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Elements and Performance Criteria

1. Identify required materials and equipment
   • Identify work requirements from production plan
   • 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 welding operations for a sequence or continuous process to ensure work follows a logical procedure
   • Examine process requirements to identify suitability of plastic materials for specified welding operations
2. Set up welding equipment and materials for sequence or continuous operation
   • Set up tools and equipment ready for production
   • Locate materials, components and consumables
   • Ensure safety equipment is available and fit for use
   • Identify non-conformances and take required action
3. Prepare plastic materials or components for welding in a sequence or continuous operation
   • Assemble components for welding processes
   • Take required action to ensure welding process is suitable for the materials being used
4. Weld to specification
   • Organise materials for sequence or continuous production
   • Weld materials to specification using appropriate welding techniques and conditions
5. Anticipate and solve problems
   • Recognise a problem or a potential problem
   • Determine problems needing priority action
   • Refer problems outside area of responsibility to appropriate person, with possible causes
   • Seek information and assistance as required to solve problems
   • Solve problems within area of responsibility
   • Follow through items initiated until final resolution has occurred

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 19480:2005 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) formulas/recipes batch sheets temporary instructions any similar instructions provided for the smooth running of the plant.
Tools and equipment	Tools and equipment include: welding system/equipment, including one or more of: hot plate (heated tool) extrusion high frequency sound (ultrasonic) electrostatic (radio frequency) thermal induction (heat) heating and feeding mechanisms material supporting/feeding mechanisms ancillary equipment that is integral to the process. Additional tools and equipment will be selected as required from: hand tools used in this process 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.
Problems	Non-routine problems must be resolved by applying operational knowledge to develop new solutions, either individually or in collaboration with relevant experts, to: determine problems needing action determine possible fault causes develop solutions to problems which do not have a known solution follow through items initiated until final resolution has occurred report problems outside area of responsibility to designated person. Non-routine problems are unexpected problems or variations of previous problems and include one or more of: variations in quality emergency situations intermittent faults. Operational knowledge includes one or more of: procedures training technical information, such as journals and engineering specifications remembered experience relevant knowledge obtained from appropriate people.

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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 designs, plans, patterns, procedures, job specifications, instruments/control panels, material labels and safety data sheets (SDS)

plan the welding process and sequence tasks

set up welding equipment and materials/components to meet specifications

operate the equipment to weld the materials

monitor key variables, including:

actual and set temperatures

speeds (including feed speed for filler, speed of weld head)

colour and uniformity

surface finish/appearance

tolerance for weld/joint

consistency of weld

product output rate

mechanical strength of weld (e.g. tensile strength results)

product integrity and general conformance to specification

make adjustments to remedy faults and non-conformity

maintain output and product quality using appropriate instruments, controls, test information and readings

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

distinguish between causes of problems, including:

operational problems

instrument failure/malfunction

electrical failure/malfunction

mechanical failure/malfunction

wrong readings

equipment design deficiencies

materials properties

process variables

raw material variations/contamination

process abnormalities

procedural errors

recognise and prioritise problems requiring action

resolve routine and non-routine problems

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 independently and to solve routine and non-routine problems, including knowledge of:

function and operating principles of welding equipment, components and ancillary equipment

types and application of common welding processes and their effect on the welded product

impact of variations in welding process conditions/variables and raw materials on product quality and production output

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

characteristics of materials and their behaviour in relation to welding process conditions/variables and stages of production

quality requirements at each production stage

common adjustments in process variables and their impact on product quality and production output

impact of variations in raw materials and equipment operation in relation to final product

possible changes to materials properties to better suit specific process requirements

routine and non-routine problems that may arise, the range of possible causes and appropriate 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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