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Elements and Performance Criteria

1. Implement planned shutdown procedures
   • Identify planned shutdown of coated paper process from work area instructions or maintenance schedules.
   • Follow coated paper process materials and supplies shutdown procedures, as required.
   • Manage plant or system shutdowns in accordance with production requirements, relevant workplace health and safety (WHS) procedures, risks and hazards identification and environmental workplace procedures.
   • Implement isolation and lock out requirements, according to standard operating procedures (SOP) and housekeeping requirements.
   • Ensure plant integrity and personnel safety by following WHS procedures.
   • Communicate planned shutdown information to relevant personnel as required.
   • Wash and clean plant and equipment for restart.
2. Assess the cause and effect of an unplanned shutdown
   • Assess the cause and effect of an unplanned shutdown within WHS and environmental procedures, SOP and housekeeping requirements.
   • Identify abnormal operating conditions by analysis of technical and operational information.
   • Determine the effects of abnormal conditions to enable appropriate adjustments and rectification.
   • Locate the source of the cause of the shutdown, to ensure rectification.
   • Notify appropriate personnel, when abnormal operating conditions prevail.
   • Identify safety issues relevant to an unplanned shut down.
3. Record and report shutdown data
   • Record and report shutdown data within WHS and environmental procedures, SOP, and housekeeping requirements.
   • Record assessment and evaluation of causes and corrective actions, as required.
   • Communicate relevant information to appropriate personnel in accordance with operational requirements.

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 that they can undertake planned and unplanned shutdowns, at least twice in line with required enterprise intervals, by:

implementing planned equipment and plant shutdown procedures for coated paper processes and following workplace schedules and requirements

implementing isolation and lock out requirements according to standard operating procedures (SOP)

following procedures to communicate with relevant personnel and preparing equipment for restart after a planned shutdown

using and interpreting electronic control systems, including Digital Control System (DCS), touch screens or robotics to control equipment and processes during shutdowns

assessing the cause and effect of an unplanned shutdown for coated paper processes and rectifying abnormal conditions causing a shutdown

communicating with stakeholders about shutdowns, including internal and external customers and suppliers, team members, production/service co-ordinators, maintenance services, operator support personnel, operational management and statutory authorities

selecting and using appropriate forms of communication, from written or verbal, to inform about shutdown causes and corrective action, according to SOP

recording and reporting on shutdowns and corrective actions, in accordance with organisational requirements.

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Knowledge Evidence

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

documentation and procedures relevant to plant and system shutdowns for coated paper processes including:

work health and safety (WHS)

Standard Operating Procedures (SOP)

productivity requirements

quality procedures

environmental sustainability requirements/practices

machinery and plant manufacturing operating manuals

enterprise policies and procedures

Material Safety Data Sheets (MSDS)

oil or chemical spills and disposal guidelines

plant isolation documentation

safe work documentation including plant clearance, job safety analysis, permit systems, product specifications and schedules, emergency procedures and responses

maintenance logs

job sheets

site agreements

safety instructions

process and instrument diagrams

machine manuals

troubleshooting guides

incidents reports

plant and equipment and their functions for coated paper processes

types, causes and effects of coated paper processes and related materials used in coated paper processes including chemicals and polymers, power, water, additives, steam, labels, felts, equipment, gas, accessories (parts) and air

base paper coated paper processes, system layout and associated services sufficient to carry out shutdown activities

production needs including output targets, production scheduling quality requirements, resources and energy use, waste minimisation

processes and procedures for plant shutdowns and unplanned shutdowns

required responses to all unplanned shutdowns (power outage, mechanical breakdown, blockages, jamming, air supply, control system failure) to ensure safety quality and productivity

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

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