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Elements and Performance Criteria

1. Prepare for work
   • Receive and give shift handover
   • Identify work requirements
   • Identify and control hazards
   • Coordinate with appropriate personnel
2. Estimate required adjustment in accordance with procedures
   • Take samples for required test
   • Interpret test results
   • Identify any conflicting or suspicious results and take action
   • Identify required adjustment protocol for this adjustment
   • Estimate amount and type of materials to be added or other adjustments required
   • Estimate duration of this adjustment
3. Make adjustment
   • Obtain required materials for adjustment
   • Determine addition rate for materials/rate of applying adjustment
   • Make adjustment at the determined rate
   • Monitor the batch as the adjustment occurs using measured/indicated data and senses
   • Take action specified by procedures
4. Recheck batch
   • Repeat the adjustment process as required to bring batch to specification
   • Identify likely problems arising from adjustment process
   • Take action specified by procedures

Range Statement

This field allows for different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.
Regulatory framework	The latest version of all legislation, regulations, industry codes of practice and Australian/international standards, or the version specified by the local regulatory authority, must be used, and include one or more of the following: legislative requirements, including work health and safety (WHS) industry codes of practice and guidelines environmental regulations and guidelines Australian and other standards licence and certification requirements All operations to which this unit applies are subject to stringent health, safety and environment (HSE) requirements, which may be imposed through state/territory or federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between performance criteria and HSE requirements, the HSE requirements take precedence.
Hazards	Hazards include one or more of the following: electricity structural hazards structural collapse equipment failures industrial (machinery, equipment and product) equipment or product mass noise, rotational equipment or vibration plant services (steam, condensate and cooling water) working at heights, in restricted or confined spaces, or in environments subjected to heat, noise, dusts or vapours flammability and explosivity hazardous products and materials unauthorised personnel sharp edges, protrusions or obstructions slippery surfaces, spills or leaks extreme weather other hazards that might arise
Monitoring	Batch is monitored for one or more of the following: product deterioration from extended processing kettle/vessel overflows from repeated material additions misleading test results causing inappropriate adjustments
Non-routine problems	Non-routine problems are unexpected problems, or variations of previous problems and must be resolved by applying operational knowledge to develop new solutions, either individually or in collaboration with relevant experts, to: determine problems needing action determine possible fault causes develop solutions to problems which do not have a known solution follow through items initiated until final resolution has occurred report problems outside area of responsibility to designated person Operational knowledge includes one or more of the following: procedures training technical information such as journals, engineering specifications remembered experience relevant knowledge obtained from appropriate people
Procedures	All operations must be performed in accordance with relevant procedures. Procedures are written, verbal, visual, computer-based or in some other form, include one or more of the following: emergency procedures work instructions standard operating procedures (SOPs) safe work method statements (SWMS) formulas/recipes batch sheets temporary instructions any similar instructions provided for the smooth running of the plant.
Operate	Operate is to monitor, adjust/make change to the production unit and/or its component items to meet specifications, by one or both of the following: manually in the plant using local controller in the plant This competency does not require the operation of a central control panel.
Product	Product includes anything produced by a process step and so includes: intermediate products, such as the product from one process step, which then becomes the feed for another
Equipment and unit operations	Equipment and unit operations which form part of the product manufacture/adjustment system include two or more of the following: kettle or mixing vessel heating and or cooling material addition equipment pumps, valves and pipes mixers fume/vapour extraction reflux systems emergency shutdown systems communications systems
Adjustment protocol	Adjustment protocols include one or more of the following: aiming to make a '90% (or other%) adjustment' first time aiming to 'hit the target' first time under/overshoot the target other techniques for achieving optimal adjustment as defined by the organisation
Adjustments required	Adjustments required include one or more of the following: adding more of some of the original materials adding some additional materials continuing to heat/stir or otherwise process the batch (with or without material addition)

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Performance Evidence

Evidence required to demonstrate competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria, and include the ability to:

analyse and interpret test results

use data and senses to monitor plant and maximise performance

apply process knowledge to determine and make adjustments to achieve specifications

identify hazards and risks and apply risk control procedures

identify early warning signs of equipment/processes needing attention or with potential problems

resolve problems.

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Knowledge Evidence

Evidence must be provided that demonstrates knowledge of:

systems’ operating parameters, integrity limits, including temperature, pressure, flow, pH and concentration

product specifications and tolerances

methods of controlling the reaction/or adjustment, including rate and yield and the advantages and disadvantages of each

routine and non-routine problems that may arise, the range of possible causes and processes to develop solutions

process-specific science (physics, chemistry and biochemistry) to the level of being able to interpret the science and extract factors controlling the process and product and by-product production rate and quality (e.g. for chemistry interpret the equation for factors controlling rate and yield and also interfering reactions, such as by-products)

hierarchy of control

hazards that may arise in the job/work environment, and:

their possible causes

potential consequences

appropriate risk controls.

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