Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.
This describes the essential skills and knowledge and their level required for this unit.
Application of knowledge of the materials, equipment and process sufficient to recognise out of specification products, process problems and materials faults.
Knowledge and ability to implement organization procedures, and relevant regulatory requirements within appropriate time constraints and work standards.
Application of the knowledge of managing risks using the hierarchy of controls applied to the calendering process. Application of approved hazard control and safety procedures and the use of PPE in relation to handling materials, equipment operation and cleanup.
Knowledge of and skills in the operation of calendering equipment and process sufficient for consistent production of quality products, including:
production workflow sequences and materials demand
calender adjustments and their effects, such as nip, bowl speed and relative bowl speeds
reasons for checking process control panels and reporting readings which are outside of normal range of process variability
the function of calendering equipment, machine components and guides
accurately monitoring equipment operation and product quality
correct selection and use of equipment, materials, processes and procedures
the potential effects of variations in raw materials and equipment operation in relation to product quality and production output
processing behaviour of polymers and the role of additives
the effect of unauthorised or emergency shutdown in relation to safety and production requirements
factors which may affect product quality or production output and appropriate remedies (such as effect of foreign objects on nip area on the compounded materials)
waste management and knowing the importance of reusing non-conforming products whenever possible.
Competence also includes the ability to:
plan own work, including predicting consequences and identifying improvements
identify when the operator is able to rectify faults, when assistance is required and who is the appropriate source for assistance
identify and describe own role and role of others involved directly in the calendering process.
Language, literacy and numeracy requirements
This unit requires the ability to read and interpret typical product specifications, job sheets, procedures, basic machine control panels, material labels and safety information as provided to operators.
Writing is required to the level of completing workplace forms.
Basic numeracy is required, eg to determine the required amount of compound required for the product run.
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 calendering operations within the plastics and rubber sectors. It includes the operation of all relevant additional equipment where that equipment is integral to the calendering process.
It includes calendering of 'solid' polymer as well as using the calender to cover/impregnate fabric, wire or other webs.
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:
calender
additional equipment (such as mill knives, thickness gauges, profiling gauges/tools/jigs, nip adjusting bars, strainers and metal detector)
manual handling equipment
product take up equipment
material feeding equipment
hoists/lifting equipment not requiring any special permits or licences
basic hand tools
relevant personal protective equipment.
Hazards
Typical hazards include:
cuts
nip hazards
material hazards
burn hazards
manual handling hazards
power failures.
Problems
Respond to routine problems means 'apply known solutions to a limited range of predictable problems'. Typical process and product problems may include:
variations in materials
contamination of materials
short scorch products (if rubber)
initial feeding of pelt/pig
uneven profiles
uneven colours
uneven surface appearance
variation in compound grain and nerve making a non-homogeneous product
lay flat and curvature standards.
Appropriate action for non-routine problems may be reporting to designated person or other actions specified in the procedures.
Variables
Key variables to be monitored include:
operating temperatures
speed
nip settings
materials consistency
surface finish
product integrity and general conformance to specifications:
Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.
Observation Checklist