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Elements and Performance Criteria

1. Assessment of performance is to be consistent with the evidence guide.
2. Identify faults in products/production.
   • Examine products/production process.
   • Identify faults.
   • Categorise faults according to type/likely cause.
   • Prioritise faults for action.
3. Determine most probable possible cause(s) of fault
   • Analyse fault to determine possible causes.
   • Investigate possible causes to eliminate less probable causes.
   • Shortlist probable causes.
   • Check hypothesis of cause(s) is supported by the data available.
   • Identify most probable cause.
4. Implement solution to fault
   • Develop recommended solution to fault.
   • Check HSE implications of solution and modify solution as appropriate.
   • Communicate this recommendation as appropriate.
   • Check recommendation has been understood and can be implemented.
   • Check all hazard controls are in place.
   • Monitor progress of implementation.
   • Modify recommended solution as required.
5. Check fault solution has worked.
   • Monitor product/process for fault.
   • Monitor HSE impacts of changes.
   • Repeat analysis and solution process if required.
   • Update records and procedures to reflect successful solution.

Required Skills

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

This competency requires a detailed understanding of

how the processequipment works

how raw material changes into product through the processequipment

impacts of different process conditions on the product

impacts of different equipment settingscomponents on the product

impacts of equipment failurechangevariation on the product

product faults and their categories according to causes

causes of all possible product faults due to processequipment problems

Note this is not primarily about faults caused by things outside the processequipment eg unspecified changes in feedraw materials but the possibility of this cause for a fault should be included as required knowledge

Language literacy and numeracy requirements

This unit requires the ability to communicate to operators tradespeople and other technical experts about technical issues

Reading is required to the level of being able to interpret and apply procedures technical manuals and manufacturer manuals Writing is also required to be able to write maintenance and similar requestsorders update procedures and write equipmentprocess condition specifications

Numeracy is required to interpret test data technical specifications instrument readings and measurements Some calculation may be involved in developing and implementing solutions

Evidence Required

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

This competency requires the diagnosis of real product faults and the development and implementation of solutions to these faults The diagnosis of a number of faults with different types of causes should be required

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

Critical aspects

It is essential that competence is demonstrated in the knowledge and skills defined in this unit These may include the ability to

recognise defective product

isolate one or two most likely causes and justify the selection of those causes

devise a permanent solution to the problem and justify that solution

check that the solution works

work with all the required people to make it happen

Consistent performance should be demonstrated For example look to see that

defects with different root causes are analysed

defects with both process condition and equipment problem causes are solved

defects across the applicable range of products and processes are solved

Context of assessment

Competence in this unit may be assessed

on a processing plant as a routine part of the job

as special projects on a processing plant

using a suitable simulation andor a range of case studiesscenarios

through 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

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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. Add any 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.

Where reference is made to industry codes of practice and/or Australian/international standards, the latest version must be used.

Context

This competency applies to technicians who have a role of problem solving product faults as it relates specifically to equipment/process problems. While the technician will take the lead role in this activity, they will need to liaise with a range of people at all levels in the organisation to obtain information and to implement the solution.

This diagnosis and improvement may take place as a result of a problem where the fault level is causing reject product, or it may occur as part of continuous improvement, or a kaizen blitz or other situation where the products are not faulty, but are being improved.

Fault

A fault is any defect in a product, whether it causes the product to be defective or not.

Typical faults may include:

colour variation (non-uniform, not to standard hue/intensity/opacity)

surface blemishes (specs, marks)

surface finish (gloss level, uneven)

size/shape (distorted, wrong, variable)

within specification, but highly variable, forms patterns etc (ie has 'assignable cause')

strength/stiffness/physical properties (too high/low, variable, uneven)

chemical properties

physical/mechanical properties

biological/biochemical/microbiological properties.

Examine

Examination of products/process may include:

visual examination

examination of product quality or other records

examination of inspection records (if used)

examination of test results (routine or otherwise)

specific examination testing undertaken as part of a product improvement activity.

Possible causes

Possible causes include all feasible causes of the problem, before checking to eliminate some.

Investigate

Investigating possible causes includes:

talking with operators and others

checking machine histories for prevailing process conditions

checking current process/equipment conditions

carrying out small tests to determine the likelihood of a causal link between a condition and a fault.

Health Safety and Environment (HSE)

All operations to which this unit applies are subject to stringent health, safety and environment requirements, which may be imposed through State 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.

Procedures

All operations are performed in accordance with procedures.

Procedures means all relevant workplace procedures, work instructions, temporary instructions and relevant industry and government codes and standards.

Tools and equipment

This competency includes use of equipment and tools such as:

laboratory test facilities for the product (although the conduct of tests is not part of this unit)

equipment test instruments for checking the condition of plant (although the conduct of these tests may not be part of this unit).

Process/equipment conditions

Process/equipment conditions may include:

settings such as temperature, pressure

rates such as feed rate, flow rate

setting and adjustment of equipment parts

worn and broken equipment parts.

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