials and material characteristics
quality requirements at each production stage
function and operating principles of equipment, machine components and ancillary equipment
impact of machine speed, temperature, pressure, time during cycles on product quality and production output
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
identify impact of mechanical, hydraulic, pneumatic and electrical/electronic principles of the production process
distinguish particular requirements of products, materials, equipment and production process
identify likely faults and remedies
recognise focus of operation of work systems and equipment
assess production workflow and the relationships with equipment, materials and product storage areas and workplace rosters and order systems
identify and correctly use equipment, processes and procedures
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
start up equipment and make appropriate adjustments to bring process on line
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 hazards of the materials and process
implement appropriate procedures for hazard control
safely handle products and materials, read relevant safety information and apply safety precautions appropriate to the task.

Critical aspects
It is essential that competence is demonstrated in the ability to:
identify equipment and components by name and operating principles and function, and to locate, interpret and apply relevant information
maintain workplace records, identify and safely handle products and materials applying safety precautions appropriate to the task
identify critical materials properties and 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.
Numeracy is also required, e.g. to determine quantities required for a run.

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.