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Elements and Performance Criteria

1. Identify production requirements
   • Read specifications and standard operating procedures (SOPs) for production run and equipment
   • Identify materials required
   • Note production control requirements for production and warm up time, pressure(s), speed(s), temperature(s) and product specifications
   • Note key stages in the process for quality checks
   • Identify equipment and components required
   • Check assembly requirements for items of production and downstream equipment or specialised componentry to ensure efficient work flow will occur
2. Set up equipment
   • Check work area to ensure adequate space for the process
   • Place equipment and components in required configuration
   • Install guards, warning devices and cut-offs as required
   • Check all connecting components and services for integrity and effectiveness
   • Check dies/moulds/jigs as required for suitability for production requirements
   • Place SOPs and quality procedures in appropriate work stations
   • Check work area for operator ergonomic efficiency, access and egress requirements
3. Explain process to operators when required
   • Explain particular requirements for machine adjustments, materials characteristics, quality specifications and key production stages to the operator
   • Explain standard operating procedures and work health and safety (WHS) issues.
   • Identify and explain appropriate contingency strategies for process faults, quality, WHS issues, materials supply or quality machine malfunctions
   • Encourage operators to ask questions and clarify procedures
4. Produce first-off production sample(s)
   • Start process following SOPs
   • Observe product quality through process and compare to standards
   • Compare machine setting ranges to documented requirements
   • Use observations of the process outcomes to fine tune the settings and other production variables
   • Check final product for the required standards
   • Compare SOPs with actual production run and note variances
5. Fine tune the process
   • Use information collected during trial to modify workplace documentation, including SOPs, machine settings and process instructions
   • Obtain appropriate advice and permission where variations are outside of quality or specification range
   • Advise operators of variations to process and document as required

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. Applicable legislation, regulations, standards and codes of practice include: health, safety and environmental (HSE) legislation, regulations and codes of practice relevant to the workplace, manual handling and hazardous materials Australian/international standards relevant to the materials being used and products being made any relevant licence and certification requirements. All operations to which this unit applies are subject to stringent 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 such requirements the legislative requirements take precedence.
Procedures	All operations must be performed in accordance with relevant procedures. Procedures are written, verbal, visual, computer-based or in some other form, and include one or any combination of: emergency procedures work instructions SOPs safe work method statements (SWMS) formulas/recipes batch sheets temporary instructions any similar instructions provided for the smooth running of the plant.
Tools and equipment	Tools and equipment include one or more of: hand carts and trolleys hoists/lifting equipment not requiring any special permits or licences basic hand tools required for opening of material packaging material loading equipment used for loading of raw materials. Additional tools and equipment will be selected as required from: relevant personal protective equipment (PPE).
Hazards	Hazards must be identified and controlled. Identifying hazards requires consideration of: weight, shape, volume of materials to be handled hazardous products and materials sharp edges, protrusions or obstructions slippery surfaces, spills or leaks heat, smoke, dust, vapours or other atmospheric hazards electricity gas gases and liquids under pressure structural hazards equipment failures machinery, equipment and product mass other hazards that might arise.
Non-routine problems	Non-routine problems 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. Non-routine problems are unexpected problems or variations of previous problems and include one or more of: variations in materials faulty components machine malfunction variation in product contamination of materials processing problems. Operational knowledge includes one or more of: procedures training technical information such as journals, engineering specifications remembered experience relevant knowledge obtained from appropriate people.

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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 demonstrate the ability to:

read and interpret procedures, job specifications, material labels and safety data sheets (SDS)

set up tools, equipment and material in a configuration that meets specifications and enables efficient workflow

provide and explain standard operating procedures (SOPs) and quality procedures to operators

start up equipment and make adjustments to bring process on line

trial run the process to produce a sample product

monitor the trial run process outcomes, settings, product quality and procedures to identify conformance and/or non-conformance to specifications

make adjustments to equipment operation to rectify variations in equipment operation or product quality and to fine tune process and/or procedures

safely shut down equipment in normal and abnormal circumstances

identify hazards and apply relevant hazard controls

distinguish between causes of problems/alarm/fault indications, such as:

operational problems

instrument failure/malfunction

electrical failure/malfunction

mechanical failure/malfunction

wrong readings

equipment design deficiencies

product parameters (temperature, flows, pressure and levels)

resolve non-routine problems

communicate effectively with team/work group and supervisors

complete workplace records

do basic arithmetical manipulations, including additions, subtractions, divisions, fractions and percentages.

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Knowledge Evidence

Must provide evidence that demonstrates knowledge relevant to their job sufficient to fulfil their job role, including knowledge of:

products, materials and material characteristics

quality requirements at each production stage

function and operating principles of equipment, machine components and ancillary equipment

impact of machine operating parameters on product quality and production output

factors which may affect product quality or production output and appropriate remedies

impact of mechanical, hydraulic, pneumatic and electrical/electronic principles of the production process

routine and non-routine problems that may arise, the range of possible causes and appropriate actions

organisation procedures relevant to the work environment/job role

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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