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Elements and Performance Criteria

1. Identify and describe the problem
   • Identify and describe the problem within documentation and procedures, work health and safety (WHS) procedures, environmental procedures, standard operating procedures (SOP), and housekeeping requirements.
   • Gather information to define thetype and extent of the problem.
   • Gather information on the effect of the problem on quality or productivity or operations.
2. Assess the situation and determine actions
   • Take immediate action if safety, quality or productivity are compromised.
   • Notify personnel, as required.
   • Refer problem to appropriate work group or department.
   • Assess and select the most appropriate problem solving methodologies.
3. Conduct analysis
   • Assemble team for analysis, if required.
   • Use selected problem solving methodology.
   • Determine possible solutions.
   • Conduct quick fixes, if required.
   • Determine favoured solutions.
4. Determine action plan
   • Develop an action plan considering contingencies.
   • Document the action plan according to SOP.
   • Communicate the action plan to personnel.
   • Gain approval for the action plan from appropriate personnel.
5. Implement plan
   • Identify and organise resources to implement the action plan and consider relevant WHS procedures, environmental procedures, SOP, and housekeeping requirements.
   • Schedule plan and communicate to team and other personnel.
   • Assist team members, where required.
   • Implement the planned changes, to solve the problem, through process adjustments, reporting to an appropriate person or rectifying the problem.
6. Monitor and evaluate the solution
   • Monitor changes.
   • Evaluate the effectiveness of the solution.
   • Implement contingency planning, if required.
7. Document and report changes
   • Finalise and complete report using the required documentation.
   • Report the outcome of the solution.
   • Communicate the outcome of the solution to team and appropriate personnel.

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 evidence that they can:

identify the equipment maintenance, product quality and process inconsistency problems in a pulp or paper mill for at least two of the following operations:

coating systems

handling and preparing primary resources

steam generation

electrical power generation

handling and preparing waste paper for pulp production

waste paper operations

pulping operations

chemical recovery operations

finishing and converting

stock preparation operations

wet end operations

dry end operations

water services

identify the resources needed to address these problems including personnel, equipment, production process, materials or supplies or trouble shooting guides

select and apply suitable problem solving methodologies from the following list, according to the extent of problems:

industry specific methodologies:

e-learning tool

lean

root cause analysis techniques

5 whys

fish bone

sirf roundtable method

cause and effect diagrams

six sigma

Kepner - Tregoe

identify the type and extent of the problem

conduct an analysis and determine a solution

develop and implement an action plan to solve problems in operations

monitor and evaluate the effectiveness of the approach and the implementation of the action plan

report using the required documentation on the solution to the problem.

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Knowledge Evidence

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

problem solving methodologies which can be applied to common systemic problems with equipment and product quality in a pulp or paper manufacturing facility

documentation and procedures relevant to problem solving, including risk and hazard identification, work health and safety (WHS), quality, environmental (including relevant sustainability requirements and practices), isolation, housekeeping and standard operating procedures.

system, processes and associated services sufficient for problem solving including:

plant layout

theory of operation

causes and effects of adjustments made to equipment and processes

relationships between system, processes and associated services

effects of process variables on production and quality

planning procedures to predict possible solutions for problem solving

monitoring and evaluation processes for problem solving techniques

problem solving reporting requirements according to SOP.

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