1. Analyse and evaluate current plant, equipment and processes.
   • Compare actual process, plant and equipment performance with requirements and/or historical data/records and/or design performance.
   • Identify abnormal or sub-optimal process, plant and equipment performance.
   • Identify hazards associated with the plant and equipment.
   • Collect and evaluate product, materials and/or process records to determine possible causes for sub-optimal performance.
   • Use appropriate techniques to rank possible causes from most to least probable cause.
2. Develop plan for corrective and/or optimisation action.
   • Analyse cause(s) to determine appropriate corrective action.
   • Predict the impact of a change in one unit/area on other related plant units/areas.
   • Predict the impact of a change on health, safety and environmental performance
   • Develop measurable objectives and evaluate alternatives.
   • Identify requirements to implement change.
   • Consult with stakeholders regarding planned changes and impacts.
   • Develop optimisation plan taking account of hazards identified and HSE implications and communicate to appropriate personnel.
   • Evaluate optimisation action to determine measures of effectiveness.
3. Coordinate corrective and/ or optimisation action plan
   • Coordinate all appropriate unit areas and operations in order to rectify problem causes in process, plant and equipment performance.
   • Initiate and/or implement all required corrective/ optimisation actions.
   • Communicate corrective/optimisation outcomes to all relevant personnel.
   • Implement procedures/systems to eliminate possible future causes.
   • Record and maintain log of all relevant information.
4. Develop continuous improvement strategies.
   • Review sources of information to identify possible factors causing sub-optimal performance.
   • Identify options for removing or controlling the risk of sub-optimal performance.
   • Assess the adequacy of existing control and quality methods and systems.
   • Identify opportunities to continuously improve performance.
   • Develop recommendations for continual improvement of process, plant and equipment effectiveness.
   • Consult with appropriate personnel and implement continuous improvement strategies.
   • Document implementation of continuous improvement strategies.

This describes the essential skills and knowledge and their level required for this unit

Knowledge and understanding of the

equipment

processes

systems

sufficient to

identify hazards associated with the process

recognise opportunities to improve andor enhance the quality of performance of the plant

This knowledge needs to include

the relevant technical theory of the plant area

an in depth understanding across the entire plant area

the organisation standard procedures and work instructions

relevant regulatory requirements including those related to OHS risk control as appropriate to processplant area optimisation

Competence includes the ability to

apply analytical skills which enable corrective or optimal conditions to prevail

identify and control hazards by applying the hierarchy of control as part of the optimisation process

interpret information and make appropriate process control decisions

Competence includes the ability to distinguish between

optimum and marginal performance of the plant

effective and marginal performance corrections and actions

as is relevant to the practical operation of all major equipmentprocesssystems within the area

Optimising process systems requires application of detailed operational and process knowledge to address issues such as

starting material quality

yield maximisation

throughput maximisation

energy efficiency

use of utilities

labour utilisation

overall cost

efficient use of equipment

reducing downtime

minimisation of waste and rework

improved workplace layout and workflow

Language literacy and numeracy requirements

This unit requires the ability to communicate at all levels about what may be complex technical matters It also requires the ability to evaluate complex information and sort often conflicting information into useful and distracting and to rankprioritise information

Writing is required to the level of reading and interpreting technical information developing and modifying plans and procedures and interpreting relevant regulatory requirements

Numeracy is required to the level of analysing productprocess performance data interpreting process condition information and deriving useful information from technical brochures papers and similar Calculation will be required to assist this and to determine priorities for optimisation plans ie benefitcost or other quantitative criteria

The Evidence Guide provides advice on assessment and must be read in conjunction with the Performance Criteria Required Skills and Knowledge the Range Statement and the Assessment Guidelines for this Training Package

Overview of assessment

A holistic approach should be taken to the assessment

Assessors must be satisfied that the person can consistently perform the unit as a whole as defined by the Elements Performance Criteria and skills and knowledge

Competence must be demonstrated in the ability to analyse and evaluate current production performance and develop and implement plans to optimise process systems

While the technician is expected to take a lead technical role and to demonstrate competence as defined above optimisation is rarely undertaken by an individual alone and liaison with all relevant stakeholders is an expected part of this competency

Where the assessee does not currently possess evidence of competency in MSASUPA Use structured problem solving tools it may be coassessed with this unit

Where the assessee does not currently possess evidence of competency in MSASUP390A Use structured problem solving tools, it may be coassessed with this unit.

Criticalaspects for assessment and evidence required to demonstrate competency in this unit

It is essential that the equipmentprocesssystem be understood in depth and that the importance of critical material propertiessettingsreadings 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 For example look to see that

nonroutine problems are recognised and defined

hazards are identified and controlled by applying the hierarchy of control

possible causes of complex problems are identified based on experience and the use of analytical techniques in solving the problem including identifying variations and cause separating single problems from multiple problems and the recognition of recurring problems

fundamental cause of process or equipment faults is determined

correctivepreventative actions are developed to avoid recurrence of the problem and optimise the condition of the process plant and equipment

product quality and uniformity are maintained

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

Competence also includes the ability to implement improvements within appropriate time constraints and in a manner relevant to the operation of the equipment processes and systems

Context of assessment

Competence in this unit may be assessed by

observation over time in a processing plant allowing for adequate assessment of operation under all normal and a range of abnormal conditions Where this is not practical additional assessment techniques must be used

using a suitable simulation andor a range of case studiesscenarios

undertaking a specific project based in the plant

a combination of these techniques

Method of assessment

In all cases it is expected that practical assessment will be combined with targeted questioning to assess the underpinning knowledge and theoretical assessment will be combined with appropriate practicalsimulation or similar assessment Assessors need to be aware of any cultural issues that may affect responses to questions

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

Specific resources for assessment

This section should be read in conjunction with the Range Statement for this unit of competency Resources required include suitable access to an operating plant or equipment that allows for appropriate and realistic simulation A bank of case studiesscenarios and questions will also be required to the extent that they form part of the assessment method Questioning may take place either in the workplace or in an adjacent quiet facility such as an office or lunchroom No other special resources are required

Access must be provided to appropriate learning andor assessment support when required Where applicable physical resources should include equipment modified for people with disabilities