Application
This unit of competency covers the skills and knowledge required to operate calendering equipment and ancillary equipment that is integral to the process. Calendering is typically used to convert plastic or rubber compound into sheets or to cover/impregnate fabric, wire or other webs.
This unit of competency applies to operators who are required to carry out pre-start, start and stop procedures, maintain feed to the calender, monitor and adjust the calender and recognise routine and non-routine problems and take appropriate action.
This unit of competency applies to an individual working alone or as part of a team or group and working 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.
Elements and Performance Criteria
Elements describe the essential outcomes. | Performance criteria describe the performance needed to demonstrate achievement of the element. | ||
1 | Check work requirements | 1.1 | Identify work requirements from production plan or request |
1.2 | Check product, materials and equipment requirements for job | ||
1.3 | Recognise requirements which may not be in accordance with usual practice | ||
1.4 | Ask questions of appropriate person to confirm unusual practice | ||
1.5 | Ensure housekeeping is to requirements | ||
1.6 | Identify hazards associated with the job and take appropriate action | ||
1.7 | Perform other pre-operational checks in accordance with procedures | ||
2 | Start up calendering equipment to procedure | 2.1 | Conduct pre-start checks on equipment |
2.2 | Start up calendering equipment | ||
3 | Operate equipment to procedures | 3.1 | Check process is operating within required limits |
3.2 | Check product is in specification and to required quality standard | ||
3.3 | Ensure product is consistently ready for next operation | ||
3.4 | Maintain supply of materials as required | ||
3.5 | Complete logs and records as required | ||
3.6 | Collect and segregate scrap, trim and other materials as required | ||
3.7 | Keep equipment and work area clean | ||
3.8 | Shut down calender as required | ||
4 | Respond to routine problems in accordance with procedures | 4.1 | Recognise known faults that occur during the operation |
4.2 | Identify and take action on causes of routine faults | ||
4.3 | Log problems as required | ||
4.4 | Identify non-routine problems and report to designated person |
Evidence of Performance
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, basic machine control panels, material labels and safety data sheets (SDS)
select and use tools and equipment to meet job specifications
monitor calendaring and ancillary equipment using measured/indicated data and smell, sight, sound and feel as appropriate
monitor and interpret key variables, including:
operating temperatures
speed
nip settings
materials consistency
surface finish
product integrity and general conformance to specifications
operate and adjust the equipment to meet product quality and production output specifications
pause the equipment or shut down equipment in normal and abnormal circumstances
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
process abnormalities
procedural errors
mechanical abnormalities
communicate effectively with team/work group and supervisors
complete workplace records
read and interpret basic control panels
do basic arithmetical manipulations, including additions, subtractions, divisions, fractions and percentages.
Evidence of Knowledge
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:
the function of calendering equipment, machine components and guides
principles of operation of the equipment
calender adjustments and their effects, including 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
processing behaviour of polymers and the role of additives
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.
Assessment Conditions
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, focusing 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.
Foundation Skills
This section describes those required skills (language, literacy and numeracy) that are essential to performance.
Foundation skills essential to performance are explicit in the performance criteria of this unit of competency.
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 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: calender ancillary equipment that is integral to the calendaring process. Additional tools and equipment will be selected as required from: mill knives thickness gauges profiling gauges/tools/jigs nip adjusting bars strainers and metal detector hoists/lifting equipment not requiring any special permits or licences manual handling aids, such as hand carts and trolleys product take up equipment material feeding equipment basic hand tools relevant personal protective equipment (PPE). |
Hazards | Hazards must be identified and controlled. Identifying hazards requires consideration of: weight, shape, volume of materials to be handled hazardous products and materials sharp edges, protrusions or obstructions slippery surfaces, spills or leaks rotational equipment or vibration heat, 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: 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 job specifications which are not in accordance with usual practice. 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. |
Sectors
Not applicable
Competency Field
Production