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:

conduct pre-start checks on machinery used for forming, filling and sealing

start, operate, monitor and adjust process equipment to achieve required quality outcomes

take corrective action in response to typical faults and inconsistencies

complete workplace records as required

apply safe work practices and identify OHS hazards and controls

safely shut down equipment

apply food safety procedures.

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, stock flow systems, production/packaging schedules

information on equipment capacity and operating parameters

specifications, control points and operating parameters

forming, filling and sealing process and related equipment and services

materials and packaging components/consumables to be formed, filled and sealed

product

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. Examples could be:

FDFOP2003A Clean equipment in place

FDFOP2004A Clean and sanitise equipment

FDFOP2011A Conduct routine maintenance

FDFOP2013A Apply sampling procedures

FDFOP2030A Operate a process control interface

MSL973001A Perform basic tests.

Guidance information for assessment

To ensure consistency in one's 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.

Required skills

Ability to:

access workplace information to identify processing requirements

select, fit and use personal protective clothing and/or equipment

confirm supply of necessary packaging components/consumables and product

conduct pre-start checks, such as inspecting equipment condition to identify any signs of wear, selecting appropriate settings and/or related parameters, cancelling isolation or lockouts as required, confirming that equipment is clean and correctly configured for packaging requirements, loading packaging components/consumables, positioning sensors and controls correctly, ensuring any scheduled maintenance has been completed, and confirming that all safety guards are in place and operational

start, operate, monitor and adjust the forming, filling and sealing process equipment to achieve required outcomes, including monitoring control points and conducting inspections as required to confirm process remains within specification, such as:

formation of container/packaging

flow rates

product weights and volumes

fill levels

temperature, including product and sealing temperatures

supply of packaging components/consumables

packaging quality and seal integrity, such as testing packaging integrity

monitor supply and flow of materials to and from the process

take corrective action in response to out-of-specification results

respond to and/or report equipment failure within level of responsibility

locate emergency stop functions on equipment

follow isolation and lock out/tag out procedures as required to take forming, filling and sealing process and related equipment off-line in preparation for cleaning and/or maintenance within level of responsibility

prepare forming, filling and sealing equipment for cleaning

demonstrate product/process changeovers

complete workplace records as required

maintain work area to meet housekeeping standards

use process control systems according to enterprise procedures

demonstrate aseptic container preparation/forming, filling and sealing according to enterprise procedures

collect samples and conduct tests according to enterprise procedures

clean and sanitise equipment according to enterprise procedures

use oral communication skills/language competence to fulfil the job role as specified by the organisation, including questioning, active listening, asking for clarification and seeking advice from supervisor

work cooperatively within a culturally diverse workforce

Required knowledge

Knowledge of:

purpose and basic principles of forming, filling and sealing, including the purpose and characteristics required of packaging materials used, and the methods used to form packaging, fill and seal product (where methods involve vacuum or map packaging, it includes an understanding of the effect of modified atmosphere on product shelf-life)

product and packaging coding requirements and related legal requirements, including product weight

basic operating principles of forming, filling and sealing equipment, such as main equipment components, status and purpose of guards, equipment operating capacities and applications, the purpose and location of sensors and related feedback instrumentation, and services required for operation of form, fill and seal equipment used in the workplace

the flow of processes supplying the forming, filling and sealing process and the effect of process output on downstream processes

quality characteristics and requirements of forming, filling and sealing, such as quality requirements of product and packaging components/consumables, requirements of packaging forming stage, filling, including fill levels and weights, and requirements of seal formation and integrity, and integrity testing procedures, where required

methods used to monitor the process, such as inspecting, measuring and testing as required by the process

inspection or test points (control points) in the process and the related procedures and recording requirements

operating requirements and parameters and corrective action required where operation is outside specified operating parameters, including restart procedures following a crash or jam up

typical equipment faults and related causes, including signs and symptoms of faulty equipment and early warning signs of potential problems

common causes of variation and corrective action required, including the effect of variation in both product characteristics and packaging components/consumables on forming, filling and sealing performance

food safety hazards and risks associated with forming, filling and sealing and related control measures

occupational health and safety (OHS) hazards and controls

requirements of different shutdowns as appropriate to the process and workplace production requirements, including emergency and routine shutdowns and procedures to follow in the event of a power outage

isolation, lock out and tag out procedures and responsibilities

product/packaging changeover procedures

procedures and responsibility for reporting production and performance information

environmental issues and controls relevant to the forming, filling and sealing process, including waste/rework collection and handling procedures related to the process

basic operating principles of process control, where relevant, including the relationship between control panels and systems and the physical equipment

aseptic container preparation/forming, filling and sealing requirements where relevant

sampling and testing procedures where relevant

cleaning and sanitation procedures where relevant

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.

Policies and procedures

Work is carried out according to company policies and procedures, regulatory and licensing requirements, legislative requirements, and industrial awards and agreements

Legislative requirements

Legislative requirements are typically reflected in procedures and specifications. Legislation relevant to this industry includes:

the Food Standards Code, including labelling, weights and measures legislation

legislation covering food safety, environmental management, OHS, anti-discrimination and equal opportunity

When applied to the pharmaceutical industry, relevant Good Manufacturing Practice (GMP) codes apply in place of the Australian Food Standards Code and reference to food safety is replaced by GMP

Workplace information

Workplace information may include:

standard operating procedures (SOPs)

specifications

production schedules and instructions

manufacturers' advice

standard forms and reports

Forming, filling and sealing equipment

Forming, filling and sealing equipment may include:

pumps

gable top fillers

film fillers

hermetic sealers

bulk bag fillers

aseptic packaging

aseptic plastic pouches

aseptic carton systems

aseptic form, fill and seal equipment

aseptic bottle fillers/cappers

bag-in-box filler

bag forming and filling machines

Typical containers formed by this process

Typical containers formed by this process include:

cartons

pouches

boxes

bags

Where bottles are formed as part of this process, also refer to PMBPROD211B Operate blow moulding equipment and PMBPROD270B Operate injection blow moulding equipment

Packaging

Packaging may include:

vacuum packing

modified atmosphere packaging (MAP)

Operation of equipment and processes

Operation of equipment and processes may require:

the use of process control panels and systems

Shutdown procedures

Shutdown procedures may include:

cleaning (in some cases cleaning may be carried out by a dedicated cleaning crew)

Services

Services are appropriate to the process to be operated. Typical examples include:

power

steam

water

vacuum

inert gas (where gas flushing is used)

compressed and instrumentation air