FDFGR4003A - Manage mill logistics and support services
Assessor Resource
FDFGR4003A Manage mill logistics and support services
Assessment tool
Version 1.0 Issue Date: May 2024
This Unit applies to a flour mill manager and other senior staff who are responsible for determining and supervising logistics and support services for a flour mill to ensure efficient operation of the mill and compliance with regulatory and commercial requirements. The Unit applies to industrial milling of all types of grain. Logistics and services covered by the Unit include stock control, transport and storage, blending, packing and despatch, security, and pest control. Supervision of dust control procedures is also covered in the Unit.
This Unit covers the management of support and logistics services to ensure safe and efficient operation of a flour mill. The Unit covers establishing and supervising the handling, storage, despatch and distribution of materials including grain, flour and byproducts. It also covers supervision of hygiene, OHS, pest control and security procedures.
You may want to include more information here about the target group and the purpose of the assessments (eg formative, summative, recognition)
Prerequisites
Nil.
Employability Skills
This Unit contains employability skills.
Evidence Required
List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.
The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.
Overview of assessment
Assessment must be carried out in a manner that recognises the cultural and literacy requirements of the assessee and is appropriate to the work performed. Competence in this Unit must be achieved in accordance with food safety standards and regulations.
Critical aspects for assessment and evidence required to demonstrate competency in this Unit
Evidence of ability to:
relate rate of production to storage capacity
identify requirements of mill customers and determine if orders are to be directly filled or met out of storage
interpret customer flour requirements and determine best blend recipe
manage pest and dust control techniques in a mill
access and use mill control system.
Context of and specific resources for assessment
Assessment must occur in a real or simulated workplace where the assessee has access to:
personal protective clothing and equipment
work procedures, including advice on safe work practices, food safety, quality and environmental requirements
equipment manuals including operating parameters
specifications, control points and processing parameters
break and reduction roll process and related equipment and services
conditioned grain suitable for the break and reduction roll process
sampling schedules and test procedures and equipment as required
documentation and recording requirements and procedures
cleaning procedures, materials and equipment as required.
Method of assessment
This Unit should be assessed together with core Units and other Units of Competency relevant to the function or work role.
Guidance information for assessment
To ensure consistency of performance, competency should be demonstrated on more than one occasion over a period of time in order to cover a variety of circumstances, cases and responsibilities, and where possible, over a number of assessment activities.
Submission Requirements
List each assessment task's title, type (eg project, observation/demonstration, essay, assingnment, checklist) and due date here
Assessment task 1: [title] Due date:
(add new lines for each of the assessment tasks)
Assessment Tasks
Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.
Required skills include:
Ability to:
interpret drawings and schematics
calculate grain holding capacity including in terms of days of production
specify grain divisions on receival to suit later blending requirements
schedule flour blending to suit customer requirements and transport logistics
identify pests
assess equipment and storage areas for dust control risks.
Required knowledge includes:
Knowledge of:
methods of storing grain, flour, bran and byproducts
temperature and moisture testing techniques for grain storage bins and silos
dust control techniques
dust explosion relief systems and equipment
fire warning and control techniques
flour blending techniques and equipment
flour milling process including purpose of the break and reduction systems
advantages and disadvantages of volumetric, batch and on-line flour blending techniques
equipment used in flour blending including:
weighers
mixers and homogenisers
pneumatic and mechanical feeders and conveyors
magnets, sifters and exhausts
identification characteristics for pest insects, rodents and birds
signs of insect and rodent infestation
strategies to eliminate or reduce pests
optimum treatments for insect, rodent and bird infestations
safe procedures for handling, using and storing pesticides and dangerous goods, identifying identification of information provided on labels, and where required, handling of gas cylinders
typical risk management and contingency planning techniques for a flour mill.
The range statement relates to the Unit of Competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.
Mill
The term mill is used to refer to the whole mill site including the actual milling equipment, equipment used for associated processes, and transport, warehouse, maintenance, testing and administration facilities.
Mill management and control system
Most flour mills will use a software program and associated hardware to control and manage all or part of a mill. These mill management and control systems can be known by a variety of generic and proprietary names including:
Systems Control and Data Acquisition (SCADA) software
Enterprise Resource Planning (ERP) systems
Materials Resource Planning (MRP) systems
various proprietary names.
Non-standard storage and despatch requirements
Non-standard storage and despatch requirements include:
storage location and time for any products that need ageing before despatch
buffer product requirements for market fluctuations, irregular orders, shutdowns and other non-production periods
contingency product storage requirements.
Site OHS plan and procedures include:
employee training
tagging and lock-out procedures
PPE distribution and use requirements
marking of pedestrian walkways
confined space procedures
visitor registration and allowed/restricted access areas
incident procedures
evacuation assembly areas
first-aid facilities
notification protocols to emergency services
training and registration of fire and first aid wardens.
