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Evidence Guide: PMBWELD309 - Weld plastic using extrusion techniques

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

 

PMBWELD309 - Weld plastic using extrusion techniques

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

Identify materials as being compatible for welding

  1. Identify materials as PE, polypropylene (PP), acrylonitrile butadiene styrene (ABS), high-impact polystyrene (HIPS) and polyvinylchloride (PVC) from specifications and work site instructions
  2. Identify plastic materials and components supplied as being compatible for welding from specifications and tests
Identify materials as PE, polypropylene (PP), acrylonitrile butadiene styrene (ABS), high-impact polystyrene (HIPS) and polyvinylchloride (PVC) from specifications and work site instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify plastic materials and components supplied as being compatible for welding from specifications and tests

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify appropriate plastics welding conditions

  1. Identify welding machine type and operating requirements
  2. Identify plastic component materials and dimensions
  3. Identify and select appropriate welding rods or granules
  4. Select welding conditions for individual welding machines and plastic components
  5. Prepare field operational sheets according to enterprise specification
Identify welding machine type and operating requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify plastic component materials and dimensions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify and select appropriate welding rods or granules

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Select welding conditions for individual welding machines and plastic components

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare field operational sheets according to enterprise specification

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Maintain, and calibrate welding equipment

  1. Set up welding equipment and work area according to enterprise specification
  2. Ensure safety equipment available and operational according to enterprise procedures
  3. Identify non-conformance, report and rectify according to enterprise procedures
  4. Check operation, and calibrate where required, heating, material feed rate and pressure systems
  5. Use personal protective equipment (PPE)
Set up welding equipment and work area according to enterprise specification

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure safety equipment available and operational according to enterprise procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify non-conformance, report and rectify according to enterprise procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check operation, and calibrate where required, heating, material feed rate and pressure systems

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Use personal protective equipment (PPE)

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Perform welding to required standard

  1. Clean machine, align and trim abutting plastic component ends according to job specification
  2. Assemble components in holding jigs
  3. Perform heating, welding and cooling phases using selected welding conditions and specifications
  4. Monitor and record achieved weld conditions for each assembly according to enterprise requirements
  5. Clean up equipment when completed according to enterprise requirements
  6. Clean up work site, dispose of scrap materials according to job specification
Clean machine, align and trim abutting plastic component ends according to job specification

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assemble components in holding jigs

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Perform heating, welding and cooling phases using selected welding conditions and specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor and record achieved weld conditions for each assembly according to enterprise requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Clean up equipment when completed according to enterprise requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Clean up work site, dispose of scrap materials according to job specification

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assess quality of completed joints

  1. Identify quality requirements for joints according to specifications
  2. Assess joints against specification requirements and report results according to enterprise requirements
  3. Identify and report non-conformances according to job specification
Identify quality requirements for joints according to specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assess joints against specification requirements and report results according to enterprise requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify and report non-conformances according to job specification

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

Identify materials as being compatible for welding

1.1

Identify materials as PE, polypropylene (PP), acrylonitrile butadiene styrene (ABS), high-impact polystyrene (HIPS) and polyvinylchloride (PVC) from specifications and work site instructions

1.2

Identify plastic materials and components supplied as being compatible for welding from specifications and tests

2

Identify appropriate plastics welding conditions

2.1

Identify welding machine type and operating requirements

2.2

Identify plastic component materials and dimensions

2.3

Identify and select appropriate welding rods or granules

2.4

Select welding conditions for individual welding machines and plastic components

2.5

Prepare field operational sheets according to enterprise specification

3

Maintain, and calibrate welding equipment

3.1

Set up welding equipment and work area according to enterprise specification

3.2

Ensure safety equipment available and operational according to enterprise procedures

3.3

Identify non-conformance, report and rectify according to enterprise procedures

3.4

Check operation, and calibrate where required, heating, material feed rate and pressure systems

3.5

Use personal protective equipment (PPE)

4

Perform welding to required standard

4.1

Clean machine, align and trim abutting plastic component ends according to job specification

4.2

Assemble components in holding jigs

4.3

Perform heating, welding and cooling phases using selected welding conditions and specifications

4.4

Monitor and record achieved weld conditions for each assembly according to enterprise requirements

4.5

Clean up equipment when completed according to enterprise requirements

4.6

Clean up work site, dispose of scrap materials according to job specification

5

Assess quality of completed joints

5.1

Identify quality requirements for joints according to specifications

5.2

Assess joints against specification requirements and report results according to enterprise requirements

5.3

Identify and report non-conformances according to job specification

Required Skills and Knowledge

Elements describe the essential outcomes.

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

1

Identify materials as being compatible for welding

1.1

Identify materials as PE, polypropylene (PP), acrylonitrile butadiene styrene (ABS), high-impact polystyrene (HIPS) and polyvinylchloride (PVC) from specifications and work site instructions

1.2

Identify plastic materials and components supplied as being compatible for welding from specifications and tests

2

Identify appropriate plastics welding conditions

2.1

Identify welding machine type and operating requirements

2.2

Identify plastic component materials and dimensions

2.3

Identify and select appropriate welding rods or granules

2.4

Select welding conditions for individual welding machines and plastic components

2.5

Prepare field operational sheets according to enterprise specification

3

Maintain, and calibrate welding equipment

3.1

Set up welding equipment and work area according to enterprise specification

3.2

Ensure safety equipment available and operational according to enterprise procedures

3.3

Identify non-conformance, report and rectify according to enterprise procedures

3.4

Check operation, and calibrate where required, heating, material feed rate and pressure systems

3.5

Use personal protective equipment (PPE)

4

Perform welding to required standard

4.1

Clean machine, align and trim abutting plastic component ends according to job specification

4.2

Assemble components in holding jigs

4.3

Perform heating, welding and cooling phases using selected welding conditions and specifications

4.4

Monitor and record achieved weld conditions for each assembly according to enterprise requirements

4.5

Clean up equipment when completed according to enterprise requirements

4.6

Clean up work site, dispose of scrap materials according to job specification

5

Assess quality of completed joints

5.1

Identify quality requirements for joints according to specifications

5.2

Assess joints against specification requirements and report results according to enterprise requirements

5.3

Identify and report non-conformances according to job specification

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, national standards, material labels and safety data sheets (SDS)

distinguish between PE, PP, ABS, HIPS and PVC materials and welding rods/granules

select welding conditions appropriate to the welding equipment and components

set up welding equipment and materials/components to meet specifications

operate the extrusion or injection welding equipment to weld the materials/components

monitor key variables, including:

temperature

rate of extrusion/injection

pressure

product output rate

integrity of weld and general conformance to specification

assess quality of completed

make adjustments to remedy faults and non-conformity

identify hazards and apply relevant hazard controls

apply safety procedures

apply housekeeping procedures

apply waste management procedures

maintain and calibrate welding equipment

recognise early warning signs of equipment/processes needing attention or with potential problems

distinguish between causes of problems, including:

operational problems

materials properties

process variables

raw material/component variations

raw material contamination

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 welding system/equipment including one (1) or more of:

electrical activated extrusion welding machine

electrical/pneumatic activated injection welding machine

extrusion and injection welding processes and their effect on the welded product

impact of variations in welding process variables and raw materials on product quality and production output

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

characteristics of materials and their behaviour in relation to welding process variables and stages of production

quality requirements

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

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:

welding system/equipment, including one or more of:

electrical activated extrusion welding machine

electrical/pneumatic activated injection welding machine

measurement devices, including, timers, temperature probes and callipers

cleaning equipment

spray equipment

plastics machining equipment

assembly jigs and clamps.

Additional tools and equipment will be selected as required from:

hand tools used in this process

hoists/lifting equipment not requiring any special permits or licences

manual handling, aids such as hand carts and trolleys

relevant PPE.

Hazards

Hazards must be identified and controlled. Identifying hazards requires consideration of:

hazardous products and materials

cutting equipment

sharp edges, swarf and scrap

protrusions or obstructions

slippery surfaces, spills or leaks

rotational equipment or vibration

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:

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:

incompatible materials (pipes/rods)

variable plastics sheet material grades and supplied welding rods/granules

equipment malfunction or wear and tear

variable factory and field site conditions.