Assessor Resource

PMC552040C
Operate glass melting process

Assessment tool

Version 1.0
Issue Date: March 2024


This unit of competency applies to operators who are responsible for operating primary melting furnaces used in glass production or the forming of glass products directly from a melting furnace.

This unit does NOT apply to the operation of furnaces used for reheating glass product, which is covered by PMC552041C Operate process ovens.

This competency is typically performed by operators working either independently or as part of a work team. At all times they would be liaising with other members of the team.

This unit of competency covers the operation of primary melting furnaces. It involves preparing and operating glass melting equipment, monitoring process operations and making necessary adjustments, identifying and solving routine problems and undertaking minor maintenance on equipment.

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

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

The unit will be assessed in as holistic a manner as is practical and may be integrated with the assessment of other relevant units of competency.

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

It is essential that the melting equipment be understood and that the importance of critical material properties, settings and readings is known.

Competence must be demonstrated in the ability to recognise and analyse potential situations requiring action and then in implementing appropriate corrective action.

Consistent performance should be demonstrated. In particular look to see that:

importance of critical material properties, settings and readings is identified

process and equipment are operated in accordance with work instructions and process parameters

temperatures are maintained within limits

melt quality is monitored to minimise wastage

start up and shut down occur first time

change in utilities (gas/power/diesel) is responded to immediately

signals and alarms are responded to immediately

process measurements and tests are continually made, observed and interpreted

melt quality is maintained to customer specifications.

Competence must be demonstrated in the operation of all ancillary equipment to the level required for this unit of competency.

Context of and specific resources for assessment

Assessment will require access to an operating plant over an extended period of time, or a suitable method of gathering evidence of operating ability over a range of situations.

Assessment will occur over a range of situations which will include disruptions to normal, smooth operation.

Simulation or case studies/scenarios may be required to allow for timely assessment of parts of this unit of competency. Simulation should be based on the actual plant and will include 'walk-throughs' of the relevant competency components. A bank of scenarios/case studies/what ifs and questions will be required to probe the reasoning behind observable actions.

Method of assessment

In all plants it may be appropriate to assess this unit concurrently with relevant teamwork and communication units.

It may be appropriate to assess this unit concurrently with:

MSAPMSUP292A Sample and test materials and product.

Guidance information for assessment

Assessment processes and techniques must be culturally appropriate and appropriate to the language and literacy capacity of the candidate and the work being performed.


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.

Required skills

Required skills include

recognising process conditions which will lead to out of specification production and taking appropriate action

implementing the enterprise's standard procedures and work instructions and relevant regulatory requirements within appropriate time constraints and in a manner relevant to the operation of the melting equipment

reading and numeracy to interpret workplace documents and technical information

Required knowledge

Required knowledge includes:

composition and nature of the glass

startup and shutdown processes

construction and limitations of the melting equipment and conditions

combustion fundamentals

out of specification situations

physics and chemistry (where appropriate) of process

principles of operation of process

control philosophy of process

distinguish between causes of faults such as:

raw material

mechanical

electrical/instrument

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.

Procedures

All operations are performed in accordance with standard procedures and work instructions

Melting equipment

This unit includes melting equipment applicable to each of the specific areas of glass products manufacture. These may include:

flat glass

insulation, glass wool insulation, laminated blankets, roll and boards

fibreglass and glass filaments

packaging, bottles and jars

Tools and equipment

Tools and equipment may include:

furnaces and associated equipment

gas stations

computers

measuring and recording equipment

communication equipment

hand tools

safety clothing and equipment

Process and products

Process and products include:

melting, refining and conditioning of raw material, including frit and other recycled glass materials, to produce glass for forming processes

It does NOT include processes involved with:

scientific glass

secondary processes

the softening of already made glass

Plant data

Plant data includes:

test results

instrument/control panel information

data from physical senses (sight, sound and hearing)

temperatures, pressures, material flow and discharge rates and effects

variations to chemical reactions/material modifications

Typical problems

Typical problems may include:

raw materials feed

alternative fuel sources

analysis of all plant data including test results, control instrument data and other observations

control of furnace temperature within specifications

surveillance of melt quality

taking corrective action

Occupational health and safety (OHS)

All operations are subject to stringent OHS requirements and these must not be compromised at any time. Where there is an apparent conflict between performance criteria and OHS requirements, the OHS requirements take precedence.

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
Establish production program and melting guidelines from the job specifications/work instructions 
Conduct furnace pre-startup procedure according to enterprise procedure checklist 
Ensure furnace startup function complies with standard operating procedures 
Ensure glass melting equipment is operated in accordance with established enterprise procedures 
Make sure furnace back-up equipment test schedule is maintained 
Conduct back-up equipment test procedures to meet specific enterprise requirements 
Interpret the molten glass mix and required furnace operation from job specifications 
Melt glass and monitor furnace and other operating parameters in accordance with established enterprise procedures 
Monitor instruments and control panels, and interpret test results for fluctuations, variations and trends 
Monitor plant and process and deduce conditions of materials in process and products being made 
Determine appropriate action to improve process operation 
Adjust furnace controls to ensure glass melt parameters are maintained to job specifications 
Check that process operation has improved 
Continue analysing data and making adjustments until desired level of process operation is achieved and product is within specifications in accordance with work instructions 
Identify the range of faults that can occur during the operation 
Determine and rectify fault causes in accordance with established enterprise procedures 
Identify and rectify equipment failure causes in accordance with established enterprise procedures 
Make sure appropriate records and log books of equipment operations are maintained to meet enterprise requirements 
Identify non-routine problems and report to designated person 
Identify hazards from the job to be done 
Identify other hazards in the work area 
Assess the risks arising from those hazards 
Implement measures to control those risks in line with procedures 

Forms

Assessment Cover Sheet

PMC552040C - Operate glass melting 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

PMC552040C - Operate glass melting 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: