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 troubleshooting and rectifying finishing and converting operations

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 finishing and converting operations

Access to the full range of equipment involved in integrated continuous manufacturing of finishing and converting operations 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

This describes the skills and knowledge required for this unit.

Required skills

Identifies, accesses and interprets relevant historical and operational data and information

Uses required forms of communication in troubleshooting and rectifying finishing and converting systems

Reads and interprets required documentation, procedures and reports

Operates communications equipment

Interprets instruments, gauges and data recording equipment

Interprets troubleshooting guides, operational data, trend analysis and test results

Accesses, navigates and enters computer-based information

Communicates effectively with personnel to assist with analysis and resolution of operational problems

Assists others to identify and resolve operational problems in the workplace

Identifies and actions systems, quality and equipment faults within level of responsibility

Identifies causes and effects of faults and corrective action on associated processes

Selects and uses appropriate troubleshooting methods

Takes timely corrective action to maximise safety, quality and productivity

Undertakes necessary calculations to aid troubleshooting as required

Identifies and monitors process control points

Maintains situational awareness in the work area

Implements isolation and lockout procedures as required

Operates required measuring and testing devices

Perform tests and interprets and record results if required

Operates high risk (and non-high risk) load shifting equipment as required

Analyses and uses sensory information to adjust process to maximise 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 finishing and converting system operation including OHS, environmental including relevant sustainability requirements/practices, SOP, isolation procedures, safe working requirements, risks and hazard identification and housekeeping

Relevant forms of communication

Detailed knowledge of finishing and converting system, processes and associated services sufficient to troubleshoot including:

plant layout

theory of operation

causes and effects of adjustments made to finishing and converting plant and processes

relationships between finishing and converting system, processes and associated services

An appropriate range of troubleshooting methods

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

Operator level maintenance requirements

Application of high risk (and non-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 finishing and converting systems 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

Finishing and converting processes may include:

winding and re-winding

decorating

lotionising

calendering

water marking

perforating

slitting and cutting

embossing

laminating

folding

printing

bonding

core making

wrapping and packing

Materials and supplies may include:

parent roll or reel

lotion

shrink and stretch wraps

pallets

sheet paper

labelling and stencilling

wrap paper

customer rolls

boxes

polythene wrap

glues

cartons

strapping

printing inks

shippers

reams

signs and labels

core board

scent

rolls

Equipment and systems may include:

separate servo controlled motors and drives

electronic sensors and proximity system

light curtains

category three plus guarding

program formatting

programmable production configurations

pre-set

modifiable

quick change parts e.g. snap lock

reels and winding equipment

wrapping and packing equipment

guillotine, knives and cutting equipment

conveying systems

materials handling equipment

flexographic printing equipment used for decorating

overhead cranes

testing and measuring equipment

roll grab attachments

warehousing equipment

warehousing control systems

electronic, pneumatic and hydraulic process controls

computer systems

electronic screens and alarms

process control systems

analogue and digital instruments

fully automated, semi-automated, manually operated plant and equipment appropriate to finishing and converting operations

Auxiliary systems may include:

air

lubrication

vacuum

dust extraction system

Electronic control systems may include:

portable control device

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 (and non-high risk) load shifting licensing requirements

Documentation, procedures and reports may include:

SOP

enterprise policies, procedures and guidelines

environmental sustainability requirements/practices

plant manufacturing operating manuals

production schedules

production plans

production specifications

quality certification e.g. ISO

quality procedures

oil or chemical spills and disposal guidelines

plant isolation documentation

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

reference documents on theory of operation of processes and systems

vendor manuals

checklists

Material Safety Data Sheets (MSDS)

Maintenance may include:

operator level maintenance as per site agreement

operator maintenance schedules

maintenance supplies

maintenance systems

maintenance suppliers

pro-active maintenance strategies e.g. Total Productive Maintenance (TPM), Reliability Centred Maintenance (RCM)

Quality checks and tests may include:

roll density

core slippage

damaged packaging

reel hardness

core size

colour matching

bulk

core strength

sheet size

roll appearance

print quality

cut quality

MD&CD tensiles

core scenting

packaged product

stretch

roll size

perforations

product identification

warehousing records

Required action in the event of a missing or faulty component may include:

operator level maintenance

involvement of maintenance personnel

replacement of component

communication with appropriate personnel

Actions may include:

process adjustments

reporting to authorised person

rectifying problem within level of responsibility

Communications may include

interaction with:

warehousing personnel

internal/external customers and suppliers

maintenance services

team members

operational management

statutory authorities

Situational awareness may include

awareness of:

traffic

pedestrians

location of equipment

product

hazards

obstruction

unexpected movement

Sensory information may include:

visual

sound

feel

touch

smell

vibration

temperature

Forms of communications may include:

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

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

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

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

signage e.g. safety, access