Unit of Competency Mapping – Information for Teachers/Assessors – Information for Learners

FDFOP2022A Mapping and Delivery Guide
Operate a high speed wrapping process

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency FDFOP2022A - Operate a high speed wrapping process
Description This unit of competency covers the skills and knowledge required to set up, operate, adjust and shut down a primary packaging process using high speed wrapping equipment to enclose product in a sealed, airtight film/cello package
Employability Skills This unit contains employability skills.
Learning Outcomes and Application This unit has application in a food processing packing environment. It typically targets the worker responsible for applying basic operating principles to the operation and monitoring of a high speed wrapping process and associated equipment.When batch or product changeover procedures are part of this work process, the procedures should be used to customise the application of this unit. Where more detailed changeovers are carried out, FDFOP2011A Conduct routine maintenance, should be considered.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.
Prerequisites/co-requisites
Competency Field
Development and validation strategy and guide for assessors and learners Student Learning Resources Handouts
Activities 		Slides
PPT 		Assessment 1 Assessment 2 Assessment 3 Assessment 4
Elements of Competency Performance Criteria              
Element: Prepare the wrapping equipment and process for operation
  • Materials and packaging components/consumables are confirmed and available to meet production requirements
  • Pre-start checks are carried out on process and related equipment to confirm readiness for use
  • Packaging components/consumables are loaded/positioned to meet requirements
  • Parameters are set to meet safety and packaging requirements
       
Element: Operate and monitor the wrapping process
  • The process is started and operated according to workplace procedures
  • Equipment is monitored to identify variation in operating conditions
  • Variation in equipment operation is identified and maintenance requirements are reported according to workplace reporting requirements
  • Packaging quality and seal integrity is monitored to confirm that specifications are met
  • Out-of-specification process outcomes are identified, rectified and/or reported to maintain the process within specification
  • The work area is maintained according to housekeeping standards
  • Work is conducted in accordance with workplace environmental guidelines
  • Workplace records are maintained according to workplace recording requirements
       
Element: Shut down the wrapping process
  • The appropriate shutdown procedure is identified
  • The process is shut down according to workplace procedures
  • Maintenance requirements are identified and reported
       


Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

The Evidence Guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment

Assessment must be carried out in a manner that recognises the cultural and literacy requirements of the assessee and is appropriate to the work performed. Competence in this unit must be achieved in accordance with food safety standards and regulations.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Evidence of ability to:

conduct pre-start checks on machinery used for high speed wrapping

start, operate, monitor and adjust process equipment to achieve required quality outcomes

take corrective action in response to typical faults and inconsistencies

complete workplace records as required

apply safe work practices and identify OHS hazards and controls

safely shut down equipment

apply food safety procedures.

Context of and specific resources for assessment

Assessment must occur in a real or simulated workplace where the assessee has access to:

personal protective clothing and equipment

work procedures, including advice on safe work practices, food safety, quality and environmental requirements, stock flow systems and production/packaging schedules

information on equipment capacity and operating parameters

specifications, control points and operating parameters

high speed wrapping machine and related equipment and services

materials to be wrapped, cello/film and other packaging components/consumables

documentation and recording requirements and procedures

cleaning procedures, materials and equipment as required.

Method of assessment

This unit should be assessed together with core units and other units of competency relevant to the function or work role. Examples could be:

FDFOP2004A Clean and sanitise equipment

FDFOP2011A Conduct routine maintenance

FDFOP2013A Apply sampling procedures

FDFOP2030A Operate a process control interface

MSL973001A Perform basic tests.

Guidance information for assessment

To ensure consistency in one's performance, competency should be demonstrated on more than one occasion over a period of time in order to cover a variety of circumstances, cases and responsibilities, and where possible, over a number of assessment activities.

Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assignment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)

Assessment Tasks

Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.

Required skills

Ability to:

access workplace information to identify wrapping requirements

select, fit and use personal protective clothing and/or equipment

confirm supply of necessary packaging materials/film/cello and product, such as inspecting the quality of both product and wrapping material to confirm that standards are met

conduct pre-start checks, such as inspecting equipment and conveyor belt condition to identify any signs of wear, selecting appropriate settings and/or related parameters to suit product type, cancelling isolation or lockouts as required, confirming that equipment is clean and correctly configured for packaging requirements, loading/threading packaging components/consumables, positioning electronic eyes and sensors correctly, ensuring all safety guards are in place and operational, and confirming coders are correctly set for date and product requirements

start, operate, monitor and adjust wrapping equipment to achieve required outcomes, including monitoring control points and conducting inspections as required to confirm process remains within specification, such as:

product alignment

product weights

packaging quality

packaging and product alignment

seal integrity, such as testing packaging integrity

codes-correct content and clarity/legibility

monitor flow of product to and from the process

take corrective action in response to out-of-specification results

respond to and/or report equipment failure within level of responsibility

locate emergency stop functions on equipment

follow isolation and lock out/tag out procedures as required to take high speed wrapping process and related equipment off-line in preparation for cleaning and/or maintenance within level of responsibility

