Assessor Resource

PMAOPS500
Optimise production systems

Assessment tool

Version 1.0
Issue Date: May 2024


This unit of competency covers the skills and knowledge required to analyse and optimise complex operating production systems. It applies to discrete projects which aim to resolve identified production problems, such as a need for improved quality, reduced variability, higher yields, less waste or better control.

This unit of competency is applicable to the optimisation of an entire plant, or for large sites, an entire process system within the site.

This unit of competency applies to senior technicians or those in similar roles who are required to apply in-depth knowledge of process and plant operations and problem solving in order to gather historical plant operating or product quality data, review the data for trends or dependencies, investigate cause and effect responses, develop a solution/improvement and take action to ensure that the improvement is implemented and effective.

No licensing, legislative or certification requirements apply to this unit at the time of publication.

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



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.

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Identify process or system for review

1.1

Review process or plant performance to determine likely areas of improvement

1.2

Gather data on the process or system design

1.3

Design the data collection system for the required data

2

Collect and analyse data

2.1

Collect or review available data from the process or plant

2.2

Analyse the data for trends or dependencies

2.3

Postulate possible cause and effect scenarios

3

Develop tests or trials

3.1

Propose controlled tests or trials to review the plant or process patterns

3.2

Discuss possible solutions to cause with relevant people

3.3

Arrange for required tests or controls to be undertaken in appropriate timeframe

3.4

Collect further data from tests or trials

3.5

Review plant or process data and compare with original data

3.6

Prepare further tests or trials as required, or until possible solutions are developed

4

Develop improvement solution

4.1

Agree required improvement solution with appropriate people

4.2

Arrange for required improvement solution to be undertaken in appropriate timeframe

4.3

Follow items initiated through until final resolution has occurred

4.4

Check effectiveness of solution and take action

4.5

Complete reports to procedure

Evidence required to demonstrate competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria, and include the ability to:

analyse and interpret schematics, technical information, performance data and operational practices

design and apply data collection system

apply problem isolation and problem-solving techniques to multi-variable processes

develop solutions/improvements

evaluate effectiveness of solutions/improvements

communicate and negotiate effectively with internal and external stakeholders

complete written/electronic records

perform complex calculations.

Evidence must be provided that demonstrates knowledge of:

plant equipment, its characteristics and limitations

process chemistry, physics and biochemistry as relevant (e.g. to the extent of writing chemical equations and identifying factors controlling reaction rate and yield or equivalent, or determining mass or heat transfer rates for a process)

problem isolation techniques

problem analysis techniques

systems operating parameters, system integrity limits, product specifications and tolerances

principles of operation of plant/equipment

hierarchy of control

hazards that may arise in the job/work environment, and:

their possible causes

potential consequences

appropriate risk controls.

The unit should be assessed holistically and the judgement of competence based on a holistic assessment of the evidence.

The collection of performance evidence is best done from a report and/or folio of evidence drawn from:

a single project which provides sufficient evidence of the requirements of all the elements and performance criteria

multiple smaller projects which together provide sufficient evidence of the requirements of all the elements and performance criteria.

A third-party report, or similar, may be needed to testify to the work done by the individual, particularly when the project has been done as part of a project team.

Assessment should use a real project in an operational workplace. Where this is not possible or practical, assessment must occur using a sufficiently rigorous simulated environment reflecting realistic operational workplace conditions. This must cover all aspects of workplace performance, including environment, task skills, task management skills, contingency management skills and job role environment skills.

Knowledge evidence may be collected concurrently with performance evidence or through an independent process, such as workbooks, written assessments or interviews (provided a record is kept).

Assessment processes and techniques must be appropriate to the language, literacy and numeracy requirements of the work being performed and the needs of the candidate.

Conditions for assessment must include access to all tools, equipment, materials and documentation required, including relevant workplace procedures, product and manufacturing specifications associated with this unit.

The regulatory framework will be reflected in workplace policies and procedures and is not required to be independently assessed.

