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Evidence Guide: PMBPROD362 - Produce gravity cast polyurethane 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

 

PMBPROD362 - Produce gravity cast polyurethane products

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

Prepare to gravity cast polyurethane materials

  1. Interpret materials specifications
  2. Identify required materials, including additives and curative
  3. Identify required equipment, including handling, control and material preparation equipment
  4. Identify materials and process hazards and plan for their elimination
  5. Locate and make ready appropriate safety equipment
Interpret materials specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify required materials, including additives and curative

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify required equipment, including handling, control and material preparation equipment

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify materials and process hazards and plan for their elimination

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Locate and make ready appropriate safety equipment

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Plan gravity casting operations

  1. Confirm product and process parameters
  2. Ensure environmental controls are valid and in place according to procedures
  3. Identify product to be made and calculate quantity of material required to produce product of correct shape and physical dimensions
  4. Determine product colour and obtain appropriate agents
  5. Plan the sequence of events from availability of the material to stripping of the final product
  6. Identify appropriate measures to minimise risks from identified hazards
Confirm product and process parameters

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure environmental controls are valid and in place according to procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify product to be made and calculate quantity of material required to produce product of correct shape and physical dimensions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine product colour and obtain appropriate agents

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Plan the sequence of events from availability of the material to stripping of the final product

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify appropriate measures to minimise risks from identified hazards

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set up and check gravity casting equipment

  1. Set up equipment following procedures and confirm these are within recommended specifications
  2. Check time, de-gasser, temperature and allowable adjustments for conformity to documented procedures
  3. Check moulds for conformity with customer order and workplace operational requirements
  4. Report and discard or make adjustments for non-conforming materials in accordance with procedures
  5. Obtain appropriate mould coating and releasing agents
Set up equipment following procedures and confirm these are within recommended specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check time, de-gasser, temperature and allowable adjustments for conformity to documented procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check moulds for conformity with customer order and workplace operational requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Report and discard or make adjustments for non-conforming materials in accordance with procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Obtain appropriate mould coating and releasing agents

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Conduct gravity casting operations

  1. Follow planned sequence and workplace procedures
  2. Ensure equipment operating temperatures and times are within specification
  3. Pour materials at the appropriate rate per minute and quantity using techniques to minimise air entrapment and aeration
  4. Check product quality, including thickness, weight and product integrity, against specifications
  5. Make adjustments to gravity casting equipment to remedy product non-conformity where applicable
  6. Demould and check products and place in holding areas
  7. Deal with material waste and scrap in accordance with workplace procedures
  8. Clean up equipment, store lubricants and manage waste in accordance with procedures
Follow planned sequence and workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure equipment operating temperatures and times are within specification

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Pour materials at the appropriate rate per minute and quantity using techniques to minimise air entrapment and aeration

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check product quality, including thickness, weight and product integrity, against specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Make adjustments to gravity casting equipment to remedy product non-conformity where applicable

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Demould and check products and place in holding areas

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Deal with material waste and scrap in accordance with workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Clean up equipment, store lubricants and manage waste in accordance with procedures

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

Prepare to gravity cast polyurethane materials

1.1

Interpret materials specifications

1.2

Identify required materials, including additives and curative

1.3

Identify required equipment, including handling, control and material preparation equipment

1.4

Identify materials and process hazards and plan for their elimination

1.5

Locate and make ready appropriate safety equipment

2

Plan gravity casting operations

2.1

Confirm product and process parameters

2.2

Ensure environmental controls are valid and in place according to procedures

2.3

Identify product to be made and calculate quantity of material required to produce product of correct shape and physical dimensions

2.4

Determine product colour and obtain appropriate agents

2.5

Plan the sequence of events from availability of the material to stripping of the final product

2.6

Identify appropriate measures to minimise risks from identified hazards

3

Set up and check gravity casting equipment

3.1

Set up equipment following procedures and confirm these are within recommended specifications

3.2

Check time, de-gasser, temperature and allowable adjustments for conformity to documented procedures

3.3

Check moulds for conformity with customer order and workplace operational requirements

3.4

Report and discard or make adjustments for non-conforming materials in accordance with procedures

