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Elements and Performance Criteria

  1. Identify and analyse causes of systems and quality faults
  2. Rectify systems and equipment faults
  3. Rectify product quality faults
  4. Record and report process performance and product quality data

Required Skills

This describes the skills and knowledge required for this unit

Required skills

Identifies accesses and interprets relevant historical and operational data and information

Uses required forms of communication in troubleshooting and rectifying dry end systems

Communicates effectively with personnel to assist with analysis and resolution of operational problems

Reads and interprets required documentation procedures and reports

Accesses navigates and enters computerbased information

Interprets instruments gauges and data recording equipment

Identifies and actions systems quality and equipment faults within level of responsibility

Assists others to identify and resolve operational problems in the workplace

Takes samples conducts tests interprets and records results

Identifies causes and effects of faults and corrective action on associated processes

Selects and uses appropriate troubleshooting methods

Takes timely corrective action to maximise safety quality and productivity

Undertakes necessary calculations to aid troubleshooting as required

Uses measuring equipment as required

Maintains situational awareness in work area

Operates high risk and nonhigh risk load shifting equipment as required

Analyses and uses sensory information to adjust process to maximise safety quality and productivity

Uses electronic and other control systems to control equipment and processes as required

Required knowledge

Procedures regulations and legislative requirements relevant to dry end systems and operations including OHS environmental including relevant sustainability requirementspractices SOP isolation procedures safe working requirements risks and hazard identification and housekeeping

Relevant forms of communication

Detailed knowledge of dry end plant processes and associated services sufficient to troubleshoot including

plant layout

theory of operation

causes and effects of adjustments made to dry end plant and processes

relationships between dry end plant processes and associated services

An appropriate range of troubleshooting methods

Sampling and testing process for plant and system operations and process monitoring purpose standards and procedures as per site agreements

Causes and effects of unplanned shutdown and appropriate responses

Mill maintenance system as it applies to dry end plant and processes

The application of high risk and nonhigh risk load shifting equipment as required

Sensory information that indicates a deviation from standard operating parameters

Sufficient knowledge of electronic and other control systems operation and application to make appropriate adjustments that control the dry end within level of responsibility

Evidence Required

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

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

Evidence should be relevant to the work It should satisfy the requirements of the elements and performance criteria and include consideration of

the required knowledge and skills tailored to the needs of the specific workplace

applicable OHS regulations environmental and safe working requirementspractices SOP and housekeeping requirements

applicable aspects of the range statement

practical workplace demonstration of skills in troubleshooting and rectifying dry end systems

Context of and specific resources for assessment

A workplace assessment must be used to assess

the application of required knowledge on the job

the application of skills on the job over time and under a range of typical conditions that may be experienced in dry end operations

Access to the full range of equipment involved in integrated continuous manufacturing of dry end operations in a pulp or paper mill is required

Method of assessment

A combination of assessment methods should be used The following examples are appropriate for this unit

observation of applied skills and knowledge on the job

workplace demonstrations via a mockup or simulation that replicate parts of the job

answers to written or verbal questions about specific skills and knowledge

thirdparty reports from relevant and skilled personnel

written evidence eg log sheet entries checklist entries test results

Assessment processes and techniques must be culturally appropriate and in keeping with the language and literacy capacity of the learner and the work being performed This includes conducting an assessment in a manner that allows thoughts to be conveyed verbally so that the learner can both understand and be understood by the assessor eg use plain English and terminology used on the job

A holistic assessment with other units relevant to the pulp and paper industry mill and job role is recommended

Additional information on approaches to assessment for the pulp and paper industry is provided in the Assessment Guidelines for this Training Package


Range Statement

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.

Productivity requirements may include:

energy efficiency

waste minimisation

evaporation minimisation, including landfill and waste water reduction

environmentally safe waste disposal

consideration of resource utilisation, including fibre efficiency

minimising delays

chemical recovery maximisation

meeting key performance indicators

line speed

handovers

quality checks

meeting output targets i.e. net tonnes per employee per annum

machine/process time availability i.e. time the machine or process is making product

machine/process production rate

Systems and functions involved in dry end operations may include:

drying processes

reeling operations

chemical additive system

monitoring systems

sheet treatment processes

tail feed systems

broke system

on-line coating systems

calendering systems

vacuum systems

laser systems

slitter systems

sheet transfer systems

accumulator

cleaning showers

Materials, supplies and stock may include:

chemicals

compressed air

water

electricity

gas

steam

additives

machine clothing

ropes and belts

Equipment may include:

scales

tape turner

hand and power tools

computer systems

electronic screens and alarms

process control systems

fully automated, semi-automated, manually operated plant and equipment appropriate to the dry end process

Electronic control systems may include:

Digital Control System (DCS)

touch screens

robotics

Hazards and risks may include:

steam and/or gas leaks

fires

nip points

compressed air

hot surfaces

electrical

entanglement

slip hazards/falls

energy

pressures

chemicals

fumes

confined spaces

dust

Legislation, regulatory, licensing and certification requirements may include:

OHS and environmental requirements (local, state and commonwealth)

activity or task specific high risk (and non-high risk) load shifting licensing requirements

Documentation, procedures and reports may include:

SOP

site policy and procedures

environmental sustainability requirements/practices

plant manufacturing operating manuals

confined space requirements

vendor documentation

reference manual

grade specifications

quality procedures

oil or chemical spills and disposal guidelines

plant isolation documentation

housekeeping

safe work documentation e.g. plant clearance, job safety analysis, permit systems

maintenance logs

job sheets

operating log

production instructions

Materials Safety Data Sheets (MSDS)

process and instrument diagrams

Maintenance may include:

operator level maintenance as per site agreements

operator maintenance schedules

maintenance systems

maintenance suppliers

pro-active maintenance strategies e.g. Total Productive Maintenance (TPM), Reliability Centred Maintenance (RCM)

Actions may include:

process adjustments

reporting to authorised person

rectifying problem within level of responsibility

Communications may include

interaction with:

team members

production/service co-ordinators

internal/external customers and suppliers

maintenance services

operational management

statutory authorities

Situational awareness may include

awareness of:

traffic

pedestrians

location of equipment

product

hazards

obstructions

unexpected movement

Sensory information may include:

visual

sound

feel

touch

smell

vibration

temperature

Forms of communications may include:

written e.g. log books, emails, incident and other reports, run sheets data entry

reading and interpreting documentation e.g. standard operating procedures, manuals, checklists, drawings

verbal e.g. radio skills, telephone, face to face, handover

non-verbal e.g. hand signals, alarms, observations

signage e.g. safety, access