Elements and Performance Criteria

This competency applies to all work environments and sectors within the plastics, rubber and cablemaking industry. It includes the operation of all relevant additional equipment where that equipment is integral to the compounding process.

This competency unit covers the compounding of all materials using a range of equipment. It does NOT include the use of internal or open mill blenders (see PMBPROD253B - Operate an internal mill blender, or PMBPROD254B - Operate an open mill blender).

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

This competency includes equipment and tools such as:
hand carts and trolleys
knives and other bag opening equipment
hoists/lifting equipment not requiring any special permits or licences
bung spanners and similar
basic hand tools required for opening of material packaging
relevant personal protective equipment.

Typical hazards include:
spills
dusts/vapours
hazardous materials
manual handling hazards
knife hazards.

'Rectify routine problems' means 'apply known solutions to a limited range of predictable problems'.

Typical process problems include:
equipment failures
uneven mixing
contamination of materials
inappropriate formula selected.

Typical product problems include:
variations in materials
contamination of materials
quantity errors.

All operations are performed in accordance with procedures.

Essential knowledge and enterprise requirements
Application of knowledge of the materials, equipment and process sufficient to recognise out of specification products, process problems and materials faults.
Knowledge of the enterprise's procedures and relevant regulatory requirements along with the ability to implement them within appropriate time constraints and work standards.

Competence includes the ability for the practical completion of the job to:
identify the function of compounding equipment, machine components and the materials used
describe changes to materials at the stages of production conducted by the employee
explain the impact of compounding machine speed, pressure, time, temperature on finished product quality, production process and output
identify the role friction plays in the compounding of product
describe causes and effects of variations in blended batches
identify and describe own role and the roles of others involved in the compounding process and in delivery within the workplace of raw and blended materials
explain the effect of unauthorised or emergency shutdown of equipment on the compounding process
plan own work sequence including identification of key checkpoints for equipment monitoring, product quality checks and monitoring of supplies and downstream operations
operate equipment and monitor product quality
identify factors which may influence product quality and production output and appropriate remedies
make appropriate authorised alterations to own work plan and equipment to maintain both product quality and required production output
locate, interpret and apply relevant information and maintain workplace records
identify and safely handle products and materials, read relevant safety information and apply safety precautions appropriate to the task
apply and/or explain the:
nature of the mechanical, hydraulic, pneumatic, electrical and electronic principles which influence the compounding equipment operation and product compounding
impact that chemical reactions/mechanical processes have on changing the state, form and condition of the materials
purpose of developing elasticity and controlling temperatures
effects of mastication, differential speed, overheating
production workflow schedule requirements
focus of operation of work systems and equipment
identification and correct use of equipment, processes and procedures
need to plan own work including predicting consequences and identifying improvements.

Critical aspects
It is essential that competence is demonstrated in the ability to:
operate the equipment within organisational guidelines
add the appropriate materials in the specified quantities
recognise potential situations requiring action and then implement appropriate action.

Consistent performance should be demonstrated. In particular look to see that:
production standards are met consistently.
material quality and consistency is maintained at the specified levels
upstream and downstream communication is timely and effective
common production faults and equipment malfunctions are identified/anticipated and appropriate action is taken (ie the fault fixed or reported)
non-routine problems are identified and reported to appropriate personnel
all safety procedures are adhered to.

Language, literacy and numeracy requirements
This unit requires the ability to read and interpret typical product specifications, job sheets, procedures, material labels and safety information as provided to operators.
Writing is required to the level of completing workplace forms.
Basic numeracy is required, e.g. to determine that two 25 kg bags are needed to make up a requirement for 50 kg.

Assessment method and context
Competence in this unit may be assessed:
on an operating plant allowing for operation under all normal and a range of abnormal conditions
by use of a suitable simulation and/or a range of case studies/scenarios
by 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 that the theoretical assessment will be combined with appropriate practical/simulation or similar assessment.

Resource implications
This section should be read in conjunction with the range of variables 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 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.