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Elements and Performance Criteria

1. Prepare for equipment/change parts installation
   • Identify all safety and emergency procedures
   • Shut down equipment in accordance with procedures/work instructions and manufacturer specifications
   • Isolate equipment according to procedures/work instructions
   • Remove ancillary equipment in accordance with procedures/work instructions and manufacturer specifications
   • Complete records and logs for removal of equipment or change parts
2. Prepare the process for production
   • Consult the production schedule to determine the product to be manufactured
   • Ensure that the raw materials are available as required
   • Ensure that the equipment/change parts, ancillaries and fixtures are available as required
   • Perform pre-instalment equipment preparation according to procedures/work instructions
   • Ensure that the equipment is in a safe condition for use
3. Set up process
   • Perform checks and tests to product and equipment specifications
   • Ensure alignment of all equipment according to product specifications and procedures/work instructions
   • Ensure that process/equipment is set up as required for the production schedule
4. Tune the process
   • Monitor operation and compare with standard operating procedures (SOPs) for appropriate operation
   • Identify any deviation from standard performance
   • Identify the cause of the deviation and take action
   • Make adjustments to the equipment settings, process conditions or raw materials to bring production into specification
   • Continue monitoring operation and making adjustments until product/equipment is within specification
5. Respond to problems
   • Identify possible routine and non-routine problems in the equipment or process
   • Determine problems needing action
   • Determine possible fault causes
   • Rectify problem using appropriate solution within area of responsibility
   • Report problems outside area of responsibility to designated person
6. Control hazards
   • Identify hazards from the job to be done
   • Identify other hazards in the work area
   • Assess the risks arising from those hazards
   • Implement measures to control those risks in line with 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. Applicable legislation, regulations, standards and codes of practice include: health, safety and environmental (HSE) legislation, regulations and codes of practice relevant to the workplace, equipment and production processes 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: manufacturer's technical information job cards drawings 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.
Hazards	Hazards must be identified and controlled. Identifying hazards requires consideration of: heat, smoke, dust, vapours or other atmospheric hazards weight, shape, volume of materials to be handled hazardous products and materials sharp edges, protrusions or obstructions slippery surfaces, spills or leaks electricity gas gases and liquids under pressure noise rotational equipment or vibration plant services (steam, condensate, cooling water, etc) structural hazards equipment failures machinery, equipment and product mass limited head spaces or overhangs working at heights working in restricted or confined spaces other hazards that might arise.
Problems	Routine and non-routine problems must be resolved. Routine problems are predictable and have known solutions and include one or more of: variations in raw materials feed equipment alignment out-of-specification settings (e.g. temperature and speed) product quality problems. Non-routine problems are unexpected problems or variations of previous 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. Operational knowledge includes one or more of: procedures training technical information, such as journals and engineering specifications remembered experience relevant knowledge obtained from appropriate people.
Records and reports	Records include one or more of: log books/sheets electronic records job/work sheets other records used for the smooth running of the plant. Reports include one or more of: paper or electronic-based logs and reports verbal/radio reports reporting items found which require action.

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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, production schedules, test results, instruments/control panels, material labels and materials data safety sheets

set up equipment to process specifications

perform pre-start checks, start-up/shutdown procedures and isolations

monitor key variables, including:

operating temperatures

pressure

material flow

discharge rates

material properties/chemical reactions

cycle time

output rate

product integrity and general conformance to specification

use data and own senses to monitor plant and maximise performance

make adjustments to equipment settings, process conditions and/or raw materials to bring production into specification

identify hazards and apply relevant hazard controls

apply safety procedures

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

distinguish between causes of problems, including:

instrument failure/malfunction

electrical/mechanical failure/malfunction

wrong readings

raw material variations/contamination

process abnormalities

procedural errors

recognise and prioritise problems requiring action

resolve routine and non-routine problems

communicate effectively with team/work group and supervisors

complete workplace records

calculate and interpret process conditions, performance and trends.

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Knowledge Evidence

Must provide evidence that demonstrates knowledge relevant to their job sufficient to operate independently and to solve routine and non-routine problems, including knowledge of:

functions, limitations and principles of operation of the equipment used in the process

impact of variations in equipment settings, process conditions and raw materials on product quality and production output

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

basic physics and chemistry relevant to the equipment/process/materials

characteristics of materials being processed and their behaviour in relation to process conditions and stages of production

quality requirements at each stage of production

common adjustments in process variables and their impact on product quality and production output

start-up and shutdown processes

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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