prepare wrapping equipment and conveyors for cleaning

demonstrate product/packaging changeovers

complete workplace records as required

maintain work area to meet housekeeping standards

use process control systems according to enterprise procedures

collect samples and conduct tests according to enterprise procedures

clean and sanitise equipment according to enterprise procedures

use oral communication skills/language competence to fulfil the job role as specified by the organisation, including questioning, active listening, asking for clarification and seeking advice from supervisor

work cooperatively within a culturally diverse workforce

Required knowledge

Knowledge of:

purpose and basic principles of wrapping, including the properties and requirements of packaging materials used, coding requirements and related legal requirements (e.g. product weight)

basic operating principles of wrapping equipment, such as main equipment components (e.g. conveyors and related guides and alignment adjustments), purpose and location of electronic eyes and sensors, status and purpose of guards, equipment operating capacities and applications, and services required for operation of wrapping equipment used in the workplace

the flow of product to the wrapping process and the effect of outputs on downstream processes

quality characteristics and requirements of product to be wrapped, wrapping materials and the final wrapped product

methods used to monitor the process, such as inspecting, measuring and testing as required by the process

inspection or test points (control points) in the process and the related procedures and recording requirements

operating requirements and parameters and corrective action required where operation is outside specified operating parameters

typical equipment faults and related causes, including signs and symptoms of faulty equipment and early warning signs of potential problems

common causes of variation and corrective action required, including the effect of variation in both product and packaging components/consumables on performance

contamination/food safety hazards and risks associated with the wrapping process and related control measures

occupational health and safety (OHS) hazards and controls

requirements of different shutdowns as appropriate to the process and workplace production requirements, including emergency and routine shutdowns and procedures to follow in the event of a power outage

isolation, lock out and tag out procedures and responsibilities

product/packaging changeover procedures

procedures and responsibility for reporting production and performance information

environmental issues and controls relevant to the filling and wrapping process, including waste/rework collection and handling procedures related to the process

basic operating principles of process control, where relevant, including the relationship between control panels and systems and the physical equipment

sampling and testing procedures where relevant

cleaning and sanitation procedures where relevant

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. 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) may also be included.

Policies and procedures

Work is carried out according to company policies and procedures, regulatory and licensing requirements, legislative requirements, and industrial awards and agreements

Legislative requirements

Legislative requirements are typically reflected in procedures and specifications. Legislation relevant to this industry includes:

the Food Standards Code, including labelling, weights and measures legislation

legislation covering food safety, environmental management, OHS, anti-discrimination and equal opportunity

When applied to the pharmaceutical industry, relevant Good Manufacturing Practice (GMP) codes apply in place of the Australian Food Standards Code and reference to food safety is replaced by GMP

Workplace information

Workplace information may include:

standard operating procedures (SOPs)

specifications

production schedules and instructions

manufacturers' advice

standard forms and reports

High speed wrapping processes and related equipment

A high speed wrapping process and related equipment may include:

conveyor systems transferring product to and from wrappers

wrapper

check weighers

metal detectors

ink jet coders

Related processes typically involve:

secondary packing into boxes, bags or other containers

Shutdown procedures

Shutdown procedures may include:

cleaning (in some cases cleaning may be carried out by a dedicated cleaning crew)

Operation of equipment and processes

Operation of equipment and processes may require:

the use of process control panels and systems

Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.

Observation Checklist

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Materials and packaging components/consumables are confirmed and available to meet production requirements 
Pre-start checks are carried out on process and related equipment to confirm readiness for use 
Packaging components/consumables are loaded/positioned to meet requirements 
Parameters are set to meet safety and packaging requirements 
The process is started and operated according to workplace procedures 
Equipment is monitored to identify variation in operating conditions 
Variation in equipment operation is identified and maintenance requirements are reported according to workplace reporting requirements 
Packaging quality and seal integrity is monitored to confirm that specifications are met 
Out-of-specification process outcomes are identified, rectified and/or reported to maintain the process within specification 
The work area is maintained according to housekeeping standards 
Work is conducted in accordance with workplace environmental guidelines 
Workplace records are maintained according to workplace recording requirements 
The appropriate shutdown procedure is identified 
The process is shut down according to workplace procedures 
Maintenance requirements are identified and reported 

Forms

Assessment Cover Sheet

FDFOP2022A - Operate a high speed wrapping process
Assessment task 1: [title]

Student name:

Student ID:

I declare that the assessment tasks submitted for this unit are my own work.

Student signature:

Result: Competent Not yet competent

Feedback to student

 

 

 

 

 

 

 

 

Assessor name:

Signature:

Date:

Assessment Record Sheet

FDFOP2022A - Operate a high speed wrapping process

Student name:

Student ID:

Assessment task 1: [title] Result: Competent Not yet competent

(add lines for each task)

Feedback to student:

 

 

 

 

 

 

 

 

Overall assessment result: Competent Not yet competent

Assessor name:

Signature:

Date:

Student signature:

Date: