Elements and Performance Criteria

RANGE STATEMENT
The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Add any essential operating conditions that may be present with training and assessment depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts.
Where reference is made to industry codes of practice, and/or Australian/international standards, the latest version must be used.
Context
This competency applies to all sectors within the plastics, rubber and cablemaking industries which use dedicated production machines. It includes the operation of all relevant additional equipment where that equipment is integral to the production process.
Requirements
Requirements may be determined from set-up sheets, job cards, product data sheets or similar.
Procedures
All operations are performed in accordance with procedures.
Procedures include all relevant workplace procedures, work instructions, temporary instructions and relevant industry and government codes and standards.
Tools and equipment
This unit of competency includes use of equipment and tools such as:
hand carts and trolleys
hoists/lifting equipment not requiring any special permits or licences
hand tools used in the process
relevant personal protective equipment.
Measuring instruments
Measuring instruments include:
levelling
temperature sensing devices such as thermocouples, pyrometers, transducers, thermometers
pressure and vacuum gauges
flow meters.
Safety interlocks and systems
Safety interlocks and systems include:
limit switches
normally open/normally closed
overstroke control systems
hydraulic temperature control
material temperature control
machine guards
nozzle purge guard
mould protection systems
ejection limit switches.
Principles of operation
Principles of operation include:
production cycle/process/sequence
function tools/components
calculation of machine cycle time/production rate
safe work procedures for checking machine cycle time/production rate
variations to the cycle/process for different systems/products.
Machine control systems
Machine control systems include:
basic controls
open loop
closed loop
shot size and correction capacity
speed/cycle time
screw position
equipment/process pressure
clamp pressure
time
screw speed
screw back pressure
screw back time
melt decompress position
sprue break.
Hazards
Typical hazards include:
spills
dusts/vapours
slip and fall, particularly due to spilt polymer granules
temperature
hazardous materials
manual handling hazards
equipment operations.
Problems
Anticipate and solve problems means resolve a wide range of routine and non-routine problems, using product and process knowledge to develop solutions to problems which do not have a known solution/a solution recorded in the procedures.
Typical process and product problems may include:
materials
equipment malfunction
process.
Variables
Key variables to be monitored include:
equipment condition
set up variables
product measurements and quality.

The Evidence Guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, the range statement and the assessment guidelines for this training package.
Overview of assessment
A holistic approach should be taken to the assessment.
Assessors must be satisfied that the person can consistently perform the unit as a whole, as defined by the Elements, Performance Criteria and skills and knowledge.
Where the assessee does not currently possess evidence of competency in a relevant PROD200 unit, it may be co-assessed with this unit.
Critical aspects for assessment and evidence required to demonstrate competency in this unit
It is essential that competence is demonstrated in the knowledge and skills defined in this unit. These may include the ability to:
bring a 'cold' machine into ready-for-production status methodically and smoothly in standard time.
Consistent performance should be demonstrated. For example, look to see that production quality and output standards are met consistently.
Assessment method and context
Assessment will occur on an industrial line in a work-like environment.
Competence in this unit may be assessed:
by using appropriate, industrial equipment
in a situation allowing for the generation of evidence of the ability to respond to problems
by using a suitable simulation and/or a range of case studies/scenarios
through 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. Assessors need to be aware of any cultural issues that may affect responses to questions.
Assessment processes and techniques must be culturally appropriate and appropriate to the oracy, language and literacy capacity of the assessee and the work being performed.
Specific resources for assessment
This section should be read in conjunction with the Range Statement 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.
Access must be provided to appropriate learning and/or assessment support when required. Where applicable, physical resources should include equipment modified for people with disabilities.