3.5

Obtain appropriate mould coating and releasing agents

4

Conduct gravity casting operations

4.1

Follow planned sequence and workplace procedures

4.2

Ensure equipment operating temperatures and times are within specification

4.3

Pour materials at the appropriate rate per minute and quantity using techniques to minimise air entrapment and aeration

4.4

Check product quality, including thickness, weight and product integrity, against specifications

4.5

Make adjustments to gravity casting equipment to remedy product non-conformity where applicable

4.6

Demould and check products and place in holding areas

4.7

Deal with material waste and scrap in accordance with workplace procedures

4.8

Clean up equipment, store lubricants and manage waste in accordance with procedures

5

Anticipate and solve problems

5.1

Recognise a problem or a potential problem

5.2

Determine problems needing priority action

5.3

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

5.4

Seek information and assistance as required to solve problems

5.5

Solve problems within area of responsibility

5.6

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

Prepare to gravity cast polyurethane materials

1.1

Interpret materials specifications

1.2

Identify required materials, including additives and curative

1.3

Identify required equipment, including handling, control and material preparation equipment

1.4

Identify materials and process hazards and plan for their elimination

1.5

Locate and make ready appropriate safety equipment

2

Plan gravity casting operations

2.1

Confirm product and process parameters

2.2

Ensure environmental controls are valid and in place according to procedures

2.3

Identify product to be made and calculate quantity of material required to produce product of correct shape and physical dimensions

2.4

Determine product colour and obtain appropriate agents

2.5

Plan the sequence of events from availability of the material to stripping of the final product

2.6

Identify appropriate measures to minimise risks from identified hazards

3

Set up and check gravity casting equipment

3.1

Set up equipment following procedures and confirm these are within recommended specifications

3.2

Check time, de-gasser, temperature and allowable adjustments for conformity to documented procedures

3.3

Check moulds for conformity with customer order and workplace operational requirements

3.4

Report and discard or make adjustments for non-conforming materials in accordance with procedures

3.5

Obtain appropriate mould coating and releasing agents

4

Conduct gravity casting operations

4.1

Follow planned sequence and workplace procedures

4.2

Ensure equipment operating temperatures and times are within specification

4.3

Pour materials at the appropriate rate per minute and quantity using techniques to minimise air entrapment and aeration

4.4

Check product quality, including thickness, weight and product integrity, against specifications

4.5

Make adjustments to gravity casting equipment to remedy product non-conformity where applicable

4.6

Demould and check products and place in holding areas

4.7

Deal with material waste and scrap in accordance with workplace procedures

4.8

Clean up equipment, store lubricants and manage waste in accordance with procedures

5

Anticipate and solve problems

5.1

Recognise a problem or a potential problem

5.2

Determine problems needing priority action

5.3

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

5.4

Seek information and assistance as required to solve problems

5.5

Solve problems within area of responsibility

5.6

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)

plan the gravity casting process and sequence tasks

prepare equipment, tools and materials to meet specifications

start and operate the gravity casting equipment

monitor key variables, including:

operating temperatures

speed of cure

colour

location of pouring basin

cycle time

use of separating agents

product weight

product integrity and general conformance to specification

make adjustments to remedy faults and non-conformity

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

materials properties

process variables

raw material variations/contamination

process abnormalities

procedural errors

recognise and prioritise problems requiring action

resolve routine and 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 gravity casting equipment, machine components and ancillary equipment

impact of variations in machine process conditions and raw materials on product quality and production output

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

gravity casting manufacturing process and phases of the cycle

importance of machine set-up and warm-up for effective processing of materials

characteristics of materials and their behaviour in relation process conditions and stages of production

quality requirements at each production stage

common adjustments in process variables and their impact on product quality and production output

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

possible changes to materials properties to better suit specific process requirements

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:

gravity casting equipment

moulds and dies

ancillary equipment that is integral to the process.

Additional tools and equipment will be selected as required from:

spanners, hammers, wrenches and other hand tools used in this process

knives and other bag opening equipment

temperature sensing equipment

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:

fumes/vapours

weight, shape, volume of materials to be handled

hazardous products and materials

rotational equipment or vibration

sharp edges, protrusions or obstructions

slippery surfaces, spills or leaks

smoke, dust 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 quality

emergency situations

intermittent faults.

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:

variations in materials

contamination of materials

mould or die problems

temperature related difficulties

product release difficulties

machine malfunction

mould/tooling problems processing problems

excessive aeration of materials

inadequately mixed materials.