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Evidence Guide: PMBPROD307 - Produce calendered products

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

 

PMBPROD307 - Produce calendered products

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

Plan own work requirements

  1. Identify equipment and processes used for production process and upstream and downstream operations from production plan or request
  2. Identify and check materials required, including additives
  3. Implement measures to control identified hazards in line with procedures and duty of care
  4. Identify requirements for materials, quality, production and equipment checks
Identify equipment and processes used for production process and upstream and downstream operations from production plan or request

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify and check materials required, including additives

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Implement measures to control identified hazards in line with procedures and duty of care

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify requirements for materials, quality, production and equipment checks

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Start up calendering process to procedures

  1. Identify process settings required for product
  2. Set process to required settings
  3. Check materials are correct
  4. Take appropriate action for non-conforming materials
  5. Set up date, batch and materials markings to specification as required
  6. Complete pre-start checks
  7. Start up calendering process
Identify process settings required for product

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set process to required settings

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check materials are correct

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Take appropriate action for non-conforming materials

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set up date, batch and materials markings to specification as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete pre-start checks

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Start up calendering process

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Operate and make adjustments to the calendering process to procedures

  1. Operate calendering process, noting key variables
  2. Monitor controls/displays/terminals for production/process data
  3. Monitor product/process quality
  4. Take samples as required and identify product out of specification
  5. Make adjustments to remedy faults and non-conformity to standard as required
  6. Establish a stable calendering process
  7. Adjust process to minimise scrap and trim
  8. Clean, adjust and lubricate equipment as required
Operate calendering process, noting key variables

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor controls/displays/terminals for production/process data

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor product/process quality

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Take samples as required and identify product out of specification

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Make adjustments to remedy faults and non-conformity to standard as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Establish a stable calendering process

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Adjust process to minimise scrap and trim

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Clean, adjust and lubricate equipment as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down machine to procedures

  1. Determine type of shutdown
  2. Select appropriate cleaning method
  3. Clean efficiently and adequately as required
  4. Leave machine in appropriate condition and with appropriate locks, tags or notices
  5. Complete relevant documentation
  6. Ensure area is clean and clear after the shutdown, in readiness for the next start-up
Determine type of shutdown

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Select appropriate cleaning method

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Clean efficiently and adequately as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Leave machine in appropriate condition and with appropriate locks, tags or notices

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete relevant documentation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure area is clean and clear after the shutdown, in readiness for the next start-up

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Anticipate and solve problems

  1. Recognise a problem or a potential problem
  2. Determine problems needing priority action
  3. Determine possible fault causes
  4. Refer problem outside area of responsibility to appropriate person, with possible causes
  5. Seek information and assistance as required to solve problems
  6. Solve problems within area of responsibility
  7. 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:

 

 

 

 

 

 

 

Determine possible fault causes

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Refer problem 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

Plan own work requirements

1.1

Identify equipment and processes used for production process and upstream and downstream operations from production plan or request

1.2

Identify and check materials required, including additives

1.3

Implement measures to control identified hazards in line with procedures and duty of care

1.4

Identify requirements for materials, quality, production and equipment checks

2

Start up calendering process to procedures

2.1

Identify process settings required for product

2.2

Set process to required settings

2.3

Check materials are correct

2.4

Take appropriate action for non-conforming materials

2.5

Set up date, batch and materials markings to specification as required

2.6

Complete pre-start checks

2.7

Start up calendering process

3

Operate and make adjustments to the calendering process to procedures

3.1

Operate calendering process, noting key variables

3.2

Monitor controls/displays/terminals for production/process data

3.3

Monitor product/process quality

3.4

Take samples as required and identify product out of specification

3.5

Make adjustments to remedy faults and non-conformity to standard as required

3.6

Establish a stable calendering process

3.7

Adjust process to minimise scrap and trim

3.8

Clean, adjust and lubricate equipment as required

4

Shut down machine to procedures

4.1

Determine type of shutdown

4.2

Select appropriate cleaning method

4.3

Clean efficiently and adequately as required

4.4

Leave machine in appropriate condition and with appropriate locks, tags or notices

4.5

Complete relevant documentation

4.6

Ensure area is clean and clear after the shutdown, in readiness for the next start-up

5

Anticipate and solve problems

5.1

Recognise a problem or a potential problem

5.2

Determine problems needing priority action

5.3

Determine possible fault causes

5.4

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

5.5

Seek information and assistance as required to solve problems

5.6

Solve problems within area of responsibility

5.7

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

Plan own work requirements

1.1

Identify equipment and processes used for production process and upstream and downstream operations from production plan or request

1.2

Identify and check materials required, including additives

1.3

Implement measures to control identified hazards in line with procedures and duty of care

1.4

Identify requirements for materials, quality, production and equipment checks

2

Start up calendering process to procedures

2.1

Identify process settings required for product

2.2

Set process to required settings

2.3

Check materials are correct

2.4

Take appropriate action for non-conforming materials

2.5

Set up date, batch and materials markings to specification as required

2.6

Complete pre-start checks

2.7

Start up calendering process

3

Operate and make adjustments to the calendering process to procedures

3.1

Operate calendering process, noting key variables

3.2

Monitor controls/displays/terminals for production/process data

3.3

Monitor product/process quality

3.4

Take samples as required and identify product out of specification

3.5

Make adjustments to remedy faults and non-conformity to standard as required

3.6

Establish a stable calendering process

3.7

Adjust process to minimise scrap and trim

3.8

Clean, adjust and lubricate equipment as required

4

Shut down machine to procedures

4.1

Determine type of shutdown

4.2

Select appropriate cleaning method

4.3

Clean efficiently and adequately as required

4.4

Leave machine in appropriate condition and with appropriate locks, tags or notices

4.5

Complete relevant documentation

4.6

Ensure area is clean and clear after the shutdown, in readiness for the next start-up

5

Anticipate and solve problems

5.1

Recognise a problem or a potential problem

5.2

Determine problems needing priority action

5.3

Determine possible fault causes

5.4

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

5.5

Seek information and assistance as required to solve problems

5.6

Solve problems within area of responsibility

5.7

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 calendering equipment to meet specifications

operate the equipment and monitor key variables, including:

operating temperatures

speed

nip settings

tension

materials consistency

surface finish

product integrity and general conformance to specification

maintain output and product quality using appropriate instruments, controls, test information and readings

safely shut down equipment in normal and abnormal circumstances

leave machine in appropriate condition with any required locks, tags or notices

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

fibre/materials 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:

products, materials and material characteristics

behaviour of materials in relation to key process variables

quality requirements at each production stage

function and operating principles of calendering equipment, machine components and ancillary equipment

mechanical , hydraulic, pneumatic, electrical and electronic principles which affect machine operation

calendering processes

behaviour of materials in relation to heat, pressure, flow rate, tension and time

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 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:

calenders

ancillary equipment that is integral to the process.

Additional tools and equipment will be selected as required from:

basic hand tools

mill knives

thickness gauges

profiling gauges/tools/jigs

nip adjusting bars

strainers

metal detector

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:

restricted spaces

weight, shape, volume of materials to be handled

hazardous products and materials

knives, blades and cutting tools

rotational equipment or vibration

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:

incorrect machine set-up, especially the nip setting tensions

temperature problems

processing problems

equipment malfunctions

uniformity of product

materials problems (e.g. raw material contamination, incorrect quantity of materials).