Elements and Performance Criteria

This competency applies to the operation of Banbury and similar processes in the plastics and rubber sectors. It includes the operation of all relevant additional equipment where that equipment is integral to the process.

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

Respond to/rectify 'non-routine problems' means 'apply known solutions to a variety of predictable problems'.

This competency may include machine, equipment and tools such as:
process electrical/mechanical machine and its major components, e.g. skid shifter/ wigwags, bale loader, overhead rubber feed
hand tools used in the process, e.g. knives
material loading equipment used for loading of raw materials, e.g. forklift, lift, hook, takeaway belt
monitoring equipment and tools, e.g. scales for weighing powders, rubber; digital sensors, computer control settings and displays; recipe cards; 2C plates; tickets of unused material; wheel marker
relevant personal protective equipment (PPE).

Typical hazards include:
chemical spills
dusts/vapours/rubbish
slip and fall
temperature
hazardous materials
manual handling hazards
equipment operations.

Typical process and product problems include:
routine and non-routine product faults
machine malfunction, e.g. caused by incorrect dip solution/rubber levels
mould/tooling/die problems
variations in materials, e.g. allowable tolerances of cut-up materials
contamination of compounds and/or materials
processing problems
dust stop leakage.

Key variables to be monitored include:
temperatures
speed
pressures
colour
mixing differences/mixing steps/plasticity
cycle steps/cycle time/process timing
output rate/machine inactivity
product weight
product integrity and general conformance to specification/sample, e.g. rubber batch differences, batch dump indicators

All operations are performed in accordance with procedures.

Essential knowledge and enterprise requirements
Application of knowledge of all compounds, materials, equipment and process sufficient to recognise compound, material and equipment conditions which may lead to out of specification production.
Knowledge of the enterprise's procedures and relevant regulatory requirements (e.g. quality system and standards, current operating standards) 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
behaviour of materials in relation to key process variables
quality requirements at each production stage
function and operating principles of equipment, machine components and ancillary equipment
impact of key process variables on product quality and production output
nature of mechanical, hydraulic, pneumatic, electrical and electronic principles which affect machine operation and product development
the importance of safe machine set-up and startup procedure for effective processing of materials, including safety trips and resets
safety procedures and the use of PPE in relation to handling materials, equipment operation and cleanup as well as working in confined space
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 reusing non-conforming materials
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
check machine for correct set-up to job specifications and implement adjustments or report deviations immediately
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 and describe own role and role of others involved directly in the process
identify factors which may affect product quality or production output and appropriate remedies
identify when the operator is able to rectify faults and when assistance is required
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
distinguish between causes of faults such as:
routine faults
incorrect quantity of materials
contaminated materials.
complete necessary documentation accurately including:
batch report sheets
stock tickets
extruder check sheets
work schedule.

Critical aspects
It is essential that competence is demonstrated in the ability to:
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
communicate with other operators effectively, check stock with laboratory, supervisor or leading hand and promote teamwork actively.

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 and production reports.
Basic numeracy is required, e.g. to determine how many 2 kg, 3 kg and 5 kg bags are needed to make up a requirement for 50 kg.
Basic statistical knowledge is required to construct histograms and control charts as well as to interpret results and recommend actions.

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.