Assessor Resource

FDFZPKPP2A
Operate a packaging process

Assessment tool

Version 1.0
Issue Date: May 2024


Not applicable.

This is a Specialist unit. It covers the skills and knowledge required to set up, operate, adjust and shut down a packaging process or sub-system. This unit is generic and should be customised for a given process. It should only be selected where no specific packaging unit is available.

This is a Specialist unit. It covers the skills and knowledge required to set up, operate, adjust and shut down a packaging process or sub-system. This unit is generic and should be customised for a given process. It should only be selected where no specific packaging unit is available

You may want to include more information here about the target group and the purpose of the assessments (eg formative, summative, recognition)

Prerequisites

Not applicable.

Employability Skills

Not applicable.



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 assessment process must address all of the following items of evidence.

Ability to:

1. Access workplace information to identify packaging requirements

2. Select, fit and use personal protective clothing and/or equipment

3. Confirm supply of necessary packaging components/consumables, materials and services

4. Conduct pre-start checks. This may involve inspecting equipment condition to identify any signs of wear, setting coders and printers, selecting appropriate equipment settings and/or related parameters, cancelling isolation or lockouts as required, confirming that equipment is clean, correctly configured for packaging requirements, sensors and controls are correctly positioned, any scheduled maintenance has been completed, and all safety guards are in place and operational

5. Start, operate, monitor and adjust packaging equipment to achieve required outcomes. This may include loading packaging components/consumables and/or product, monitoring control points such as weights, codes, placement, glue temperatures, alignment and appearance, configuration and seal integrity as required to confirm process remains within specification

6. Monitor supply and flow of materials to and from the process

7. Take corrective action in response to out-of-specification results

8. Respond to and/or report equipment failure within level of responsibility

9. Locate emergency stop functions on equipment

10. Follow isolation and lock out/tag out procedures as required to take packaging equipment off line in preparation for cleaning and/or maintenance within level of responsibility

11. Demonstrate batch/process changeovers

12. Complete workplace records as required

13. Maintain work area to meet housekeeping standards

May include ability to:

14. Use process control systems

15. Integrity testing of packaging

16. Carry out routine maintenance

17. Clean and sanitize equipment

Knowledge of:

18. Purpose and basic principles of the packaging process. This includes an understanding of the purpose and characteristics required of packaging materials used the principles of the packaging process used. Where methods involve vacuum or MAP packaging, it includes an understanding of the effect of modified atmosphere on product shelf life

19. Product and packaging coding requirements and related legal requirements including product weight

20. Basic operating principles of equipment. This may include an operational understanding of main equipment components, status and purpose of guards, equipment operating capacities and applications and the purpose and location of sensors and related feedback instrumentation. It also includes knowledge of services required and action to take if services are not available

21. The flow of processes supplying the packaging process and the effect of outputs on downstream processes

22. Quality characteristics required of the packaging process. This may include an understanding of the seal integrity requirements

23. Effect of variation in inputs which may include packaging components/consumables, materials and/or services, on process performance

24. Operating requirements and parameters and corrective action required where operation is outside specified operating parameters. This includes an understanding of restart procedures following a crash or jam up

25. Typical equipment faults and related causes. This includes recognition of signs and symptoms of faulty equipment and early warning signs of potential problems

26. Methods used to monitor the packaging process. This may include visual inspecting, measuring and testing as required by the process. It requires awareness of inspection or test points (control points) in the process and the related procedures and recording requirements

27. Contamination/food safety risks related to stages in the packaging process and related control measures

28. Common causes of variation and corrective action required

29. OHS hazards and controls

30. Requirements of different shut downs as appropriate to the packaging process. This includes emergency and routine shutdowns and procedures to follow in the event of a power outage. This may involve conducting basic equipment referencing

31. Product/packaging changeover procedures and responsibilities

32. Isolation, lock out and tag out procedures and responsibilities

33. Procedures and responsibility for reporting production and performance information

34. Environmental issues and controls relevant to the process. This includes waste/rework collection and handling procedures related to the process

May include knowledge of:

35. Basic operating principles of process control where relevant. This includes the relationship between control panels and systems and the physical equipment

36. Routine maintenance procedures

37. Packaging integrity testing

38. Cleaning and sanitation procedures

The assessment process must address all of the following items of evidence.

Ability to:

1. Access workplace information to identify packaging requirements

2. Select, fit and use personal protective clothing and/or equipment

3. Confirm supply of necessary packaging components/consumables, materials and services

4. Conduct pre-start checks. This may involve inspecting equipment condition to identify any signs of wear, setting coders and printers, selecting appropriate equipment settings and/or related parameters, cancelling isolation or lockouts as required, confirming that equipment is clean, correctly configured for packaging requirements, sensors and controls are correctly positioned, any scheduled maintenance has been completed, and all safety guards are in place and operational

5. Start, operate, monitor and adjust packaging equipment to achieve required outcomes. This may include loading packaging components/consumables and/or product, monitoring control points such as weights, codes, placement, glue temperatures, alignment and appearance, configuration and seal integrity as required to confirm process remains within specification

6. Monitor supply and flow of materials to and from the process

7. Take corrective action in response to out-of-specification results

8. Respond to and/or report equipment failure within level of responsibility

9. Locate emergency stop functions on equipment

10. Follow isolation and lock out/tag out procedures as required to take packaging equipment off line in preparation for cleaning and/or maintenance within level of responsibility

11. Demonstrate batch/process changeovers

12. Complete workplace records as required

13. Maintain work area to meet housekeeping standards

May include ability to:

14. Use process control systems

15. Integrity testing of packaging

16. Carry out routine maintenance

17. Clean and sanitize equipment

Knowledge of:

18. Purpose and basic principles of the packaging process. This includes an understanding of the purpose and characteristics required of packaging materials used the principles of the packaging process used. Where methods involve vacuum or MAP packaging, it includes an understanding of the effect of modified atmosphere on product shelf life

19. Product and packaging coding requirements and related legal requirements including product weight

20. Basic operating principles of equipment. This may include an operational understanding of main equipment components, status and purpose of guards, equipment operating capacities and applications and the purpose and location of sensors and related feedback instrumentation. It also includes knowledge of services required and action to take if services are not available

21. The flow of processes supplying the packaging process and the effect of outputs on downstream processes

22. Quality characteristics required of the packaging process. This may include an understanding of the seal integrity requirements

23. Effect of variation in inputs which may include packaging components/consumables, materials and/or services, on process performance

24. Operating requirements and parameters and corrective action required where operation is outside specified operating parameters. This includes an understanding of restart procedures following a crash or jam up

25. Typical equipment faults and related causes. This includes recognition of signs and symptoms of faulty equipment and early warning signs of potential problems

26. Methods used to monitor the packaging process. This may include visual inspecting, measuring and testing as required by the process. It requires awareness of inspection or test points (control points) in the process and the related procedures and recording requirements

27. Contamination/food safety risks related to stages in the packaging process and related control measures

28. Common causes of variation and corrective action required

29. OHS hazards and controls

30. Requirements of different shut downs as appropriate to the packaging process. This includes emergency and routine shutdowns and procedures to follow in the event of a power outage. This may involve conducting basic equipment referencing

31. Product/packaging changeover procedures and responsibilities

32. Isolation, lock out and tag out procedures and responsibilities

33. Procedures and responsibility for reporting production and performance information

34. Environmental issues and controls relevant to the process. This includes waste/rework collection and handling procedures related to the process

May include knowledge of:

35. Basic operating principles of process control where relevant. This includes the relationship between control panels and systems and the physical equipment

36. Routine maintenance procedures

37. Packaging integrity testing

38. Cleaning and sanitation procedures

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.

Not applicable.

The range statement indicates the context for demonstrating competence. This statement is a guide and unless otherwise indicated, items may or may not apply as required by the work context.

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

- Legislative requirements are typically reflected in procedures and specifications. Legislation relevant to this industry includes labelling, weights and measures legislation and legislation covering food safety, environmental management, occupational health and safety, anti-discrimination and equal opportunity. When applied to the pharmaceutical industry, relevant GMP codes apply in place of the Australian Food Standards Code and reference to food safety is replaced by GMP

- Workplace information may include Standard Operating Procedures (SOPs), specifications, production schedules and instructions, manufacturers' advice, standard forms and reports

- A packaging process may relate to primary and/or secondary packaging activities. It typically requires the operation of a series of related items of equipment to achieve the required outcome. Where a single item of packaging equipment is operated, refer to the unit FDFZPRBE1A Operate basic equipment

- Typical equipment that may form a packaging sub-system includes conveyor systems, filling, sealing, wrapping, thermo-form equipment, case packers, bundlers, ink jet coders, labellers, palletisers, shrink wrappers and strappers

- Packaging may include vacuum packing and Modified Atmosphere Packaging (MAP)

- Operators carry out changeovers within workplace arrangements and the relevant changeover procedures should be used to customise the details of this unit. Where more detailed changeovers are carried out, also refer to FDFOPTCRM2 A Conduct routine maintenance

- Shut down procedures may include cleaning. In some cases cleaning may be carried out by a dedicated cleaning crew

- Operation of equipment and processes may require the use of process control panels and systems

The range statement indicates the context for demonstrating competence. This statement is a guide and unless otherwise indicated, items may or may not apply as required by the work context.

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

- Legislative requirements are typically reflected in procedures and specifications. Legislation relevant to this industry includes labelling, weights and measures legislation and legislation covering food safety, environmental management, occupational health and safety, anti-discrimination and equal opportunity. When applied to the pharmaceutical industry, relevant GMP codes apply in place of the Australian Food Standards Code and reference to food safety is replaced by GMP

- Workplace information may include Standard Operating Procedures (SOPs), specifications, production schedules and instructions, manufacturers' advice, standard forms and reports

- A packaging process may relate to primary and/or secondary packaging activities. It typically requires the operation of a series of related items of equipment to achieve the required outcome. Where a single item of packaging equipment is operated, refer to the unit FDFZPRBE1A Operate basic equipment

- Typical equipment that may form a packaging sub-system includes conveyor systems, filling, sealing, wrapping, thermo-form equipment, case packers, bundlers, ink jet coders, labellers, palletisers, shrink wrappers and strappers

- Packaging may include vacuum packing and Modified Atmosphere Packaging (MAP)

- Operators carry out changeovers within workplace arrangements and the relevant changeover procedures should be used to customise the details of this unit. Where more detailed changeovers are carried out, also refer to FDFOPTCRM2 A Conduct routine maintenance

- Shut down procedures may include cleaning. In some cases cleaning may be carried out by a dedicated cleaning crew

- Operation of equipment and processes may require the use of process control panels and systems
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
Packaging components/consumables, materialsand items to be packaged are confirmed and available to meetoperating requirements 
Cleaning and maintenance requirements andstatus are identified and confirmed 
Machine components and related attachments arefitted and adjusted to meet operating requirements 
Operating parameters are entered as requiredto meet safety and production requirements 
Materials, product and packagingcomponents/consumables are loaded or positioned as required to meetpackaging requirements 
Equipment performance is checked and adjustedas required 
Pre-start checks are carried out as requiredby workplace requirements 
The process is started and operated accordingto workplace procedures 
Equipment is monitored to identify variationin operating conditions 
Variation in equipment operation is identifiedand maintenance requirements are reported according to workplacereporting requirements 
The process is monitored to confirm thatspecifications are met 
Out-of-specification process outcomes areidentified, rectified and/or reported to maintain the processwithin specification 
The workplace meets housekeeping standards 
Workplace records are maintained according toworkplace recording requirements 
The appropriate shutdown procedure isidentified 
The process is shut down according toworkplace procedures 
Maintenance requirements are identified andreported according to workplace reporting requirements 

Forms

Assessment Cover Sheet

FDFZPKPP2A - Operate a packaging process
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

FDFZPKPP2A - Operate a packaging process

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

Assessor name:

Signature:

Date:

Student signature:

Date: