Assessor Resource

PPMCPP440
Troubleshoot and rectify coated paper processes

Assessment tool

Version 1.0
Issue Date: March 2024


This unit of competency describes the outcomes required to diagnose, rectify and report on plant, equipment or product quality faults in coated paper processes.

This unit applies to senior operators and production specialists who troubleshoot and rectify coated paper processes in a pulp or paper manufacturing facility. This work typically involves complex integrated equipment and continuous operations. 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, drying systems, internal unloading and combine rollers.

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. Identify and diagnose causes of process variation, plant or equipment faults

1.1. Identify and diagnose plant or equipment faults in coated paper processes in accordance with production requirements, relevant workplace health and safety (WHS) procedures, risks and hazards identification and environmental workplace procedures.

1.2. Interpret visual assessments and machine alarm systems to determine fault type and location.

1.3. Identify faults through routine physical inspections of plant, processes and equipment.

1.4. Use appropriate techniques to identify and locate cause and source of process variation, plant or equipment faults.

1.5. Access and analyse relevant historical data, as required to confirm diagnosis.

1.6. Communicate problems to relevant personnel.

2. Rectify process variation, plant and equipment faults

2.1. Initiate, prior to fault rectification, emergency stop or shutdown, isolation and lockout procedures.

2.2. Isolate, repair or replace faulty equipment or instrumentation and undertake appropriate adjustments and rectification.

2.3. Implement corrective operational adjustments and maintenance requirements.

2.4. Restore normal operations and communicate to relevant personnel.

3. Identify and rectify product quality faults

3.1. Identify by observation, systematic sampling and testing product faults or variations.

3.2. Manage out of specification product.

3.3. Undertake sampling for tests to identify product faults or variations.

3.4. Conduct required tests.

3.5. Interpret test results and adjust to correct variations.

4. Record and report troubleshooting activities

4.1. Identify recording and reporting workplace requirements for troubleshooting.

4.2. Document variations from specification and machine operation faults.

4.3. Record assessment and evaluation of causes of deviation, and corrective action undertaken, as required.

4.4. Communicate relevant information to personnel.

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 evidence that they can troubleshoot and rectify coated paper processes, at least twice in line with required enterprise intervals, by:

selecting and using appropriate skills in trouble shooting in coated paper processes

identifying, diagnosing and rectifying faults in plant, equipment and product quality relevant to coated paper processes

undertaking sampling and testing on products and interpret test results

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

reading and interpreting documentation, procedures and reports relevant to coated paper processes

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

communicating effectively and working safely with others, in the work area when troubleshooting and rectifying coated paper processes.

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

documentation and procedures relevant to troubleshooting and rectifying coated paper processes in the pulp and paper industry including:

work health and safety (WHS) including high risk load shifting licensing requirements

Standard Operating Procedures (SOP)

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

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

maintenance logs

job sheets

site agreements

safety instructions

process and instrument diagrams

machine manuals

troubleshooting guides

incident reports

coated paper processes and associated services sufficient to troubleshoot including:

plant layout

operating principles

causes and effects of adjustments made to coated paper plant and processes

relationships between coated paper processes and associated services

troubleshooting methods applicable to the operation of coated paper processes

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

cause and effect of test results and actions relevant to troubleshooting

product grade and process adjustment procedures for coated paper

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

workplace procedures relevant to coated paper processes including work health and safety (WHS), environmental guidelines including relevant sustainability practices, Standard Operating Procedures (SOP), isolation procedures, safe working requirements, risks and hazard identification and housekeeping.

The following resources must be made available:

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

electronic control systems which includes Digital Control System (DCS), touch screens or robotics

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. Identify and diagnose causes of process variation, plant or equipment faults

1.1. Identify and diagnose plant or equipment faults in coated paper processes in accordance with production requirements, relevant workplace health and safety (WHS) procedures, risks and hazards identification and environmental workplace procedures.

1.2. Interpret visual assessments and machine alarm systems to determine fault type and location.

1.3. Identify faults through routine physical inspections of plant, processes and equipment.

1.4. Use appropriate techniques to identify and locate cause and source of process variation, plant or equipment faults.

1.5. Access and analyse relevant historical data, as required to confirm diagnosis.

1.6. Communicate problems to relevant personnel.

2. Rectify process variation, plant and equipment faults

2.1. Initiate, prior to fault rectification, emergency stop or shutdown, isolation and lockout procedures.

2.2. Isolate, repair or replace faulty equipment or instrumentation and undertake appropriate adjustments and rectification.

2.3. Implement corrective operational adjustments and maintenance requirements.

2.4. Restore normal operations and communicate to relevant personnel.

3. Identify and rectify product quality faults

3.1. Identify by observation, systematic sampling and testing product faults or variations.

3.2. Manage out of specification product.

3.3. Undertake sampling for tests to identify product faults or variations.

3.4. Conduct required tests.

3.5. Interpret test results and adjust to correct variations.

4. Record and report troubleshooting activities

4.1. Identify recording and reporting workplace requirements for troubleshooting.

4.2. Document variations from specification and machine operation faults.

4.3. Record assessment and evaluation of causes of deviation, and corrective action undertaken, as required.

4.4. Communicate relevant information to personnel.

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 evidence that they can troubleshoot and rectify coated paper processes, at least twice in line with required enterprise intervals, by:

selecting and using appropriate skills in trouble shooting in coated paper processes

identifying, diagnosing and rectifying faults in plant, equipment and product quality relevant to coated paper processes

undertaking sampling and testing on products and interpret test results

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

reading and interpreting documentation, procedures and reports relevant to coated paper processes

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

communicating effectively and working safely with others, in the work area when troubleshooting and rectifying coated paper processes.

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

documentation and procedures relevant to troubleshooting and rectifying coated paper processes in the pulp and paper industry including:

work health and safety (WHS) including high risk load shifting licensing requirements

Standard Operating Procedures (SOP)

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

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

maintenance logs

job sheets

site agreements

safety instructions

process and instrument diagrams

machine manuals

troubleshooting guides

incident reports

coated paper processes and associated services sufficient to troubleshoot including:

plant layout

operating principles

causes and effects of adjustments made to coated paper plant and processes

relationships between coated paper processes and associated services

troubleshooting methods applicable to the operation of coated paper processes

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

cause and effect of test results and actions relevant to troubleshooting

product grade and process adjustment procedures for coated paper

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

workplace procedures relevant to coated paper processes including work health and safety (WHS), environmental guidelines including relevant sustainability practices, Standard Operating Procedures (SOP), isolation procedures, safe working requirements, risks and hazard identification and housekeeping.

The following resources must be made available:

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

electronic control systems which includes Digital Control System (DCS), touch screens or robotics

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 and diagnose plant or equipment faults in coated paper processes in accordance with production requirements, relevant workplace health and safety (WHS) procedures, risks and hazards identification and environmental workplace procedures. 
Interpret visual assessments and machine alarm systems to determine fault type and location. 
Identify faults through routine physical inspections of plant, processes and equipment. 
Use appropriate techniques to identify and locate cause and source of process variation, plant or equipment faults. 
Access and analyse relevant historical data, as required to confirm diagnosis. 
Communicate problems to relevant personnel. 
Initiate, prior to fault rectification, emergency stop or shutdown, isolation and lockout procedures. 
Isolate, repair or replace faulty equipment or instrumentation and undertake appropriate adjustments and rectification. 
Implement corrective operational adjustments and maintenance requirements. 
Restore normal operations and communicate to relevant personnel. 
Identify by observation, systematic sampling and testing product faults or variations. 
Manage out of specification product. 
Undertake sampling for tests to identify product faults or variations. 
Conduct required tests. 
Interpret test results and adjust to correct variations. 
Identify recording and reporting workplace requirements for troubleshooting. 
Document variations from specification and machine operation faults. 
Record assessment and evaluation of causes of deviation, and corrective action undertaken, as required. 
Communicate relevant information to personnel. 

Forms

Assessment Cover Sheet

PPMCPP440 - Troubleshoot and rectify 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

PPMCPP440 - Troubleshoot and rectify 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: