Elements and Performance Criteria

This competency applies to the production/building of rubber rollers in the rubber industry. It includes the operation of all relevant additional equipment where that equipment is integral to the roller building process.

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

This competency includes tools and equipment such as:
hand carts and trolleys
knives and other sheet cutting equipment
hoists/lifting equipment not requiring any special permits or licences
solvent application/wiping gear
hand tools used in the roller building process
relevant personal protective equipment.

Typical hazards include:
solvent vapours
hazardous materials
manual handling hazards
knife hazards.

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

Typical process and product problems include:
variations in materials
contamination of materials
contamination of core/spindle
porous, damaged or unsuitable core/spindle
processing problems.

Key variables to be monitored include:
operating temperatures
speed
colour
cushion specification
cycle time
output rate
product integrity and general conformance to specification/sample.

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:
identify the function of roller building equipment, machine components and the materials used
identify faulty cores/mandrels
describe changes to materials at the stages of production conducted by the employee
explain the impact of roller building machine temperature, pressure and adhesive flash off time on product quality and production output
identify and describe own role and the roles of others involved directly in the roller building process
decide if they (the operator) are able to rectify the fault or if assistance is required
explain the effect of unauthorised or emergency shutdown of equipment on the roller building process
plan own work sequence including identification of key checkpoints for equipment monitoring, product quality checks and monitoring of supplies and downstream operations monitor equipment operation and 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:
impact of incorrect or faulty materials
production workflow sequences and materials demand
focus of operation of work systems and equipment
correct selection and use of equipment, materials, processes and procedures
hazards of the materials and process and appropriate hazard control procedures
the nature of the mechanical, hydraulic, pneumatic, electrical and electronic principles which influence the roller building equipment operation and product development
the impact that chemical reactions/mechanical processes have on changing the state, form and condition of the materials
production workflow schedule requirements
focus of operation of work systems and equipment
identification and correct use of equipment, processes and procedures
plan own work including predicting consequences and identifying improvements
distinguish between causes of faults such as:
wrong raw materials
incorrect building
contaminated materials/core/spindle
core/spindle fault.

Critical aspects
It is essential that competence is demonstrated in the ability to:
identify critical materials properties and roller building 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.
Basic numeracy is also required to interpret specifications and lay out geometric shapes

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.