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

FPPCPP440A Mapping and Delivery Guide
Troubleshoot and rectify coated paper processes

Version 1.0
Issue Date: March 2024


Qualification -
Unit of Competency FPPCPP440A - Troubleshoot and rectify coated paper processes
Description This unit describes the outcomes required to troubleshoot and rectify coated paper processes in the pulp and paper industryGeneral legislation, regulatory, licensing and certification requirements applicable to this unit are detailed in the range statementSpecific high risk licensing requirements for this unit may be applicable and are to be met separately and prior to the achievement of this unit
Employability Skills This unit contains employability skills
Learning Outcomes and Application This unit applies to operators who troubleshoot and rectify coated paper processes in the pulp and paper industry. This work typically involves complex integrated equipment and continuous operationsThis unit generally applies to those who:identify and diagnose causes of process variation, plant or equipment faultsrectify process variation, plant and equipment faultsidentify and rectify product quality faults, andrecord and report troubleshooting activitiesto meet safety, quality and productivity requirementsIt does not include monitoring and controlling, starting up or shutting down coated paper processes
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.
Prerequisites/co-requisites Not Applicable
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: Identify and diagnose causes of process variation, plant or equipment faults
  • Causes of process variation, plant or equipment faults are identified and diagnosed within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements
  • Visual assessments and machine alarm systems are interpreted to determine fault type and location
  • Routine physical inspections of plant and processes are made to identify faults
  • Cause and source of process variation, plant or equipment faults is identified and located using appropriate techniques
  • Relevant historical data is accessed and analysed to confirm diagnosis as required
  • Problems are communicated to relevant personnel
       
Element: Rectify process variation, plant and equipment faults
  • Process variation, plant and equipment faults are rectified within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements
  • Emergency stop or shutdown, isolation and lockout procedures are initiated prior to fault rectification
  • Faulty equipment or instrumentation is isolated and repaired or replaced
  • Corrective operational adjustments and maintenance requirements are implemented
  • Restoration to normal operation is achieved and communicated to relevant personnel
       
Element: Identify and rectify product quality faults
  • Product quality faults are identified and rectified within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements
  • Product faults or variations are identified by observation, systematic sampling and testing
  • Out-of-specification product is managed
  • Sampling for a range of tests is undertaken
  • Required tests are conducted
  • Test results are interpreted and operations are adjusted to correct variations
       
Element: Record and report troubleshooting activities
  • Troubleshooting activities are recorded and reported within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements
  • Variations from specification and machine operation faults are documented
  • Assessment and evaluation of causes of deviation, and corrective action undertaken is recorded as required
  • Relevant information is communicated to appropriate personnel
       


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

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

Evidence should be relevant to the work. It should satisfy the requirements of the elements and performance criteria and include consideration of:

the required knowledge and skills tailored to the needs of the specific workplace

applicable OHS regulations, environmental and safe working requirements/practices, SOP and housekeeping requirements

applicable aspects of the range statement

practical workplace demonstration of skills in troubleshooting and rectifying coated paper processes

Context of and specific resources for assessment

A workplace assessment must be used to assess:

the application of required knowledge on the job

the application of skills on the job, over time and under a range of typical conditions that may be experienced in coated paper processes

Access to the full range of equipment involved in integrated continuous manufacturing of coated paper processes in a pulp or paper mill is required

Method of assessment

A combination of assessment methods should be used. The following examples are appropriate for this unit:

observation of applied skills and knowledge on the job

workplace demonstrations via a mock-up or simulation that replicate part/s of the job

answers to written or verbal questions about specific skills and knowledge

third-party reports from relevant and skilled personnel

written evidence e.g. log sheet entries, checklist entries, test results

Assessment processes and techniques must be culturally appropriate and in keeping with the language and literacy capacity of the learner and the work being performed. This includes conducting an assessment in a manner that allows thoughts to be conveyed verbally so that the learner can both understand and be understood by the assessor (e.g. use plain English and terminology used on the job)

A holistic assessment with other units relevant to the pulp and paper industry, mill and job role is recommended

Additional information on approaches to assessment for the pulp and paper industry is provided in the Assessment Guidelines for this Training Package


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.

This describes the skills and knowledge required for this unit.

Required skills

Identifies, accesses and interprets relevant historical and operational data and information

Uses required forms of communication in troubleshooting and rectifying coated paper processes

Reads and interprets required documentation, procedures and reports

Prepares written information for a range of audiences

Makes recommendations for further action

Accesses, navigates and enters computer-based information

Monitors, analyses and interprets data

Interprets instruments, gauges and data recording equipment

Communicates effectively with personnel to assist with analysis and resolution of operational problems

Assists others to identify and resolve operational problems in the workplace

Identifies and actions systems, quality and equipment faults within level of responsibility

Identifies causes and effects of faults and corrective action on associated processes

Selects and uses appropriate troubleshooting methods

Takes timely corrective action to maximise safety, quality and productivity

Undertakes necessary calculations to aid troubleshooting, as required

Identifies and monitors process control points

Maintains situational awareness in the work area

Responds to emergencies or unplanned shutdowns in accordance with SOP

Implements isolations and lockouts according to SOP

Identifies and implements operational procedures

Maintains plant operation and production with minimal interruptions

Maintains grade specification and quality or initiates appropriate action to rectify

Identifies and implements test requirements

Takes samples, conducts tests and interprets and records results if required

Uses measuring equipment as required

Operates high risk load shifting equipment as required

Uses technology to assist work performance

Analyses and uses sensory information to adjust process to maximise safety, quality and productivity

Uses electronic and other control systems to control equipment and processes as required

Required knowledge

Procedures, regulations and legislative requirements relevant to coated paper processes including OHS, environmental including relevant sustainability requirements/practices, SOP, isolation procedures, safe working requirements, risks and hazard identification and housekeeping

Relevant forms of communication

Detailed knowledge of coated paper processes and associated services sufficient to troubleshoot including:

plant layout

theory of operation

causes and effects of adjustments made to coated paper plant and processes

relationships between coated paper processes and associated services

An appropriate range of troubleshooting methods

Impact of inappropriate responses

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

Cause and effect of test results and actions

Product grade and process adjustment procedures

Application of high risk load shifting equipment as required

Sensory information that indicates a deviation from standard operating parameters

Sufficient knowledge of electronic and other control systems, operation and application to make appropriate adjustments that control coated paper processes, within level of responsibility

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.

Productivity requirements may include:

energy efficiency

waste minimisation

evaporation minimisation, including landfill and waste water reduction

environmentally safe waste disposal

consideration of resource utilisation, including fibre efficiency

minimising delays

chemical recovery maximisation

meeting key performance indicators

line speed

handovers

quality checks

meeting output targets i.e. net tonnes per employee per annum

machine/process time availability i.e. time the machine or process is making product

machine/process production rate

Coated paper processes may include:

tail feed systems

chemical and material batching

laminating and coating

splicing

clay plant operation

calender

pre-reeler operations

super calendering

monitoring systems

rewindering

drying systems

internal unloading

combine rollers

testing

Materials and supplies may include:

chemicals and polymers

power

water

additives

steam

labels

felts

equipment

gas

accessories (parts)

air

base paper

Equipment may include:

coater

splicer

pre-reelers

crimpers

calender

super-calender

parent rolls and reels

cranes

pigment

coating makedown plant

starch cooker

slitter

computer systems

electronic screens and alarms

process control systems

analogue and digital instrumentation

fully automated, semi-automated, manually operated plant and equipment appropriate to the coated paper process

Electronic control systems may include:

Digital Control System (DCS)

touch screens

robotics

Legislation, regulatory, licensing and certification requirements may include:

OHS and environmental requirements (local, state and commonwealth)

activity or task specific high risk licensing requirements

Documentation, procedures and reports may include:

SOP

quality procedures

environmental sustainability requirements/practices

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 e.g. plant clearance, job safety analysis, permit systems

product specifications and schedules

maintenance logs

job sheets

site agreements

safety instructions

process and instrument diagrams

machine manuals

troubleshooting guides

incidents reports

Maintenance may include:

operator level maintenance as per site agreements

operator maintenance schedules

maintenance systems

maintenance suppliers

proactive maintenance strategies e.g. Total Productive Maintenance (TPM), Reliability Centred Maintenance (RCM)

Actions may include:

process adjustments

reporting to authorised person

rectifying problem within level of responsibility

Communications may include

interaction with:

internal/external customers and suppliers

team members

production/service co-ordinators

maintenance services

operator support personnel

operational management

statutory authorities

Situational awareness may include

awareness of:

traffic

pedestrians

location of equipment

product

hazards

obstruction

unexpected movement

Forms of communication may include:

written e.g. log books, emails, incident and other reports, run sheets, data entry

reading and interpreting documentation e.g. SOP, manuals, checklists, drawings

verbal e.g. radio skills, telephone, face to face, handover

non-verbal e.g. hand signals, alarms, observations

signage e.g. safety, access

Sensory information may include:

visual

sound

feel

touch

smell

vibration

temperature

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
Causes of process variation, plant or equipment faults are identified and diagnosed within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements 
Visual assessments and machine alarm systems are interpreted to determine fault type and location 
Routine physical inspections of plant and processes are made to identify faults 
Cause and source of process variation, plant or equipment faults is identified and located using appropriate techniques 
Relevant historical data is accessed and analysed to confirm diagnosis as required 
Problems are communicated to relevant personnel 
Process variation, plant and equipment faults are rectified within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 
Emergency stop or shutdown, isolation and lockout procedures are initiated prior to fault rectification 
Faulty equipment or instrumentation is isolated and repaired or replaced 
Corrective operational adjustments and maintenance requirements are implemented 
Restoration to normal operation is achieved and communicated to relevant personnel 
Product quality faults are identified and rectified within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 
Product faults or variations are identified by observation, systematic sampling and testing 
Out-of-specification product is managed 
Sampling for a range of tests is undertaken 
Required tests are conducted 
Test results are interpreted and operations are adjusted to correct variations 
Troubleshooting activities are recorded and reported within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 
Variations from specification and machine operation faults are documented 
Assessment and evaluation of causes of deviation, and corrective action undertaken is recorded as required 
Relevant information is communicated to appropriate personnel 

Forms

Assessment Cover Sheet

FPPCPP440A - Troubleshoot and rectify coated paper processes
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

FPPCPP440A - Troubleshoot and rectify coated paper processes

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: