Elements and Performance Criteria

This competency applies to the production of vulcanised rubber products within the rubber industries. It includes the operation of all relevant additional equipment where that equipment is integral to the vulcanising autoclave process. It includes the operation of all ancillary steam equipment, but not boiler operation.

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 trimming equipment
hoists/lifting equipment not requiring any special permits or licences
basic hand tools
relevant personal protective equipment.

Typical hazards include:
heat
confined spaces
manual handling hazards
knife hazards.

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

Typical problems include:
air/water blinding of steam equipment
faulty/unreliable gauges
matching loads requiring the same cure conditions
adjusting temperature/pressure profile to match load and product.

Key variables to be monitored include:
operating temperatures
stacking and loading off product for autoclaving
material composition
operating pressure
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 vulcanising equipment, components and the materials used
describe changes to materials at the stages of production conducted by the employee
explain relationship between steam pressure and temperatures and the effects this and time will have on product quality and production output
describe the role of heat and pressure in relation to providing strength, stiffness, resistance to deformation, fatigue and abrasion
identify and describe own role and the roles of others involved directly in the vulcanising 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 vulcanising 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 product section/thickness on cure requirements
impact of compound cure system on cure requirements
impact of heating too quickly/slowly on final product properties
distinguish between causes of faults such as:
wrong cure cycle
changed product cure systems/section
steam problems.

Critical aspects
It is essential that competence is demonstrated in the ability to:
identify critical materials properties and rubber vulcanising 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, e.g. to determine required steam pressure to give necessary time/temperature cycle.

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.