Unit of Competency Mapping – Information for Teachers/Assessors – Information for Learners

PMBWELD309 Mapping and Delivery Guide
Weld plastic using extrusion techniques

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency PMBWELD309 - Weld plastic using extrusion techniques
Description
Employability Skills
Learning Outcomes and Application This unit of competency covers the skills and knowledge required to weld polyethylene (PE) and other plastic components using extrusion or injection welding techniques. It applies to welding undertaken in the field and in factory conditions. This unit of competency applies to experienced operators who are required to confirm that materials and components are compatible for the weld, set up equipment, perform the welding, maintain and calibrate the equipment, assess joints against specifications and solve problems within area of responsibility.This unit of competency applies to an experienced operator demonstrating theoretical and technical knowledge and well developed skills in situations that require some discretion and judgement. The operator may work alone or as a member of a team or group and will work in liaison with other shift team members, team leader and supervisor, as appropriate.No licensing, legislative or certification requirements apply to this unit at the time of publication.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.

The unit should be assessed holistically and the judgement of competence shall be based on a holistic assessment of the evidence.

In all plants it may be appropriate to assess this unit concurrently with units such as:

teamwork

communication.

The collection of performance evidence:

should occur over a range of situations which include typical disruptions to normal, smooth operation of an operating plant

will typically include a supervisor/third-party report or other evidence, focussing on consistent performance and problem recognition and solving. A supervisor/third-party report must be prepared by someone who has a direct, relevant, current relationship with the person being assessed and who is in a position to form a judgement on workplace performance relevant to the unit of competency

must include the use of an appropriate industrial item of equipment requiring demonstration of operation, start and stop procedures and responding to problems

may use industry-based simulation for all or part of the unit particularly where safety, lack of opportunity or significant cost is an issue.

Assessment should occur in operational workplace situations. Where this is not possible or where personal safety or environmental damage are limiting factors assessment must occur in a sufficiently rigorous simulated environment that reflects realistic operational workplace conditions. This must cover all aspects of workplace performance, including environment, task skills, task management skills, contingency management skills and job role environment skills.

Assessment in a simulated environment should use evidence collected from demonstration of skills and one or more of:

walk-throughs

pilot plant operation

industry-based case studies/scenarios

‘what ifs’.

Knowledge evidence may be collected concurrently with performance evidence or through an independent process, such as workbooks, written assessments or interviews.

Assessment processes and techniques must be appropriate to the language, literacy and numeracy requirements of the work being performed and the needs of the candidate.

Conditions for assessment must include access to all tools, equipment, materials and documentation required, including relevant workplace procedures, product and manufacturing specifications associated with this unit.

The regulatory framework will be reflected in workplace policies and procedures and is not required to be independently assessed.

Foundation skills are integral to competent performance of the unit and should not be assessed separately.

Assessors must satisfy the assessor competency requirements that are in place at the time of the assessment as set by the VET regulator.

In addition the assessor or anyone acting in subject matter expert role in assessment shall demonstrate both technical competency and currency. If the assessor cannot demonstrate technical competency and currency they shall assess with a subject matter expert who does meet these requirements.

Technical competence can be demonstrated through one or more of:

relevant VET or other qualification/Statement of Attainment

appropriate workplace experience undertaking the type of work being assessed under routine and non-routine conditions

appropriate workplace experience supervising/evaluating the type of work being assessed under routine and non-routine conditions

Currency can be demonstrated through one or more of:

being currently employed undertaking the type of work being assessed

being employed by the organisation undertaking the type of work being assessed and having maintained currency in accordance with that organisation’s policies and procedures

having consulted/had contact with an organisation undertaking the type of work being assessed within the last twelve months, the consultation/contact being related to assessment

conducting on the job training/assessments of the type of work being assessed

being an active member of a relevant professional body and participating in activities relevant to the assessment of this type of work.
Prerequisites/co-requisites
Competency Field Welding
Development and validation strategy and guide for assessors and learners Student Learning Resources Handouts
Activities 		Slides
PPT 		Assessment 1 Assessment 2 Assessment 3 Assessment 4
Elements of Competency Performance Criteria              
Element: Identify materials as being compatible for welding
  • Identify materials as PE, polypropylene (PP), acrylonitrile butadiene styrene (ABS), high-impact polystyrene (HIPS) and polyvinylchloride (PVC) from specifications and work site instructions
  • Identify plastic materials and components supplied as being compatible for welding from specifications and tests
       
Element: Identify appropriate plastics welding conditions
  • Identify welding machine type and operating requirements
  • Identify plastic component materials and dimensions
  • Identify and select appropriate welding rods or granules
  • Select welding conditions for individual welding machines and plastic components
  • Prepare field operational sheets according to enterprise specification
       
Element: Maintain, and calibrate welding equipment
  • Set up welding equipment and work area according to enterprise specification
  • Ensure safety equipment available and operational according to enterprise procedures
  • Identify non-conformance, report and rectify according to enterprise procedures
  • Check operation, and calibrate where required, heating, material feed rate and pressure systems
  • Use personal protective equipment (PPE)
       
Element: Perform welding to required standard
  • Clean machine, align and trim abutting plastic component ends according to job specification
  • Assemble components in holding jigs
  • Perform heating, welding and cooling phases using selected welding conditions and specifications
  • Monitor and record achieved weld conditions for each assembly according to enterprise requirements
  • Clean up equipment when completed according to enterprise requirements
  • Clean up work site, dispose of scrap materials according to job specification
       
Element: Assess quality of completed joints
  • Identify quality requirements for joints according to specifications
  • Assess joints against specification requirements and report results according to enterprise requirements
  • Identify and report non-conformances according to job specification
       


Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Identify materials as being compatible for welding

1.1

Identify materials as PE, polypropylene (PP), acrylonitrile butadiene styrene (ABS), high-impact polystyrene (HIPS) and polyvinylchloride (PVC) from specifications and work site instructions

1.2

Identify plastic materials and components supplied as being compatible for welding from specifications and tests

2

Identify appropriate plastics welding conditions

2.1

Identify welding machine type and operating requirements

2.2

Identify plastic component materials and dimensions

2.3

Identify and select appropriate welding rods or granules

2.4

Select welding conditions for individual welding machines and plastic components

2.5

Prepare field operational sheets according to enterprise specification

3

Maintain, and calibrate welding equipment

3.1

Set up welding equipment and work area according to enterprise specification

3.2

Ensure safety equipment available and operational according to enterprise procedures

3.3

Identify non-conformance, report and rectify according to enterprise procedures

3.4

Check operation, and calibrate where required, heating, material feed rate and pressure systems

3.5

Use personal protective equipment (PPE)

4

Perform welding to required standard

4.1

Clean machine, align and trim abutting plastic component ends according to job specification

4.2

Assemble components in holding jigs

4.3

Perform heating, welding and cooling phases using selected welding conditions and specifications

4.4

Monitor and record achieved weld conditions for each assembly according to enterprise requirements

4.5

Clean up equipment when completed according to enterprise requirements

4.6

Clean up work site, dispose of scrap materials according to job specification

5

Assess quality of completed joints

5.1

Identify quality requirements for joints according to specifications

5.2

Assess joints against specification requirements and report results according to enterprise requirements

5.3

Identify and report non-conformances according to job specification

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, national standards, material labels and safety data sheets (SDS)

distinguish between PE, PP, ABS, HIPS and PVC materials and welding rods/granules

select welding conditions appropriate to the welding equipment and components

set up welding equipment and materials/components to meet specifications

operate the extrusion or injection welding equipment to weld the materials/components

monitor key variables, including:

temperature

rate of extrusion/injection

pressure

product output rate

integrity of weld and general conformance to specification

assess quality of completed

make adjustments to remedy faults and non-conformity

identify hazards and apply relevant hazard controls

apply safety procedures

apply housekeeping procedures

apply waste management procedures

maintain and calibrate welding equipment

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

distinguish between causes of problems, including:

operational problems

materials properties

process variables

raw material/component variations

raw material contamination

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.

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 system/equipment including one (1) or more of:

electrical activated extrusion welding machine

electrical/pneumatic activated injection welding machine

extrusion and injection welding processes and their effect on the welded product

impact of variations in welding process 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 variables and stages of production

quality requirements

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

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.

Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assignment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)

Assessment Tasks

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.

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Identify materials as being compatible for welding

1.1

Identify materials as PE, polypropylene (PP), acrylonitrile butadiene styrene (ABS), high-impact polystyrene (HIPS) and polyvinylchloride (PVC) from specifications and work site instructions

1.2

Identify plastic materials and components supplied as being compatible for welding from specifications and tests

2

Identify appropriate plastics welding conditions

2.1

Identify welding machine type and operating requirements

2.2

Identify plastic component materials and dimensions

2.3

Identify and select appropriate welding rods or granules

2.4

Select welding conditions for individual welding machines and plastic components

2.5

Prepare field operational sheets according to enterprise specification

3

Maintain, and calibrate welding equipment

3.1

Set up welding equipment and work area according to enterprise specification

3.2

Ensure safety equipment available and operational according to enterprise procedures

3.3

Identify non-conformance, report and rectify according to enterprise procedures

3.4

Check operation, and calibrate where required, heating, material feed rate and pressure systems

3.5

Use personal protective equipment (PPE)

4

Perform welding to required standard

4.1

Clean machine, align and trim abutting plastic component ends according to job specification

4.2

Assemble components in holding jigs

4.3

Perform heating, welding and cooling phases using selected welding conditions and specifications

4.4

Monitor and record achieved weld conditions for each assembly according to enterprise requirements

4.5

Clean up equipment when completed according to enterprise requirements

4.6

Clean up work site, dispose of scrap materials according to job specification

5

Assess quality of completed joints

5.1

Identify quality requirements for joints according to specifications

5.2

Assess joints against specification requirements and report results according to enterprise requirements

5.3

Identify and report non-conformances according to job specification

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, manual handling and hazardous materials

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:

electrical activated extrusion welding machine

electrical/pneumatic activated injection welding machine

measurement devices, including, timers, temperature probes and callipers

cleaning equipment

spray equipment

plastics machining equipment

assembly jigs and clamps.

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 PPE.

Hazards

Hazards must be identified and controlled. Identifying hazards requires consideration of:

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

Routine and non-routine problems must be resolved.

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.

Routine problems are predictable and have known solutions and include one or more of:

incompatible materials (pipes/rods)

variable plastics sheet material grades and supplied welding rods/granules

equipment malfunction or wear and tear

variable factory and field site conditions.

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

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Identify materials as PE, polypropylene (PP), acrylonitrile butadiene styrene (ABS), high-impact polystyrene (HIPS) and polyvinylchloride (PVC) from specifications and work site instructions 
Identify plastic materials and components supplied as being compatible for welding from specifications and tests 
Identify welding machine type and operating requirements 
Identify plastic component materials and dimensions 
Identify and select appropriate welding rods or granules 
Select welding conditions for individual welding machines and plastic components 
Prepare field operational sheets according to enterprise specification 
Set up welding equipment and work area according to enterprise specification 
Ensure safety equipment available and operational according to enterprise procedures 
Identify non-conformance, report and rectify according to enterprise procedures 
Check operation, and calibrate where required, heating, material feed rate and pressure systems 
Use personal protective equipment (PPE) 
Clean machine, align and trim abutting plastic component ends according to job specification 
Assemble components in holding jigs 
Perform heating, welding and cooling phases using selected welding conditions and specifications 
Monitor and record achieved weld conditions for each assembly according to enterprise requirements 
Clean up equipment when completed according to enterprise requirements 
Clean up work site, dispose of scrap materials according to job specification 
Identify quality requirements for joints according to specifications 
Assess joints against specification requirements and report results according to enterprise requirements 
Identify and report non-conformances according to job specification 

Forms

Assessment Cover Sheet

PMBWELD309 - Weld plastic using extrusion techniques
Assessment task 1: [title]

Student name:

Student ID:

I declare that the assessment tasks submitted for this unit are my own work.

Student signature:

Result: Competent Not yet competent

Feedback to student

 

 

 

 

 

 

 

 

Assessor name:

Signature:

Date:

Assessment Record Sheet

PMBWELD309 - Weld plastic using extrusion techniques

Student name:

Student ID:

Assessment task 1: [title] Result: Competent Not yet competent

(add lines for each task)

Feedback to student:

 

 

 

 

 

 

 

 

Overall assessment result: Competent Not yet competent

Assessor name:

Signature:

Date:

Student signature:

Date: