Assessor Resource

FPPCPP320A
Prepare and start up coated paper processes

Assessment tool

Version 1.0
Issue Date: March 2024


This unit applies to operators who prepare and start up coated paper processes in the pulp and paper industry. This work typically involves complex integrated equipment and continuous operations

This unit generally applies to those who:

determine production requirements

inspect and prepare systems for startup

co-ordinate startup operations, and

establish and stabilise production and quality processes

to meet safety, quality and productivity requirements

It does not include monitoring and controlling, shutting down or troubleshooting and rectifying coated paper processes

This unit describes the outcomes required to prepare and start up coated paper processes in the pulp and paper industry

General legislation, regulatory, licensing and certification requirements applicable to this unit are detailed in the range statement

Specific high risk licensing requirements for this unit may be applicable and are to be met separately and prior to the achievement of this unit

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

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

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Evidence should be relevant to the work. It should satisfy the requirements of the elements and performance criteria and include consideration of:

the required knowledge and skills tailored to the needs of the specific workplace

applicable OHS regulations, environmental and safe working requirements/practices, SOP and housekeeping requirements

applicable aspects of the range statement

practical workplace demonstration of skills in preparing and starting up coated paper processes

Context of and specific resources for assessment

A workplace assessment must be used to assess:

the application of required knowledge on the job

the application of skills on the job, over time and under a range of typical conditions that may be experienced in coated paper processes

Access to the full range of equipment involved in integrated continuous manufacturing of coated paper processes in a pulp or paper mill is required

Method of assessment

A combination of assessment methods should be used. The following examples are appropriate for this unit:

observation of applied skills and knowledge on the job

workplace demonstrations via a mock-up or simulation that replicate part/s of the job

answers to written or verbal questions about specific skills and knowledge

third-party reports from relevant and skilled personnel

written evidence e.g. log sheet entries, checklist entries, test results

Assessment processes and techniques must be culturally appropriate and in keeping with the language and literacy capacity of the learner and the work being performed. This includes conducting an assessment in a manner that allows thoughts to be conveyed verbally so that the learner can both understand and be understood by the assessor (e.g. use plain English and terminology used on the job)

A holistic assessment with other units relevant to the pulp and paper industry, mill and job role is recommended

Additional information on approaches to assessment for the pulp and paper industry is provided in the Assessment Guidelines for this Training Package


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.

This describes the skills and knowledge required for this unit.

Required skills

Uses required forms of communication in preparing and starting up coated paper processes

Communicates operational requirements clearly to relevant personnel

Reads and interprets required documentation, procedures and reports

Prepares written information and data to support groups and teams

Accesses, navigates and enters computer-based information

Monitors, analyses and interprets data

Interprets instruments, gauges and data recording equipment

Interprets control systems and display monitors in accordance with SOP and other specifications

Responds to control systems and display alarms in accordance with SOP

Confirms production ready status with team members and relevant personnel

Identifies and actions problems within level of responsibility

Responds to faults of process flow-through systems if required

Responds to faults of plant if required

Identifies and monitors process control points

Maintains situational awareness in the work area

Takes samples, conducts tests and interprets and records results if required

Uses measuring equipment as required

Calculates performance measures

Determines coating production requirements (e.g. sheet, coating chemicals)

Conducts checks to ensure availability of sheet, coating chemicals and electrical power

Conducts checks to ensure space availability for coated sheet where applicable

Ensures isolations are removed according to SOP

Conducts pre-startup checks of plant and equipment including instrumentation

Inputs operational settings (e.g. set points) in preparation for startup in accordance with SOP

Activates and confirms operation of coating system according to SOP

Operates high risk load shifting equipment as required

Makes process control adjustments to stabilise production and obtain product quality

Conducts routine maintenance checks

Analyses and uses sensory information to adjust process to maintain and co-ordinate safety, quality and productivity

Uses electronic and other control systems to control equipment and processes as required

Required knowledge

Procedures, regulations and legislative requirements relevant to coated paper processes including OHS, environmental including relevant sustainability requirements/practices, SOP, isolation procedures, safe working requirements, risks and hazard identification and housekeeping

Relevant forms of communication

Information provided on the production specification sheet

Navigation of computer control system displays

Relationships within the coating area members and with the area's suppliers and customers

Basic problem-solving techniques consistent with level of responsibility

Cause and effect of operational equipment faults

Working knowledge of coated paper processes, system layout and associated services sufficient to carry out startup activities within level of responsibility

Sampling and testing process for plant and system operations and process monitoring - purpose, standards and procedures as per site agreements

Purpose of each of the steps in the preparation of the coating system for production

Purpose of each component of the coating system

Purpose and location of the coating chemical supply system

Critical control points of the preparation for startup procedure

Purpose of the process controls and how changes affect the production variables

Critical control points of the startup procedure

Critical control points of the monitoring process during startup

Awareness of high risk load shifting equipment, as required

Sensory information that indicates a deviation from standard operating parameters

Sufficient knowledge of electronic and other control systems, operation and application to make appropriate adjustments that control coated paper processes, within level of responsibility

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.

Productivity requirements may include:

energy efficiency

waste minimisation

evaporation minimisation, including landfill and waste water reduction

environmentally safe waste disposal

consideration of resource utilisation, including fibre efficiency

minimising delays

chemical recovery maximisation

meeting key performance indicators

line speed

handovers

quality checks

meeting output targets i.e. net tonnes per employee per annum

machine/process time availability i.e. time the machine or process is making product

machine/process production rate

Coated paper processes may include:

tail feed systems

chemical and material batching

laminating and coating

splicing

clay plant operation

calender

pre-reeler operations

super calendering

monitoring systems

rewindering

drying systems

internal unloading

combine rollers

testing

Materials and supplies may include:

chemicals and polymers

power

water

additives

steam

labels

felts

equipment

gas

accessories (parts)

air

base paper

Equipment may include:

coater

splicer

pre-reelers

crimpers

calender

super-calender

parent rolls and reels

cranes

pigment

coating makedown plant

starch cooker

slitter

computer systems

electronic screens and alarms

process control systems

analogue and digital instrumentation

fully, automated, semi-automated, manually operated plant and equipment appropriate to the coated paper process

Electronic control systems may include:

Digital Control System (DCS)

touch screens

robotics

Legislation, regulatory, licensing and certification requirements may include:

OHS and environmental requirements (local, state and commonwealth)

activity or task specific high risk licensing requirements

Documentation, procedures and reports may include:

SOP

quality procedures

environmental sustainability requirements/practices

plant manufacturing operating manuals

enterprise policies and procedures

Material Safety Data Sheets (MSDS)

oil or chemical spills and disposal guidelines

plant isolation documentation

safe work documentation e.g. plant clearance, job safety analysis, permit systems

product specifications and schedules

maintenance logs

job sheets

site agreements

safety instructions

process and instrument diagrams

machine manuals

troubleshooting guides

incidents reports

Maintenance may include:

operator level maintenance as per site agreements

operator maintenance schedules

maintenance systems

maintenance suppliers

proactive maintenance strategies e.g. Total Productive Maintenance (TPM), Reliability Centred Maintenance (RCM)

Actions may include:

process adjustments

reporting to authorised person

rectifying problem within level of responsibility

Communications may include

interaction with:

internal/external customers and suppliers

team members

production/service co-ordinators

maintenance services

operator support personnel

operational management

statutory authorities

Situational awareness may include

awareness of:

traffic

pedestrians

location of equipment

product

hazards

obstruction

unexpected movement

Forms of communication may include:

written e.g. log books, emails, incident and other reports, run sheets, data entry

reading and interpreting documentation e.g. SOP, manuals, checklists, drawings

verbal e.g. radio skills, telephone, face to face, handover

non-verbal e.g. hand signals, alarms, observations

signage e.g. safety, access

Sensory information may include:

visual

sound

feel

touch

smell

vibration

temperature

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
Production requirements are determined within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements 
Production plan is interpreted 
Grade specifications and limits are confirmed and communicated to relevant personnel 
Process requirements are determined 
Process supplies are confirmed available for production 
Chemical and material requirements are determined 
Systems are inspected and prepared for startup within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 
Isolations (if any) are removed 
Pre-startup checks on equipment (e.g. coater and supply systems) are completed 
Electrical power and process supplies are confirmed as available for production 
Chemical/material delivery system is prepared for operation 
Operational settings are made and confirmed within specification 
Production ready status is confirmed with relevant personnel 
Monitoring devices/systems are checked and confirmed operational 
Faults are identified and rectified as required 
Startup operations are co-ordinated within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 
Equipment startups are co-ordinated for production 
System functions are co-ordinated and confirmed by monitoring plant, equipment and control system/display monitors 
Process operation status is communicated to relevant personnel 
Production startup details are logged, recorded or filed 
Production and quality processes are established and stabilised within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 
Processes are monitored and adjusted to rectify variations from specification 
Adjustments/modifications are made to stabilise coating quality within specification 
Samples are taken as required to ensure product quality requirements are met 
Product tests are verified as within specification, where applicable 
Process operation, production and quality data is recorded as required 

Forms

Assessment Cover Sheet

FPPCPP320A - Prepare and start up coated paper processes
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Assessment Record Sheet

FPPCPP320A - Prepare and start up coated paper processes

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Assessment task 1: [title] Result: Competent Not yet competent

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