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Evidence Guide: PMBPROD306 - Prepare and start equipment for production

Student: __________________________________________________

Signature: _________________________________________________

Tips for gathering evidence to demonstrate your skills

The important thing to remember when gathering evidence is that the more evidence the better - that is, the more evidence you gather to demonstrate your skills, the more confident an assessor can be that you have learned the skills not just at one point in time, but are continuing to apply and develop those skills (as opposed to just learning for the test!). Furthermore, one piece of evidence that you collect will not usualy demonstrate all the required criteria for a unit of competency, whereas multiple overlapping pieces of evidence will usually do the trick!

From the Wiki University

 

PMBPROD306 - Prepare and start equipment for production

What evidence can you provide to prove your understanding of each of the following citeria?

Perform pre-start checks

  1. Check all emergency stops, guards and controls
  2. Identify requirements for materials, quality and production run
  3. Check and adjust equipment as required
  4. Check that the equipment has been set-up correctly
Check all emergency stops, guards and controls

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify requirements for materials, quality and production run

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check and adjust equipment as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check that the equipment has been set-up correctly

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Carry out pre-start operations to procedures

  1. Restore all power to the machine and ancillary equipment
  2. Start up the ancillary equipment and set the temperature and other controllers as required
  3. Check all machine settings as required
  4. Select and load the correct raw material
  5. Charge, purge and clean machine as required
Restore all power to the machine and ancillary equipment

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Start up the ancillary equipment and set the temperature and other controllers as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check all machine settings as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Select and load the correct raw material

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Charge, purge and clean machine as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Start machine and hand over to operator

  1. Start and check machine
  2. Adjust machine as required to bring to operational speed/ condition
  3. Check and run machine until a quality product is obtained
  4. Make adjustments to machine and extra equipment in line to produce an acceptable product
  5. Make any adjustments required to ensure the machine and its upstream and downstream extra equipment in line are in balance
  6. Give the operator all necessary instructions and hand over the machine
  7. Shut down machine as required
Start and check machine

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Adjust machine as required to bring to operational speed/ condition

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check and run machine until a quality product is obtained

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Make adjustments to machine and extra equipment in line to produce an acceptable product

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Make any adjustments required to ensure the machine and its upstream and downstream extra equipment in line are in balance

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Give the operator all necessary instructions and hand over the machine

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down machine as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Anticipate and solve problems

  1. Recognise a problem or a potential problem
  2. Determine problems needing priority action
  3. Refer problems outside area of responsibility to appropriate person, with possible causes
  4. Seek information and assistance as required to solve problems
  5. Solve problems within area of responsibility
  6. Follow through items initiated until final resolution has occurred
Recognise a problem or a potential problem

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine problems needing priority action

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Refer problems outside area of responsibility to appropriate person, with possible causes

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Seek information and assistance as required to solve problems

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Solve problems within area of responsibility

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Follow through items initiated until final resolution has occurred

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

Elements describe the essential outcomes.

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

1

Perform pre-start checks

1.1

Check all emergency stops, guards and controls

1.2

Identify requirements for materials, quality and production run

1.3

Check and adjust equipment as required

1.4

Check that the equipment has been set-up correctly

2

Carry out pre-start operations to procedures

2.1

Restore all power to the machine and ancillary equipment

2.2

Start up the ancillary equipment and set the temperature and other controllers as required

2.3

Check all machine settings as required

2.4

Select and load the correct raw material

2.5

Charge, purge and clean machine as required

3

Start machine and hand over to operator

3.1

Start and check machine

3.2

Adjust machine as required to bring to operational speed/ condition

3.3

Check and run machine until a quality product is obtained

3.4

Make adjustments to machine and extra equipment in line to produce an acceptable product

3.5

Make any adjustments required to ensure the machine and its upstream and downstream extra equipment in line are in balance

3.6

Give the operator all necessary instructions and hand over the machine

3.7

Shut down machine as required

4

Anticipate and solve problems

4.1

Recognise a problem or a potential problem

4.2

Determine problems needing priority action

4.3

Refer problems outside area of responsibility to appropriate person, with possible causes

4.4

Seek information and assistance as required to solve problems

4.5

Solve problems within area of responsibility

4.6

Follow through items initiated until final resolution has occurred

Required Skills and Knowledge

Elements describe the essential outcomes.

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

1

Perform pre-start checks

1.1

Check all emergency stops, guards and controls

1.2

Identify requirements for materials, quality and production run

1.3

Check and adjust equipment as required

1.4

Check that the equipment has been set-up correctly

2

Carry out pre-start operations to procedures

2.1

Restore all power to the machine and ancillary equipment

2.2

Start up the ancillary equipment and set the temperature and other controllers as required

2.3

Check all machine settings as required

2.4

Select and load the correct raw material

2.5

Charge, purge and clean machine as required

3

Start machine and hand over to operator

3.1

Start and check machine

3.2

Adjust machine as required to bring to operational speed/ condition

3.3

Check and run machine until a quality product is obtained

3.4

Make adjustments to machine and extra equipment in line to produce an acceptable product

3.5

Make any adjustments required to ensure the machine and its upstream and downstream extra equipment in line are in balance

3.6

Give the operator all necessary instructions and hand over the machine

3.7

Shut down machine as required

4

Anticipate and solve problems

4.1

Recognise a problem or a potential problem

4.2

Determine problems needing priority action

4.3

Refer problems outside area of responsibility to appropriate person, with possible causes

4.4

Seek information and assistance as required to solve problems

4.5

Solve problems within area of responsibility

4.6

Follow through items initiated until final resolution has occurred

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, instruments/control panels, material labels and safety data sheets (SDS)

set up and adjust machine control system to produce product to specification, including one or more of:

basic controls

open loop

closed loop

shot size and correction capacity

speed/cycle time

screw position

equipment/process pressure

clamp pressure

time

screw speed

screw back pressure

screw back time

melt decompress position

sprue break

start up process and monitor key variables, including:

equipment condition

set up variables

product measurements

product integrity and general conformance to specification

make adjustments to process to:

remedy faults and nonconformity

establish a stable process

establish balance with upstream and downstream processes

give instructions to the operator and handover over the machine

safely 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

distinguish between causes of problems, including:

operational problems

instrument failure/malfunction

electrical failure/malfunction

mechanical failure/malfunction

wrong readings

equipment design deficiencies

polymer properties

process variables

recognise and prioritise problems requiring action

resolve 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 machine and components

products, materials and material characteristics

behaviour of materials in relation to key process variables

quality requirements at each production stage

function of and readings from measuring instruments, including one or more of:

levelling

thermocouples

pyrometers

transducers

thermometers

pressure gauges

vacuum gauges

flow meters

purpose and operation of safety interlocks and systems, including one or more of:

limit switches

normally open/normally closed

overstroke control systems

hydraulic temperature control

material temperature control

machine guards

nozzle purge guard

mould protection systems

ejection limit switches

impact of machine operating parameters on product quality and production output

factors which may affect product quality or production output and appropriate remedies

polymer properties and their interactions with process conditions

impact of variations in raw materials and equipment operation in relation to final product

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.

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, 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:

production plant/equipment

machine control systems

safety interlocks and systems

measuring instruments

ancillary equipment that is integral to the process.

Additional tools and equipment will be selected as required from:

hand tools used in the process

hoists/lifting equipment not requiring any special permits or licences

manual handling aids, such as hand carts and trolleys

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

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:

unstable process variables

sub-optimal operation

variations in feed rates

variations in quality

emergency situations.

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:

processing problems

equipment malfunctions

materials problems.