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Elements and Performance Criteria

1. Identify required materials and equipment
   • Identify work requirements from production plan or request
   • Identify quantity and quality of product required and any special requirements, including welding specifications
   • Interpret plans, patterns, designs or product specifications
   • Recognise hazards and steps required to ensure safety
   • Plan sequence of welding operations for the whole process to ensure work follows a logical procedure
   • Recognise requirements which may not be in accordance with usual practice
   • Ask questions of appropriate person to confirm unusual practice
   • Examine process requirements to identify suitability of plastics materials for manual welding operations
2. Set up equipment and materials
   • Set up tools and equipment ready for production
   • Locate materials, patterns and consumables
   • Ensure safety equipment is available and fit for use
   • Identify non-conformances and take required action
3. Weld to specification
   • Assemble components using clamps and jigs as required
   • Organise materials and equipment prior to welding
   • Weld materials to specification
   • Collect and segregate scrap, trim and other materials as required
   • Complete logs and records as required
   • Keep equipment and work area clean
4. Respond to routine problems in accordance with procedures
   • Check finished welds or products against specifications
   • Recognise known faults that occur during the operation
   • Identify and take action on causes of routine faults
   • Log problems as required
   • Identify non-routine process and quality problems and take appropriate action

Range Statement

This field allows for different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.
Regulatory framework	The latest version of all legislation, regulations, industry codes of practice and Australian/international standards, or the version specified by the local regulatory authority, must be used. Applicable legislation, regulations, standards and codes of practice include: health, safety and environmental (HSE) legislation, regulations and codes of practice relevant to the workplace, equipment and production processes and hazardous materials ISO/TR 19480 Polyethylene pipes and fittings for the supply of gaseous fuels or water - Training and assessment of fusion operators, or its replacement other Australian/international standards relevant to the materials being used and products being made any relevant licence and certification requirements. All operations to which this unit applies are subject to stringent HSE requirements, which may be imposed through state/territory or federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between performance criteria and such requirements the legislative requirements take precedence.
Procedures	All operations must be performed in accordance with relevant procedures. Procedures are written, verbal, visual, computer-based or in some other form, and include one or any combination of: emergency procedures work instructions standard operating procedures (SOPs) safe work method statements (SWMS) formulae/recipes batch sheets temporary instructions any similar instructions provided for the smooth running of the plant.
Tools and equipment	Tools and equipment include: welding equipment, including one or more of: butt fusion welding electro fusion welding extrusion welding heated wedge welding high speed nozzle hot gas welding infrared welding socket fusion welding. Additional tools and equipment will be selected as required from: hot air and other hand held welding equipment jigs, clamps and other fixing devices hand tools hoists/lifting equipment not requiring any special permits or licences manual handling aids, such as hand carts and trolleys relevant personal protective equipment (PPE).
Hazards	Hazards must be identified and controlled. Identifying hazards requires consideration of: power tools, leads and power supplies hazardous products and materials cutting equipment sharp edges, swarf and scrap protrusions or obstructions slippery surfaces, spills or leaks rotational equipment or vibration smoke, dust, vapours or other atmospheric hazards high temperatures electricity gas gases and liquids under pressure structural hazards equipment failures machinery, equipment and product mass other hazards that might arise.
Routine problems	Routine problems must be resolved by applying known solutions. Routine problems are predictable and include one or more of: pattern incorrect or inaccurate assembly or clamping incorrect filler rods selected poor surface preparation incorrect selection of welding nozzle or attachments moisture contacting welding devices burns to electrical leads sequencing problems, weld run too fast or too slow bonding problems weld deposit incomplete plastication not achieved. Known solutions are drawn from one or more of: procedures training remembered experience. Non-routine problems must be reported according to according to relevant procedures.

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Performance Evidence

Evidence required to demonstrate competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria and demonstrate the ability to:

read and interpret procedures, job specifications, material labels and safety data sheets (SDS)

select and use materials, tools and equipment to meet job specifications

monitor and interpret key variables, including:

weld temperature

feed rate of filler rod

variations in materials being welded

thickness of materials being welded

operate and adjust tools/equipment to meet product quality and production output specifications

identify hazards and apply relevant hazard controls

apply safety procedures

apply housekeeping procedures

apply waste management procedures

recognise early warning signs of equipment/processes needing attention or with potential problems

recognise routine and non-routine problems

identify when the operator is able to rectify faults, when assistance is required and who is the appropriate source for assistance

take action to resolve faults or report faults to appropriate personnel

distinguish between possible causes of routine faults, including:

raw material variations/contamination

changes to materials during the welding process

process abnormalities

procedural errors

maintenance requirements

equipment adjustment/set up

communicate effectively with team/work group and supervisors

complete workplace records

do basic arithmetical manipulations, including additions, subtractions, divisions, fractions and percentages.

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Knowledge Evidence

Must provide evidence that demonstrates knowledge relevant to their job sufficient to operate under routine only supervision and to solve routine problems including knowledge of:

types of plastics materials commonly used in the sector/work environment and their behaviour when prepared and welded

types of welding equipment, related procedures and suitability for different materials

types of welds and how to achieve them

welding symbols

the potential effects of variations in raw materials and outside variables in relation to quality of product

reasons for checking process control panels and reporting readings which are outside of normal range of process variability

production workflow sequences and materials demand

factors which may affect product quality or production output and appropriate remedies

routine problems, their probable causes and relevant corrective actions

organisation procedures relevant to the work environment/job role

hierarchy of control

hazards that may arise in the job/work environment and:

their possible causes

potential consequences

appropriate risk controls.

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