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Evidence Guide: PMBPROD308B - Take a machine out of 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

 

PMBPROD308B - Take a machine out of production

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

Take over operation of the machine.

  1. Arrange handover from the operator (if necessary).
  2. Determine type and reason for shutdown.
  3. Implement measures to control identified hazards in line with procedures and duty of care.
Arrange handover from the operator (if necessary).

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine type and reason for shutdown.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Notify relevant associated personnel.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Perform long-term shutdown.

  1. Stop material feed,
  2. Purge, using appropriate materials as required.
  3. Switch off ancillaries as required.
  4. Make required adjustments to ensure the safety of machine and materials.
  5. Isolate, lock out and make machine safe for personnel, leave with appropriate tags or notices.
  6. Complete relevant documentation.
Stop material feed,

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Purge, using appropriate materials as required.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Switch off ancillaries as required.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Make required adjustments to ensure the safety of machine and materials.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Isolate, lock out and make machine safe for personnel, leave with appropriate tags or notices.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete relevant documentation.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Perform post-shutdown preventive maintenance and cleanup after long-term shutdown.

  1. Clean all components as required.
  2. Apply required surfaces treatments
  3. Leave all parts in required condition.
  4. Confirm all isolations have been done.
  5. Pack/process any remaining goods/ product and label as required.
  6. Sort material that can be salvaged from waste and arrange reprocessing/disposal to procedures.
  7. Ensure area is clean and clear, ready for restarting of the machine
Clean all components as required.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Apply required surfaces treatments

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Leave all parts in required condition.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Confirm all isolations have been done.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Pack/process any remaining goods/ product and label as required.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Sort material that can be salvaged from waste and arrange reprocessing/disposal to procedures.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure area is clean and clear, ready for restarting of the machine

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

The Evidence Guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, the range statement and the assessment guidelines for this training package.

Overview of assessment

A holistic approach should be taken to the assessment.

Assessors must be satisfied that the person can consistently perform the unit as a whole, as defined by the Elements, Performance Criteria and skills and knowledge.

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

It is essential that competence is demonstrated in the knowledge and skills defined in this unit. These may include the ability to:

identify the key activities involved in performing a shutdown in relation to the specific process and machinery involved

make adjustments to the process as required

identify and take appropriate action on problems and potential problems

Consistent performance should be demonstrated. For example, look to see that:

the shutdown is done in an efficient manner, to standard requirements

all safety procedures are always followed.

Assessment method and context

Assessment will occur on an industrial equipment shutdown and will be undertaken in a work-like environment.

Competence in this unit may be assessed:

by using an appropriate equipment requiring long term shutdown

in a situation allowing for the generation of evidence of the ability to respond to problems

by using a suitable simulation and/or a range of case studies/scenarios

through a combination of these techniques.

In all cases it is expected that practical assessment will be combined with targeted questioning to assess the underpinning knowledge and theoretical assessment will be combined with appropriate practical/simulation or similar assessment. Assessors need to be aware of any cultural issues that may affect responses to questions.

Assessment processes and techniques must be culturally appropriate and appropriate to the oracy, language and literacy capacity of the assessee and the work being performed.

Specific resources for assessment

This section should be read in conjunction with the Range Statement for this unit of competency. Resources required include suitable access to an operating plant or equipment that allows for appropriate and realistic simulation. A bank of case studies/scenarios and questions will also be required to the extent that they form part of the assessment method. Questioning may take place either in the workplace, or in an adjacent, quiet facility such as an office or lunchroom. No other special resources are required.

Access must be provided to appropriate learning and/or assessment support when required. Where applicable, physical resources should include equipment modified for people with disabilities.

Required Skills and Knowledge

This describes the essential skills and knowledge and their level required for this unit.

Application of the knowledge of equipment and process sufficient to recognise equipment conditions which may lead to out of specification production. For example purging compound left in cylinder can lead to lamination defect

Knowledge and ability to implement organisation procedures and relevant regulatory requirements, within appropriate time constraints and work standards.

Application of the knowledge of managing risks using the hierarchy of controls applied to machine shutdown operations. Application of approved hazard control and safety procedures and the use of PPE in relation to handling materials, equipment operation and cleanup.

Knowledge of and skills in equipment shutdown operations sufficient for effective and efficient performance and solving of problems associated with the job, including:

machine construction, component parts ,structure, functions and general operating principles

machine safety interlocks and systems (including limit switches, overstroke control systems, hydraulic temperature control, material temperature control, machine guards, nozzle purge guard, mould protection systems, ejection limit switches)

production cycle/process/sequence and the effect ofvariations to the different systems/products

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

machine controls, their identification and function, includes basic controls, open loop, closed loop, shot size and correction capacity, speed, screw position, pressure, clamp pressure, time, screw speed, screw back pressure, screw back time, melt decompress position, sprue break

differences between analogue controls, digital controls, and microprocessor based process controls.

measuring instruments and their function: levelling, temperature sensing devices, thermocouples and pyrometers, transducers, thermometers, pressure and vacuum gauges, flow meters

waste management and importance of non-conforming materials.

Competence also includes the ability to:

plan own work, including predicting consequences and identifying improvements

identify and describe own role and role of others involved directly in equipment shutdown operations

identify when assistance is required to solve problems.

Language, literacy and numeracy requirements

Literacy is required to the level of being able to read and interpret technical specifications and production schedules and specifications.

Verbal communication is required to the extent necessary to instruct the operator.

An appreciation of numbers is also required to the extent needed to set and interpret numeric data.

Range Statement

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Add any 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.

Where reference is made to industry codes of practice, and/or Australian/international standards, the latest version must be used.

Context

This competency applies to long term shutdown of equipment within the plastics, rubber and cablemaking industries. A long-term stop is where the machine needs to be, or will become, 'cold'.

Procedures

All operations are performed in accordance with procedures.

Procedures include all relevant workplace procedures, work instructions, temporary instructions and relevant industry and government codes and standards.

Ancillaries

Ancillaries includes chillers and heaters.

Tools and equipment

This competency includes use of equipment and tools such as:

hand carts and trolleys

hoists/lifting equipment not requiring any special permits or licences

hand tools used in the process

relevant personal protective equipment.

Hazards

Typical hazards include:

spills dusts/vapours

slip and fall, particularly due to spilt polymer granules

temperature

hazardous materials

manual handling hazards

mechanical hazards.

Problems

Anticipate and solve problems means resolve a wide range of routine and non-routine problems, using knowledge of equipment and materials to develop solutions to problems which do not have a known solution/s in the procedures.

Typical process and product problems may include:

cycle interruptions

degradation of materials

cooling and solidification of compounds

rusting and corrosion of moulds put in storage

clearing jams

damage to equipment.

Appropriate action for solving problems outside area of responsibility may be reporting to an appropriate person.

Appropriate action for solving problems within area of responsibility includes asking questions and seeking assistance from appropriate persons/sources.

Variables

Key variables to be monitored include:

temperature

fill rate

screw RPM

speed

brakes

stopping distance.