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

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

The evidence required to demonstrate competency in this unit must be relevant to workplace operations and satisfy all of the requirements of the performance criteria and required skills and knowledge.

A person who demonstrates competency in this unit must be able to:

observe safety procedures and requirements

select methods and techniques for machining and blueprinting appropriate to the circumstances

complete preparatory activity in a systematic manner

complete blueprinting of a range of engines to workplace requirements

conduct machining operations according to workplace, manufacturer and component supplier requirements

complete work without damage to tools and equipment or injury to persons.

Context of, and specific resources for assessment

Competency is to be assessed in the workplace or a simulated workplace environment that accurately reflects performance in a real workplace setting. Performance is demonstrated consistently over a period of time and in a suitable range of contexts.

Assessment is to occur:

using standard workplace practices and procedures

following safety requirements

applying environmental constraints.

Assessment is to comply with relevant:

regulatory requirements

Australian standards

industry codes of practice.

The following resources must be made available for the assessment of this unit:

appropriate worksite

engines appropriate to the workplace, including in-line multi-cylinder engine blocks and vee-configuration multi-cylinder engine blocks

fixed and portable hand, air and power tools, and equipment appropriate to blueprinting engines

specifications and work instructions.

Method of assessment

Assessment must satisfy the endorsed Assessment Guidelines of this Training Package.

Assessment methods must confirm consistency and accuracy of performance (over time and in a range of workplace relevant contexts) together with application of required skills and knowledge.

Assessment methods must be by direct observation of tasks and include questioning on required skills and knowledge to ensure its correct interpretation and application.

Assessment must confirm that competency is able not only to be satisfied under the particular circumstance, but is able to be transferred to other circumstances.

Competence in this unit may be assessed in conjunction with other units which together form part of a holistic work role.

Where applicable, reasonable adjustment must be made to work environments and training situations to accommodate ethnicity, age, gender, demographics and disability.

Assessment processes and techniques must be culturally sensitive and appropriate to the language and literacy capacity of the candidate and the work being performed.

Required skills

technical skills to:

select and use machines required for blueprinting

measure to specified tolerances and dimensions

communication skills to:

follow oral instructions

report deviations from specifications

interact with customers and team members

literacy skills to:

read and interpret routine job instructions, specifications, drawings and standard operating procedures

identify and analyse technical information

understand quality procedures

numeracy skills to use mathematical ideas and techniques to:

assess tolerances

apply accurate measurements

calculate material requirements

establish quality checks

problem-solving skills to:

locate, interpret and apply workplace policies and procedures, including manufacturer and component supplier procedures

identify and avoid planning and scheduling problems

prevent time and material wastage

organise work and plan processes

self-management skills to:

select and use appropriate equipment, materials, processes and procedures

follow workplace documentation, such as codes of practice and operating procedures

technology skills to use communication devices to search and gather supporting material

Required knowledge

WHS regulations and requirements, equipment, material and personal safety requirements, including:

personal protective equipment (PPE) for handling engine blocks and using machines

equipment relevant to blueprinting

procedures for blueprinting cylinder block, including:

testing the engine block, including sonic testing and crack testing

line boring main tunnels to produce datum/zero point

chasing threads to remove debris

fitting bearings and checking crush with bearing blue

recording sizes of main bearing tunnel with bearings fitted

selecting bearings for correct grading and clearances

resizing connecting rods and fitting new bolts to ensure centre-to-centre length is correct

cross-drilling crankshaft to enhance oil flow

grinding crankshaft to suit bearings and to achieve desired clearance and phasing consistency

sleeving lifter bores to centreline of camshaft

fitting semi-finished camshaft bearings and line boring to ensure crankshaft to camshaft alignment

squaring up the deck to the crankshaft tunnel to ensure crankshaft is parallel to block

chasing head bolt retaining threads

fitting torque plate to bore and hone

honing cylinders, matching individual pistons to respective bores

dummy assembling to achieve consistent piston height for desired compression ratio and checking rotational clearance

setting ring end gap

procedures to blueprint cylinder heads, including:

machining for larger valves

operating flow bench

porting for improved air flow and to balance combustion chambers

calculating capacity of individual combustion chambers and machining combustion chambers to achieve consistency

calculating compression ratio

selecting camshaft

setting valve heights

dialling camshaft

machining pistons to achieve desired compression ratio

setting rocker geometry, including length and sweep

Australian standards relating to engine reconditioning

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, 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.

Workplace instructions may include:

computer-generated instructions

verbal instructions

written instructions.

Information may include:

Australian standards

engineer’s design specifications and instructions

instructions issued by authorised workplace or external persons

workplace specifications and requirements

regulatory and legislative requirements relating to the automotive industry, including Australian Design Rules

safe work procedures relating to the operation of machinery associated with machining and blueprinting engine components

verbal, written and graphical instructions, signage, work schedules, plans, specifications, work bulletins, memos, material safety data sheets (MSDS), diagrams or sketches.

Tools and measuring equipment may include:

burette

degree wheel

dial indicator

dummy push rod

feeler gauge

flow bench

gauge for setting valve protrusion

micrometer

ring end gapper

sonic tester

valve spring tester.

OHS requirements may include:

operational risk assessment and treatments associated with:

electrical safety

machinery movement and operation

manual and mechanical lifting and shifting

toxic substances

working in proximity to others and site visitors

PPE required by legislation, regulations, codes of practice and workplace policies and procedures.

Environmental requirements are to include:

clean-up management

dust and noise minimisation

waste management.