Assessor Resource

PPMCPP330
Co-ordinate the shutdown of coated paper processes

Assessment tool

Version 1.0
Issue Date: March 2024


This unit of competency describes the outcomes required to assess and execute planned and unplanned shutdowns in the pulp and paper industry. This typically involves working in a facility with complex integrated equipment and continuous operations.

The unit applies to operators and technicians who co-ordinate the shutdown of coated paper processes in a pulp or paper manufacturing facility. Coated paper processes describe a range of systems and sub systems including tail feed systems, chemical and material batching, laminating and coating, splicing, clay plant operation, calendaring, pre-reeler operations, super calendaring, rewindering and drying systems.

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

PERFORMANCE CRITERIA

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold italicised text is used, further information is detailed in the range of conditions.

1. Implement planned shutdown procedures

1.1. Identify planned shutdown of coated paper process from work area instructions or maintenance schedules.

1.2. Follow coated paper process materials and supplies shutdown procedures, as required.

1.3. Manage plant or system shutdowns in accordance with production requirements, relevant workplace health and safety (WHS) procedures, risks and hazards identification and environmental workplace procedures.

1.4. Implement isolation and lock out requirements, according to standard operating procedures (SOP) and housekeeping requirements.

1.5. Ensure plant integrity and personnel safety by following WHS procedures.

1.6. Communicate planned shutdown information to relevant personnel as required.

1.7. Wash and clean plant and equipment for restart.

2. Assess the cause and effect of an unplanned shutdown

2.1. Assess the cause and effect of an unplanned shutdown within WHS and environmental procedures, SOP and housekeeping requirements.

2.2 Identify abnormal operating conditions by analysis of technical and operational information.

2.3. Determine the effects of abnormal conditions to enable appropriate adjustments and rectification.

2.4. Locate the source of the cause of the shutdown, to ensure rectification.

2.5. Notify appropriate personnel, when abnormal operating conditions prevail.

2.6. Identify safety issues relevant to an unplanned shut down.

3. Record and report shutdown data

3.1. Record and report shutdown data within WHS and environmental procedures, SOP, and housekeeping requirements.

3.2. Record assessment and evaluation of causes and corrective actions, as required.

3.3. Communicate relevant information to appropriate personnel in accordance with operational requirements.

A person demonstrating competency in this unit must satisfy all of the elements, performance criteria and foundation skills of this unit, and must be able to provide sufficient evidence that they can undertake planned and unplanned shutdowns, at least twice in line with required enterprise intervals, by:

implementing planned equipment and plant shutdown procedures for coated paper processes and following workplace schedules and requirements

implementing isolation and lock out requirements according to standard operating procedures (SOP)

following procedures to communicate with relevant personnel and preparing equipment for restart after a planned shutdown

using and interpreting electronic control systems, including Digital Control System (DCS), touch screens or robotics to control equipment and processes during shutdowns

assessing the cause and effect of an unplanned shutdown for coated paper processes and rectifying abnormal conditions causing a shutdown

communicating with stakeholders about shutdowns, including internal and external customers and suppliers, team members, production/service co-ordinators, maintenance services, operator support personnel, operational management and statutory authorities

selecting and using appropriate forms of communication, from written or verbal, to inform about shutdown causes and corrective action, according to SOP

recording and reporting on shutdowns and corrective actions, in accordance with organisational requirements.

A person competent in this unit must be able to demonstrate knowledge of:

documentation and procedures relevant to plant and system shutdowns for coated paper processes including:

work health and safety (WHS)

Standard Operating Procedures (SOP)

productivity requirements

quality procedures

environmental sustainability requirements/practices

machinery and 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 including plant clearance, job safety analysis, permit systems, product specifications and schedules, emergency procedures and responses

maintenance logs

job sheets

site agreements

safety instructions

process and instrument diagrams

machine manuals

troubleshooting guides

incidents reports

plant and equipment and their functions for coated paper processes

types, causes and effects of coated paper processes and related materials used in coated paper processes including chemicals and polymers, power, water, additives, steam, labels, felts, equipment, gas, accessories (parts) and air

base paper coated paper processes, system layout and associated services sufficient to carry out shutdown activities

production needs including output targets, production scheduling quality requirements, resources and energy use, waste minimisation

processes and procedures for plant shutdowns and unplanned shutdowns

required responses to all unplanned shutdowns (power outage, mechanical breakdown, blockages, jamming, air supply, control system failure) to ensure safety quality and productivity

operation and application of electronic and other control systems, to make appropriate adjustments that control coated paper processes.

The following resources must be made available:

access to the full range of equipment involved in integrated continuous manufacturing of coated paper processes in a pulp or paper manufacturing facility

electronic screens and alarms, process control systems, analogue and digital instrumentation for coated paper processes

equipment, machinery and resources to co-ordinate the shutdown of coated paper systems

applicable work health and safety (WHS) and isolation work place procedures, environmental guidelines and safe working requirements, risks and hazard identification and workplace housekeeping requirements

personal protective equipment required for operating coated paper processes

relevant personnel for the purposes of communicating information

sample workplace documentation on work health and safety (WHS) procedures, risks and hazards identification procedures, environmental and safe working requirements/practices, SOP and housekeeping requirements.

Competency is to be assessed in the workplace or in a productive environment that accurately reflects performance in a workplace.

Assessor requirements

Assessors must:

hold the appropriate assessor competency standards as outlined in regulations; and

be able to demonstrate vocational competencies at least to the level being assessed; and

be able to demonstrate how they are continuing to develop their VET knowledge and skills as well as maintaining their industry currency and assessor competence.


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

PERFORMANCE CRITERIA

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold italicised text is used, further information is detailed in the range of conditions.

1. Implement planned shutdown procedures

1.1. Identify planned shutdown of coated paper process from work area instructions or maintenance schedules.

1.2. Follow coated paper process materials and supplies shutdown procedures, as required.

1.3. Manage plant or system shutdowns in accordance with production requirements, relevant workplace health and safety (WHS) procedures, risks and hazards identification and environmental workplace procedures.

1.4. Implement isolation and lock out requirements, according to standard operating procedures (SOP) and housekeeping requirements.

1.5. Ensure plant integrity and personnel safety by following WHS procedures.

1.6. Communicate planned shutdown information to relevant personnel as required.

1.7. Wash and clean plant and equipment for restart.

2. Assess the cause and effect of an unplanned shutdown

2.1. Assess the cause and effect of an unplanned shutdown within WHS and environmental procedures, SOP and housekeeping requirements.

2.2 Identify abnormal operating conditions by analysis of technical and operational information.

2.3. Determine the effects of abnormal conditions to enable appropriate adjustments and rectification.

2.4. Locate the source of the cause of the shutdown, to ensure rectification.

2.5. Notify appropriate personnel, when abnormal operating conditions prevail.

2.6. Identify safety issues relevant to an unplanned shut down.

3. Record and report shutdown data

3.1. Record and report shutdown data within WHS and environmental procedures, SOP, and housekeeping requirements.

3.2. Record assessment and evaluation of causes and corrective actions, as required.

3.3. Communicate relevant information to appropriate personnel in accordance with operational requirements.

Not Applicable

A person demonstrating competency in this unit must satisfy all of the elements, performance criteria and foundation skills of this unit, and must be able to provide sufficient evidence that they can undertake planned and unplanned shutdowns, at least twice in line with required enterprise intervals, by:

implementing planned equipment and plant shutdown procedures for coated paper processes and following workplace schedules and requirements

implementing isolation and lock out requirements according to standard operating procedures (SOP)

following procedures to communicate with relevant personnel and preparing equipment for restart after a planned shutdown

using and interpreting electronic control systems, including Digital Control System (DCS), touch screens or robotics to control equipment and processes during shutdowns

assessing the cause and effect of an unplanned shutdown for coated paper processes and rectifying abnormal conditions causing a shutdown

communicating with stakeholders about shutdowns, including internal and external customers and suppliers, team members, production/service co-ordinators, maintenance services, operator support personnel, operational management and statutory authorities

selecting and using appropriate forms of communication, from written or verbal, to inform about shutdown causes and corrective action, according to SOP

recording and reporting on shutdowns and corrective actions, in accordance with organisational requirements.