Foundation skills are integral to competent performance of the unit and should not be assessed separately.

Assessors must satisfy the assessor competency requirements that are in place at the time of the assessment as set by the VET regulator.

In addition, the assessor or anyone acting in subject matter expert role in assessment must demonstrate both technical competency and currency. If the assessor cannot demonstrate technical competency and currency they must assess with a subject matter expert who does meet these requirements.

Technical competence can be demonstrated through one or more of:

relevant VET or other qualification/Statement of Attainment

appropriate workplace experience undertaking the type of work being assessed under routine and non-routine conditions

appropriate workplace experience supervising/evaluating the type of work being assessed under routine and non-routine conditions

Currency can be demonstrated through one or more of:

being currently employed undertaking the type of work being assessed

being employed by the organisation undertaking the type of work being assessed and having maintained currency in accordance with that organisation’s policies and procedures

having consulted/had contact with an organisation undertaking the type of work being assessed within the last twelve months, the consultation/contact being related to assessment

conducting on-the-job training/assessments of the type of work being assessed

being an active member of a relevant professional body and participating in activities relevant to the assessment of this type of work.


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.

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Identify process or system for review

1.1

Review process or plant performance to determine likely areas of improvement

1.2

Gather data on the process or system design

1.3

Design the data collection system for the required data

2

Collect and analyse data

2.1

Collect or review available data from the process or plant

2.2

Analyse the data for trends or dependencies

2.3

Postulate possible cause and effect scenarios

3

Develop tests or trials

3.1

Propose controlled tests or trials to review the plant or process patterns

3.2

Discuss possible solutions to cause with relevant people

3.3

Arrange for required tests or controls to be undertaken in appropriate timeframe

3.4

Collect further data from tests or trials

3.5

Review plant or process data and compare with original data

3.6

Prepare further tests or trials as required, or until possible solutions are developed

4

Develop improvement solution

4.1

Agree required improvement solution with appropriate people

4.2

Arrange for required improvement solution to be undertaken in appropriate timeframe

4.3

Follow items initiated through until final resolution has occurred

4.4

Check effectiveness of solution and take action

4.5

Complete reports to procedure

This field allows for different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.

Regulatory framework

The latest version of all legislation, regulations, industry codes of practice and Australian/international standards, or the version specified by the local regulatory authority, must be used, and include one or more of the following:

legislative requirements, including work health and safety (WHS)

industry codes of practice and guidelines

environmental regulations and guidelines

Australian and other standards

licence and certification requirements

All operations to which this unit applies are subject to stringent health, safety and environment (HSE) requirements, which may be imposed through state/territory or federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between performance criteria and HSE requirements, the HSE requirements take precedence.

Hazards

Hazards include one or more of the following:

electricity

gas

gases and liquids under pressure

structural hazards

structural collapse

equipment failures

industrial (machinery, equipment and product)

equipment or product mass

noise, rotational equipment or vibration

plant services (steam, condensate and cooling water)

limited head spaces or overhangs

working at heights, in restricted or confined spaces, or in environments subjected to heat, dusts or vapours

fire and explosion

flammability and explosivity

hazardous products and materials

unauthorised personnel

sharp edges, protrusions or obstructions

slippery surfaces, spills or leaks

extreme weather

other hazards that might arise

Procedures

All operations must be performed in accordance with relevant procedures.

Procedures are written, verbal, visual, computer-based or in some other form, include one or more of the following:

emergency procedures

work instructions

standard operating procedures (SOPs)

safe work method statements (SWMS)

formulas/recipes

batch sheets

temporary instructions

any similar instructions provided for the smooth running of the plant

Evidence required to demonstrate competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria, and include the ability to:

analyse and interpret schematics, technical information, performance data and operational practices

design and apply data collection system

apply problem isolation and problem-solving techniques to multi-variable processes

develop solutions/improvements

evaluate effectiveness of solutions/improvements

communicate and negotiate effectively with internal and external stakeholders

complete written/electronic records

perform complex calculations.

