This unit applies to the manufacture of all types of metal patterns, master patterns, core boxes and associated equipment including cast plates etc., applying pattern making principles.

Patterns may be made directly or from a master pattern.

Patterns may be integral with the plate or mounted to the plates with gating. Depending upon specifications, production core boxes also may be loose or mounted into core box rigs etc.

Patterns and core boxes are manufactured from a range of ferrous, non-ferrous and alloy materials, using a range of metal cutting and shaping tools and machines.

Where the manufacture of polymer production patterns is required, Unit MEM04011B (Produce polymer patterns) should be considered.

Where precision measurement is required, Unit MEM12003B (Perform precision mechanical measurement) should also be considered.

Band: A

Unit Weight: 8

Path 1

MEM04010B

Develop and manufacture wood patterns

MEM04012B

Assemble plated patterns

MEM04018B

Perform general woodworking machine operations

MEM07005C

Perform general machining

MEM09002B

Interpret technical drawing

MEM12006C

Mark off/out (general engineering)

MEM12023A

Perform engineering measurements

MEM12024A

Perform computations

MEM18001C

Use hand tools

MEM18002B

Use power tools/hand held operations

MEM30012A

Apply mathematical techniques in a manufacturing engineering or related environment

ELEMENT

PERFORMANCE CRITERIA

1. Determine job requirements

1.1. Drawings, instructions and specifications are interpreted and understood.

1.2. Pattern type and design is conceptualised and planned with reference to customer's specification (written or verbal) for number, layout, runner system and core box design.

1.3. Pattern design is interpreted and visualised from drawings, prints or plans and checked against customer requirements.

1.4. A plan is developed for sequence of manufacture for either a high or low volume foundry production pattern.

2. Develop pattern equipment

2.1. Appropriate materials are selected and obtained to meet requirements of strength, durability and component finish etc.

2.2. Calculations appropriate to establishing pattern parameters are performed, including angles, tapers, contraction, etc. where applicable.

3. Manufacture production patterns and core boxes

3.1. Appropriate machines and machining process are selected to shape/produce production patterns and core boxes to specification.

3.2. A range of hand and hand held power tools are selected to fashion/manufacture production patterns and core boxes to specification.

3.3. Production patterns and core boxes are checked to specification and surface finish and are checked for mouldability.

Required skills

Look for evidence that confirms skills in:

determining job requirements from written instructions, sketches and drawings

planning and sequencing manufacturing operations

checking and clarifying task-related information

selecting appropriate metals to suit the moulding/casting techniques and foundry process

laying out/constructing production pattern/core boxes

joining and fixing component parts

checking pattern for conformance to specifications

measuring components to specified tolerances

calculating contraction rates

Required knowledge

Look for evidence that confirms knowledge of:

characteristics of metals and alloys and their application in the development/manufacture of production patterns

tolerances and contraction rates typically used in the manufacture of production patterns

production moulding and casting techniques

tooling required for casting/moulding

methoding techniques

the use and application of jigs and fixtures

methods of construction including machining provision and clamping arrangements

appropriate techniques, tools and equipment to measure, mark out and produce production patterns

the formulae and mathematical techniques required for manufacturing production patterns/core boxes i.e. contraction, taper, clearances, machining allowances etc.

identification coding and numbering

pattern checking techniques

mouldability i.e. surface finish, face taper, convex or concave perspectives, undercuts, etc.

use and application of personal protective equipment

safe work practices and procedures

hazards and control measures associated with developing and manufacturing production patterns

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 develop and manufacture production patterns. Competency in this unit cannot be claimed until all prerequisites have been satisfied.

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

Assessors must be satisfied that the candidate can competently and consistently perform all elements of the unit as specified by the criteria, including required knowledge, and be capable of applying the competency in new and different situations and contexts.

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, that is the candidate is not in productive work, then an appropriate simulation 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. The assessment environment should not disadvantage the candidate.

This unit could be assessed in conjunction with any other units addressing the safety, quality, communication, materials handling, recording and reporting associated with developing and manufacturing production patterns or other units requiring the exercise of the skills and knowledge covered by this unit.

Method of assessment

Assessors should gather a range of evidence that is valid, sufficient, current and authentic. Evidence can be gathered through a variety of ways including direct observation, supervisor's reports, project work, samples and questioning. Questioning techniques should not require language, literacy and numeracy skills beyond those required in this unit of competency. The candidate must have access to all tools, equipment, materials and documentation required. The candidate must be permitted to refer to any relevant workplace procedures, product and manufacturing specifications, codes, standards, manuals and reference materials.

Guidance information for assessment

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 materials

A range of ferrous, non-ferrous and alloy materials

Calculations

The determination of contraction rates as well as general engineering calculations

Appropriate machines

Lathes, milling machines, grinders, pedestal drills, pantographs and other machines as needed

Unit sector

Casting and moulding

This unit contains employability skills.