Elements and Performance Criteria

This competency applies to the operation of tyre finishing processes within the tyre sector. It includes the operation of all relevant additional equipment where that equipment is integral to the process.

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

This competency may include equipment and tools such as:
process electrical/mechanical machine and its major components, e.g. radial runout machine, x-ray console (manual/auto), vulcaniser, spreader, force variation machine, camera throw out unit, radial run out and lateral run out peak unit, grinders, high point tape, harmonic balance
process equipment and its major components, e.g. digital measuring equipment, visual display unit, printer, labelling equipment, inflation panel, inspection station, trimming tools, power tools for tyre repair, repair table, foot pedal, marking chalk and table
hand tools used in the process, e.g. hand held trimmers
material loading machine/equipment used for loading/unloading of tyres may include mechanical crane, chucks, push trolleys, stillages, conveyors, etc.
relevant personal protective equipment, e.g. radiation discs for x-ray inspection
relevant protective clothing which may include gloves, safety glasses and appropriate footwear.

This competency includes repair materials such as:
cement
paint
silicone.

Typical hazards include:
dusts/vapours
slip and fall
temperature
hazardous materials
manual handling hazards, e.g. loading and unloading tyres from machines/equipment
machine/equipment operations, e.g. hand held trimmers, x-ray machines, inflating panels.

Respond to/rectify 'non-routine problems' means 'apply known solutions to a variety of predictable problems'.

Typical process and product problems include:
routine and non-routine product faults, e.g. excess flash
machine malfunction
mould/tooling/die problems
variations in materials and/or contamination of materials
processing problems, e.g. flow-through of tyres.

Typical tyre information includes:
mould numbers
tread patterns and codes
running serial numbers
other relevant numbers and codes
tyre sizes
coloured tread identification lines.

Key variables to be monitored include:
temperatures
speed
pressures
colour
tyre components
repair standards
limits for repair
tyre construction/integrity and general conformance to specification/sample, e.g. bumps/dips on tyres.

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 material and equipment conditions which may lead to out of specification production.
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:
apply and/or explain:
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 equipment, machine components and ancillary equipment
impact of key process variables on product quality and production output
nature of mechanical, hydraulic, pneumatic, electrical and electronic principles which affect machine operation and product development
the importance of machine set-up and start-up procedure for effective processing of materials
safety procedures and the use of PPE in relation to handling materials, equipment operation and clean up, e.g. maximum number of tyres to be stacked per stillage
the hierarchy of control including engineering controls
impact of variations in raw materials and equipment operation in relation to final product
changes to materials at various stages of production
waste management and importance of reusing non-conforming materials
plan own work including predicting consequences and identifying improvements
interpret from production requests the correct selection and use of equipment, materials, processes and procedures
maintain output and product quality using appropriate instruments, controls, test information and readings
make adjustments to equipment operation to rectify variations in equipment operation or product quality
check machine for correct set-up to job specifications and implement adjustments or report deviations immediately
start up equipment and make appropriate adjustments to bring process on line
take samples when required and identify product out of specification
safely shut down equipment in normal or abnormal circumstances
identify and describe own role and role of others involved directly in the process
identify factors which may affect product quality or production output and appropriate remedies
identify when the operator is able to rectify faults and when assistance is required
identify hazards of the materials and process and take appropriate hazard control
use PPE, safely handle products and materials, read relevant safety information and apply safety precautions appropriate to the task
distinguish between causes of faults such as:
routine faults
incorrect quantity of materials
contaminated materials
complete accurately necessary workplace documents (manually and/or electronically) which may include:
input data into computer system
grading record sheets, etc.
liaise with and/or disseminate information regarding updates and changes to other colleagues who may include:
other operators and/or forklift drivers
records personnel
supervisors.

Critical aspects
It is essential that competence is demonstrated in the ability to:
identify critical materials properties and process characteristics in relation to the process requirements and the end product
plan own work process within workplace procedures and explain the reasons for the steps in the process
take appropriate action to observe equipment, materials and products for out of specification results, make adjustments and identify problems to be reported.

Consistent performance should be demonstrated. In particular look to see that:
production quality and output standards are met consistently
problems are anticipated from process observations
problems are efficiently resolved
the process runs consistently and smoothly.

Language, literacy and numeracy requirements
This unit requires the ability to read and interpret typical product specifications, job sheets and material labels as provided to operators.
Writing is required to the level of completing workplace forms and production reports.
For operation of force variation machine, basic statistical knowledge is required to understand concepts of variance and process control as well as to recognise and interpret process control charts.

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 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 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.