A person competent in this unit must be able to demonstrate knowledge of:

documentation and procedures relevant to plant and system shutdowns for coated paper processes including:

work health and safety (WHS)

Standard Operating Procedures (SOP)

productivity requirements

quality procedures

environmental sustainability requirements/practices

machinery and 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 including plant clearance, job safety analysis, permit systems, product specifications and schedules, emergency procedures and responses

maintenance logs

job sheets

site agreements

safety instructions

process and instrument diagrams

machine manuals

troubleshooting guides

incidents reports

plant and equipment and their functions for coated paper processes

types, causes and effects of coated paper processes and related materials used in coated paper processes including chemicals and polymers, power, water, additives, steam, labels, felts, equipment, gas, accessories (parts) and air

base paper coated paper processes, system layout and associated services sufficient to carry out shutdown activities

production needs including output targets, production scheduling quality requirements, resources and energy use, waste minimisation

processes and procedures for plant shutdowns and unplanned shutdowns

required responses to all unplanned shutdowns (power outage, mechanical breakdown, blockages, jamming, air supply, control system failure) to ensure safety quality and productivity

operation and application of electronic and other control systems, to make appropriate adjustments that control coated paper processes.

The following resources must be made available:

access to the full range of equipment involved in integrated continuous manufacturing of coated paper processes in a pulp or paper manufacturing facility

electronic screens and alarms, process control systems, analogue and digital instrumentation for coated paper processes

equipment, machinery and resources to co-ordinate the shutdown of coated paper systems

applicable work health and safety (WHS) and isolation work place procedures, environmental guidelines and safe working requirements, risks and hazard identification and workplace housekeeping requirements

personal protective equipment required for operating coated paper processes

relevant personnel for the purposes of communicating information

sample workplace documentation on work health and safety (WHS) procedures, risks and hazards identification procedures, environmental and safe working requirements/practices, SOP and housekeeping requirements.

Competency is to be assessed in the workplace or in a productive environment that accurately reflects performance in a workplace.

Assessor requirements

Assessors must:

hold the appropriate assessor competency standards as outlined in regulations; and

be able to demonstrate vocational competencies at least to the level being assessed; and

be able to demonstrate how they are continuing to develop their VET knowledge and skills as well as maintaining their industry currency and assessor competence.

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
Identify planned shutdown of coated paper process from work area instructions or maintenance schedules. 
Follow coated paper process materials and supplies shutdown procedures, as required. 
Manage plant or system shutdowns in accordance with production requirements, relevant workplace health and safety (WHS) procedures, risks and hazards identification and environmental workplace procedures. 
Implement isolation and lock out requirements, according to standard operating procedures (SOP) and housekeeping requirements. 
Ensure plant integrity and personnel safety by following WHS procedures. 
Communicate planned shutdown information to relevant personnel as required. 
Wash and clean plant and equipment for restart. 
Assess the cause and effect of an unplanned shutdown within WHS and environmental procedures, SOP and housekeeping requirements. 
Identify abnormal operating conditions by analysis of technical and operational information. 
Determine the effects of abnormal conditions to enable appropriate adjustments and rectification. 
Locate the source of the cause of the shutdown, to ensure rectification. 
Notify appropriate personnel, when abnormal operating conditions prevail. 
Identify safety issues relevant to an unplanned shut down. 
Record and report shutdown data within WHS and environmental procedures, SOP, and housekeeping requirements. 
Record assessment and evaluation of causes and corrective actions, as required. 
Communicate relevant information to appropriate personnel in accordance with operational requirements. 

Forms

Assessment Cover Sheet

PPMCPP330 - Co-ordinate the shutdown of coated paper processes
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

PPMCPP330 - Co-ordinate the shutdown of coated paper processes

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: