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PMBCAQA PolyformSimulated workplace
Simulated workplace
Scenario · Cable Works

Produce the Harbourline twin and earth cable order

You are a cable production operator following an order through the Bayswater works.

Intermediate4 to 6 hours8 tasks
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The situation

What has happened

Job card JC-26-3318 calls for 40 kilometres of 2.5 square millimetre twin and earth flat cable for Harbourline Electrical Wholesale in 500 metre reels. Copper rod lot CU-26-1190 is in the rod store, the PVC insulation compound is running low, and the 2.5 millimetre insulation die set has been re-centred after a high voltage failure on another order last week. Die centring must now be checked at every reel change. Every reel must pass conductor resistance, spark and high voltage tests before it is marked with the approval marking and released. A weekend shift has been announced to finish the order.

Your brief. Follow the order through wire drawing, bunching, insulation, lay-up and sheathing to the construction sheet, carry out the die centring and wall thickness checks at every reel change, test every reel, record the results, raise a nonconformance for any failure and release conforming reels with the correct marking.
Read the work request in your inbox
Tasks

Deliverables

  • Test and check list with recording points
  • Material lot and shortfall record
  • Die centring and wall thickness records at each reel change
  • Reel test records with any nonconformance entry
  • Updated job card and weekend shift note

Documents to use

Systems to use

Production Job Cards

Tracks every production, trial and site service job from release through setup, first-off approval, running, inspection and packing.

Raw Materials and Compounds Stock

Keeps the stock record for resins, masterbatch, copper rod, rubber ingredients, compounds and chemicals with lot numbers, quantities and locations.

Quality Nonconformance Register

Records nonconforming product, process deviations, cable test failures and customer complaints with disposition and corrective action.

Tool and Die Register

Holds every mould, extrusion die, calibrator and cable die with its version, condition, service history, cavity or size details and storage location.

For trainers and assessors

Units of competency

Current on training.gov.au for the Plastics, Rubber and Cablemaking as at 10 September 2026.

PMBPROD301EDraw wire
PMBPROD302EBunch and strand wire
PMBPROD303EProduce cable and tape lay-up cables
PMBPROD304EWind up wire or belts
PMBPROD209EOperate cable winding equipment

Qualifications

PMB30121Certificate III in Polymer Processing
Assessor notes

What to look for

Evidence guide

Look for the die centring and wall thickness check at every reel change, not only at start-up, conductor resistance compared with the standard's value, and every reel tested before marking. A failing reel must go to the nonconformance register with copper recovery recorded. Material lots must be traceable on the job card. Safety controls at the drawing capstans and take-ups must be stated.

The student's evidence summary lists every record they created or changed in the systems named above, their notes and the tasks they ticked. Verify it against the deliverables and your own assessment tool.