Pest control methods may include:
fumigation
application of insecticides, dusts, gas and/or baits (using registered controlled and generally available substances).
Where use of pesticides include work conditions covered by SafeWork Australia and/or State and Territory health and safety authorities, the assessment criteria and methods prescribed by these authorities must also be met.
Fire protection plan and fire protection facilities include:
location and type of extinguishers
suppression systems
alarms
appointment of wardens
evacuation areas and procedures
notification and liaison procedures for emergency services.
Contractors
Contractors used will vary according to each mill and may include contractors for:
maintenance
transport
testing and accreditation services
labour supply
security.
Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.
Observation Checklist
Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice
Yes
No
Comments/feedback
Ensure incorporation of grain and other materials receiving locations.
Ensure incorporation of all grain, flour and by-product storage facilities.
Review mill flow diagram for inclusion of all break and reduction system equipment and intermediate storage facilities.
Ensure incorporation of all administration, maintenance, utilities and storage areas.
Identify directly milled and blended flour products in product flow diagrams and relate to storage and despatch facilities.
Review facilities and set operating procedures for grain receival.
Ensure operators have required training and test materials for testing grain.
Ensure storage availability for received grain including any divisions.
Determine intermediate storage requirements based on forward production schedule.
Establish product handling, storage and despatch procedures for just-in-time customers.
Establish product handling, storage and despatch procedures for daily, weekly or other regular deliveries.
Identify any non–standard storage and despatch requirements.
Establish and supervise inspection and cleaning regime for bins and silos.
Establish and supervise temperature and moisture testing for storage bins and silos.
Integrate warehouse control and information requirements with mill management and control system.
Ensure customer orders are passed as soon as possible after receipt to production, storage, and transport departments.
Establish bin stock measuring frequency and method.
Set and monitor weighbridge operation and recording procedures for all bulk inward and outward grain and mill products.
Identify locations for automatic and manual recording of internal product transfers.
Establish authorisation and access procedures for use of additives and adjuncts.
Supervise internal transfer of flour to holding bins.
Determine if volumetric, on-line or batch blending is to be used.
Determine formula for required blend including any required additives and adjuncts.
Specify flours to be used to most economically achieve required formula.
Supervise blending operation including data entry into batch or process control computer.
Supervise transfer of blended flour to packing, despatch or storage.
Set and monitor "give away" margin above minimum weight in packed flour.
Supervise operation of bag and sack packing, closing equipment.
Determine where required if enterprise or contract vehicles are to be used.
Supervise bag, sack and bulk flour despatch as appropriate.
Supervise packing and despatch of by-products including palletisation of wheatfeed where required.
Establish or review perimeter security.
Establish site access control point for all vehicle and pedestrian traffic.
Review adequacy of truck holding and turnaround facilities.
Establish or review site OHS plan and procedures.
Ensure personal protective equipment (PPE), pedestrian walkways, and other pedestrian safety procedures are known and followed.
Review fire protection plan and fire protection facilities including location and type of extinguishers, suppression systems and alarms.
Review visitor reception, registration and escort protocols for visitor access to non-administration areas.
Establish compliance procedures for environmental, food safety and other regulatory requirements.
Review equipment and storage cleaning schedule and procedures for dust control effectiveness.
Arrange regular inspections for potential ignition sources.
Review current dust control and dust explosion relief equipment and arrange for any required maintenance or additional dust control/dust explosion relief equipment.
Establish training in dust control procedures for all employees and contractors.
Review site pest control plan.
Ensure all employees are trained to identify signs of insect, rodent and bird infestation.
Establish inspection, sampling and testing regime for all equipment, storage areas and all inward and outward goods.
Determine cause and type of infestations.
Specify appropriate control measures for insect.
Supervise protection of employees, community and product during treatments.
Ensure compliance with regulations and environmental guidelines.
Establish pest reporting and treatment recording procedures.
Establish schedule of contractors and their capabilities for services not performed in–house.
Establish procedures and delegations for engaging contractors.
Establish site access register for contractors.
Ensure contractors are briefed on all mill regulatory and commercial requirements.
Forms
Assessment Cover Sheet
FDFGR4003A - Manage mill logistics and support services
Assessment task 1: [title]
Student name:
Student ID:
I declare that the assessment tasks submitted for this unit are my own work.
Student signature:
Result: Competent Not yet competent
Feedback to student
Assessor name:
Signature:
Date:
Assessment Record Sheet
FDFGR4003A - Manage mill logistics and support services
Student name:
Student ID:
Assessment task 1: [title] Result: Competent Not yet competent
(add lines for each task)
Feedback to student:
Overall assessment result: Competent Not yet competent