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Elements and Performance Criteria

1. Determine production requirements
   • Access and interpret production plan.
   • Confirm grade specifications and limits and communicate to relevant personnel.
   • Determine process requirements according to standard operating procedures (SOP).
   • Confirm process supplies are available for production.
   • Determine chemical and material requirements.
2. Inspect and prepare systems for startup
   • Remove isolations according to housekeeping requirements.
   • Complete pre-startup checks on equipment in line with work health and safety (WHS), environmental and safe working requirements and practices.
   • Confirm electrical power and process supplies as available for production.
   • Prepare chemical and material delivery system for operation.
   • Confirm operational settings within specification.
   • Confirm production ready status with relevant personnel.
   • Check monitoring devices and systems and confirm as operational.
   • Identify faults and rectify as required.
3. Co-ordinate startup operations
   • Co-ordinate equipment startups for production.
   • Co-ordinate and confirm system functions by monitoring plant, equipment and control system/display monitors.
   • Communicate process operation status to relevant personnel.
   • Log, record and file production startup details.
4. Stabilise production process after startup
   • Monitor processes and adjust to rectify variations from specification.
   • Make adjustments/modifications to stabilise coating quality within specification.
   • Take samples as required to ensure product quality requirements are met.
   • Verify product tests as within specification.
   • Record process operation, production and quality data.

Range Statement

Not Applicable

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Performance Evidence

A person demonstrating competency in this unit must satisfy all of the elements, performance criteria and foundation skills of this unit, and must be able to provide sufficient evidence of the ability to:

prepare and start up coated paper processes, at least twice in line with required enterprise intervals, for at least one of the following systems:

tail feed systems

chemical and material batching

laminating and coating

splicing

clay plant operation

calender

pre-reeler operations

super calendering

rewinding

drying systems

combine rollers

determine coating production requirements

conduct checks to ensure availability of sheet, coating chemicals and electrical power

conduct checks to ensure space availability for coated sheet

ensure isolations are removed according to standard operating procedures

conduct pre-startup checks of plant and equipment including instrumentation

input operational settings in preparation for startup in according to standard operating procedures

activate and confirm operation of coating system according to standard operating procedures

take samples, conduct tests on product post startup and interpret and record results

make process control adjustments to stabilise production and ensure product quality

conduct routine maintenance checks on equipment.

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Knowledge Evidence

A person competent in this unit must be able to demonstrate knowledge of:

information provided on the production specification sheet

working knowledge of coated paper processes, system layout and associated services sufficient to carry out startup activities

interaction requirements within the coating area members and with the area's suppliers and customers

cause and effect of operational equipment faults

sampling and testing process for plant and system operations and process monitoring - purpose, standards and procedures as per site agreements

purpose of each of the steps in the preparation of the coating system for production

purpose of each component of the coating system

purpose and location of the coating chemical supply system

critical control points of the preparation for startup procedure

purpose of the process controls and how changes affect the production variables

critical control points of the startup procedure

critical control points of the monitoring process during startup

electronic and other control systems, operation and application to make appropriate adjustments that control coated paper processes.

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