Evidence must be provided that demonstrates knowledge of:

plant equipment, its characteristics and limitations

process chemistry, physics and biochemistry as relevant (e.g. to the extent of writing chemical equations and identifying factors controlling reaction rate and yield or equivalent, or determining mass or heat transfer rates for a process)

problem isolation techniques

problem analysis techniques

systems operating parameters, system integrity limits, product specifications and tolerances

principles of operation of plant/equipment

hierarchy of control

hazards that may arise in the job/work environment, and:

their possible causes

potential consequences

appropriate risk controls.

The unit should be assessed holistically and the judgement of competence based on a holistic assessment of the evidence.

The collection of performance evidence is best done from a report and/or folio of evidence drawn from:

a single project which provides sufficient evidence of the requirements of all the elements and performance criteria

multiple smaller projects which together provide sufficient evidence of the requirements of all the elements and performance criteria.

A third-party report, or similar, may be needed to testify to the work done by the individual, particularly when the project has been done as part of a project team.

Assessment should use a real project in an operational workplace. Where this is not possible or practical, assessment must occur using a sufficiently rigorous simulated environment reflecting realistic operational workplace conditions. This must cover all aspects of workplace performance, including environment, task skills, task management skills, contingency management skills and job role environment skills.

Knowledge evidence may be collected concurrently with performance evidence or through an independent process, such as workbooks, written assessments or interviews (provided a record is kept).

Assessment processes and techniques must be appropriate to the language, literacy and numeracy requirements of the work being performed and the needs of the candidate.

Conditions for assessment must include access to all tools, equipment, materials and documentation required, including relevant workplace procedures, product and manufacturing specifications associated with this unit.

The regulatory framework will be reflected in workplace policies and procedures and is not required to be independently assessed.

Foundation skills are integral to competent performance of the unit and should not be assessed separately.

Assessors must satisfy the assessor competency requirements that are in place at the time of the assessment as set by the VET regulator.

In addition, the assessor or anyone acting in subject matter expert role in assessment must demonstrate both technical competency and currency. If the assessor cannot demonstrate technical competency and currency they must assess with a subject matter expert who does meet these requirements.

Technical competence can be demonstrated through one or more of:

relevant VET or other qualification/Statement of Attainment

appropriate workplace experience undertaking the type of work being assessed under routine and non-routine conditions

appropriate workplace experience supervising/evaluating the type of work being assessed under routine and non-routine conditions

Currency can be demonstrated through one or more of:

being currently employed undertaking the type of work being assessed

being employed by the organisation undertaking the type of work being assessed and having maintained currency in accordance with that organisation’s policies and procedures

having consulted/had contact with an organisation undertaking the type of work being assessed within the last twelve months, the consultation/contact being related to assessment

conducting on-the-job training/assessments of the type of work being assessed

being an active member of a relevant professional body and participating in activities relevant to the assessment of this type of work.

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
Review process or plant performance to determine likely areas of improvement 
Gather data on the process or system design 
Design the data collection system for the required data 
Collect or review available data from the process or plant 
Analyse the data for trends or dependencies 
Postulate possible cause and effect scenarios 
Propose controlled tests or trials to review the plant or process patterns 
Discuss possible solutions to cause with relevant people 
Arrange for required tests or controls to be undertaken in appropriate timeframe 
Collect further data from tests or trials 
Review plant or process data and compare with original data 
Prepare further tests or trials as required, or until possible solutions are developed 
Agree required improvement solution with appropriate people 
Arrange for required improvement solution to be undertaken in appropriate timeframe 
Follow items initiated through until final resolution has occurred 
Check effectiveness of solution and take action 
Complete reports to procedure 

Forms

Assessment Cover Sheet

PMAOPS500 - Optimise production systems
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

PMAOPS500 - Optimise production systems

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: