The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment

A person who demonstrates competency in this unit must be able to evaluate rolling tools and rolling processes for safety, economy and fitness for purpose.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Assessors must be satisfied that the candidate can competently and consistently:

determine parameters and context of rolling tools in manufacturing processes

review design and construction features, functions, applications and limitations of rolling tools

identify principles, design, analysis techniques and software required to evaluate and optimise rolling tools and related manufacturing processes

evaluate WHS, regulatory and risk management compliance

report and document results.

Context of and specific resources for assessment

This unit may be assessed on the job, off the job or a combination of both on and off the job. Where assessment occurs off the job, then a simulated working environment must be used where the range of conditions reflects realistic workplace situations.

The competencies covered by this unit would be demonstrated by an individual working alone or as part of a team.

Where applicable, reasonable adjustment must be made to work environments and training situations to accommodate ethnicity, age, gender, demographics and disability.

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.

Method of assessment

Assessment must satisfy the endorsed Assessment Guidelines of the MEM05 Metal and Engineering Training Package.

Assessment methods must confirm consistency and accuracy of performance (over time and in a range of workplace relevant contexts) together with application of underpinning knowledge.

Assessment methods must be by direct observation of tasks and include questioning on underpinning knowledge to ensure correct interpretation and application.

Assessment may be applied under project-related conditions (real or simulated) and require evidence of process.

Assessment must confirm a reasonable inference that competency is not only able to be satisfied under the particular circumstance, but is able to be transferred to other circumstances.

Assessment may be in conjunction with assessment of other units of competency where required.

Guidance information for assessment

Assessment processes and techniques must be culturally appropriate and appropriate to the language and literacy capacity of the candidate and the work being performed.

Required skills

Required skills include:

determining features and performance requirements of rolling tools in the manufacturing processes

reviewing hot and cold rolling tools design and construction, including tooling materials, treatment, finishing and assembly, tool installation and operation, related manufacturing processes and materials processed

selecting and using appropriate analysis techniques and software for evaluation and optimisation of rolling tools and related manufacturing processes

identifying WHS, regulatory and risk management compliance

investigating sustainability implications of rolling tools and associated manufacturing processes

assessing use of rolling tools for integration with:

lean manufacturing systems and techniques

manufacturing control software, such as system control and data acquisition (SCADA) software

establishing of cross-sectional dimensions

developing of a flower pattern for progressive forming

establishing product and roll orientation

designing rolls to suit the flower pattern

adding support operations, such as fixtures, guides, side rolls, straightening devices, cutting and punching

applying systems thinking, continuous improvement, and constraint and contingency management to evaluation of rolling tools

reporting and documenting scoping, principles and techniques identification and evaluation of tooling and related manufacturing processes, tooling graphics and models

Required knowledge

Required knowledge includes:

properties of hot and cold working of metals and alloys, including:

recrystalisation temperature

grain size and microstructure

functions and context of rolling tools in a manufacturing operation

sourves of technical and professional assistance

WHS and regulatory compliance requirements and risk management practices for rolling tools and related manufacturing and maintenance processes

sustainability and lean systems implications for rolling tools and related manufacturing processes

hot rolling, including:

critical design considerations for tooling

multi-pass, multi-roll (eg. 3 high, 4 high mills) and reversing mills

range of hot rolled products

effect of hot rolling and variations in rolling process on properties of rolled materials

ring rolling

cold rolling, including:

critical design considerations for tooling

related processes (e.g. pickling, cleaning, annealing and slitting)

range of cold rolled prpducts

properties of cold rolled materials, including strength and hardness increase and ductility decrease

hot and cold rolling effects

roll forming:

thread rolling for screws and bolts

combined rolling techniques

roll pass design features:

product mechanical properties:

yield strength in tension and shear

work hardening strain rate effect

driven and non-driven rolls, and applied tension

friction in rolling process

roll bite geometry

deflection compensation

roll materials, manufacture and heat treatment

roll force, torque and power

product guide systems

roll and product temperature and cooling rate control

roll forming pass design features

labour and skills distribution requirements

systems thinking, continuous improvement, constraint and contingency management, and comparative supply chain performance

WHS and regulatory requirements, codes of practice, standards, risk management and registration requirements

documentation, drawings, specifications, instructions required, process information and programming

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. 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) may also be included.

Appropriate technical and professional assistance

Appropriate technical and professional assistance may include:

technical support and advice relating to elements which have intrinsic dangers, such as:

high pressure

energised fluid vessels

high temperatures and heat energy capacity

wiring with high current control voltages above extra low voltage

professional support for technologies, such as:

specialist electric motor drives and controllers

specialist materials, plastics, metal alloys and nano materials

special processes, foundry, alloy welding, heat treatment, sealing and fastening

WHS, regulatory requirements and enterprise procedures

WHS, regulatory requirements and enterprise procedures may include:

WHS Acts and regulations

relevant standards

codes of practice from Australian and overseas engineering and technical associations and societies

risk assessments

registration requirements

safe work practices

state and territory regulatory requirements

Standards and codes

Standards and codes refer to all relevant Australian and international standards and codes applicable to roll tooling for engineering and related application tasks

Sustainability

Sustainability is used to mean the entire sustainable performance of the organisation/plant, including:

meeting all regulatory requirements

conforming to all industry covenants, protocols and best practice guides

minimising ecological and environmental footprint of process, plant and product

maximising economic benefit of process plant and product to the organisation and the community

minimising the negative WHS impact on employees, community and customer

Systems thinking

Systems thinking refers to the conduct of engineering work in a manner that demonstrates knowledge of how the interaction of different technical systems on equipment, machinery or structures, as well as the skills and techniques of personnel, combine to perform or support engineering-related operations, processes or projects. It embraces determining or establishing how the function of each technical system or component, as well as the skills and techniques of personnel, effects or potentially may effect, outcomes. Systems should be interpreted broadly within the context of the organisation and depending on the project or operation can include equipment, related facilities, material, software, internal services and personnel, and other organisations in the value chain

Continuous improvement implementation

Continuous improvement implementation may relate to plant, products, processes, systems or services, including design, development, implementation or manufacture, commissioning, operation or delivery and maintenance.

Improvement processes may include techniques, such as:

balanced scorecard

current and future state mapping

measuring performance against benchmarks

process improvement, problem solving and decision making

data management, generation, recording, analysing, storing and use of software

training for improvement systems participation

technical training

Constraints and contingencies

Constraints and contingencies may be:

financial

organisational, procedural or cultural

physical constraints, such as limits to resources, limits to site access or logistical limitations

design constraints imposed by materials or process limitations