Assessor Resource

PMC553040C
Set up and optimise glass forming process

Assessment tool

Version 1.0
Issue Date: April 2024


This unit of competency applies to experienced operators, leading hands or supervisors who are responsible for setting up and adjusting the glass forming process from the requirements as set out in production schedules and specifications. The operator is able to run trials and adjust all of the equipment settings to have the production equipment perform satisfactorily.

This unit does NOT apply to the set up and optimisation of secondary glass furnace processes, which is covered by PMC553041C Set up and optimise glass furnace process.

Typically an operator would:

set up, monitor and tune equipment for optimum performance

identify and rectify routine and non-routine operational problems

adjust and optimise processes to gain maximum yield

undertake detailed quality measurements and inspections

implement emergency recovery

undertake housekeeping

complete records and logs.

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 setting up and tuning of the glass forming process including technical fault finding and non-routine problem solving, emergency recovery, optimising the process to gain maximum yield, and detailed knowledge of forming process.

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 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. The emphasis should be on the ability to stay out of trouble rather than on recovery from a disaster.

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

setup/tuning is completed to specifications

temperature and pressures are maintained within limits

adjustments made are completed in a timely manner in accordance with procedures/work instructions

quality is monitored to minimise wastage

startup and shutdown occur first time

early warning signs of equipment/processes needing attention or potential problems are recognised and dealt with in a timely manner

process measurements are continually made or observed

the range of possible causes can be identified and the most likely cause determined

appropriate action is taken to ensure a timely return to full performance

obvious problems to related plant areas are recognised and an appropriate contribution made to their solution.

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.

Individual enterprises may choose to add prerequisites and co-requisites relevant to their processes.

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

implementing the enterprise's standard procedures and work instructions and relevant regulatory requirements in a manner relevant to the operation of the process

reading and numeracy to interpret workplace documents and technical information

Required knowledge

Required knowledge includes:

composition and nature of the glass

setup and tuning of all equipment

startup and shutdown processes

optimisation of process for yield maximisation

energy utilisation

importance of atmospheric conditions and effect on process

construction and limitations of the equipment

out of specification situations

quality problems

distinguish between causes of problems, such as:

raw materials

mould equipment

variables

mechanical and thermal

electrical/instrument

atmospheric

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

Product to be made

The product to be made may be determined by consulting the production schedule or similar means

Required setup

Required setup includes:

alignment of all equipment

checks and adjustments according to product specifications and procedures

production schedule requirements

Monitoring

Monitoring includes analysing and interpreting data for:

variations

fluctuations

trends

with a view to establishing stable, efficient operation producing goods as required

Process data

Process data include that from:

equipment

instruments

control panels

test results

Appropriate action

Appropriate action includes adjusting:

temperature controls

equipments settings

process conditions

to ensure process parameters are maintained to job specifications

Records

Records may be in:

hard copy

electronic form

Application of equipment:

This unit includes equipment applicable to forming glass in each of the specific areas of glass products manufacture:

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:

forming and associated equipment such as:

bushings

finshields

applicators

shoe and winder assemblies

spinners

lapping equipment

process water

lehr

furnace

forehearth

bath

fiberisers

computers

measuring and recording equipment

communication equipment

hand tools

safety clothing and equipment

Process

The process includes:

setting up, monitoring and tuning equipment for optimum performance especially during startup, job change and equipment changes

Typical problems

Typical problems may include:

raw materials supply

equipment alignment

analysis of all plant data

control of temperature within specification

product quality

equipment speed

taking corrective action

Plant data

Plant data may include:

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

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
Determine the product to be manufactured 
Ensure that the equipment change parts, ancillaries and fixtures are available as required 
Perform pre-instalment equipment preparation according to procedures 
Ensure that the equipment is in a safe condition for use 
Identify and implement all safety and emergency procedures 
Shut down equipment in accordance with procedures. 
Isolate equipment as per procedures 
Remove ancillary equipment in accordance with procedures 
Complete records and logs for removal of current equipment 
Perform required checks and tests prior to installation 
Identify any faults in equipment/tooling and take appropriate action 
Install and set up appropriate ancillary equipment in accordance with procedures 
Set up equipment/tooling as required 
Monitor and adjust until production is as required 
Monitor process data 
Ensure forming equipment startup function complies with work instructions 
Operate glass forming equipment in accordance with procedures 
Monitor plant and process and deduce conditions of materials in process and products being made 
Take appropriate action to improve process operation 
Check that process operation has improved 
Monitor and adjust until production is as required 
Sample as required by the product and in line with enterprise requirements 
Complete appropriate test to enterprise and client requirements 
Identify variations from process parameters and take appropriate action 
Measure/graph and record operating parameters, according to enterprise requirements 
Record test results as required by procedures 
Identify the range of equipment and quality faults that can occur during the operation 
Diagnose possible causes of equipment and quality faults 
Rectify cause of equipment failure and quality faults by established enterprise procedures 
Identify and rectify equipment failure causes in accordance with established enterprise procedures 
Ensure appropriate records and logs of equipment operations are maintained to meet enterprise requirements 
Identify non-routine problems and report to designated person 
Shut down equipment in accordance with procedures 
Complete appropriate records and logs 
Shut down equipment in an emergency situation 
Isolate equipment in accordance with work instructions 
Make sure area is clear and safe for maintenance 
Complete all records and logs 
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

PMC553040C - Set up and optimise glass forming 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

PMC553040C - Set up and optimise glass forming 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: