FPPRES340A - Troubleshoot and rectify primary resource operations Competency Mapping Template

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

FPPRES340A Mapping and Delivery Guide
Troubleshoot and rectify primary resource operations

Version 1.0
Issue Date: April 2024

Qualification	-	Unit of Competency	FPPRES340A - Troubleshoot and rectify primary resource operations
Description	This unit describes the outcomes required to troubleshoot and rectify primary resource operations in the pulp and paper industry General legislation, regulatory, licensing and certification requirements applicable to this unit are detailed in the range statementSpecific high risk (and non-high risk) load shifting 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 primary resource operations in the pulp and paper industry. This work typically involves complex integrated equipment and continuous operations This unit generally applies to those who:identify and diagnose causes of process variation, plant or equipment faultsrectify process variation, plant or equipment faultsidentify and rectify product quality faults, andrecord and report troubleshooting activitiesto meet safety, quality and productivity requirementsIt does not include receiving or unloading materials, preparing and operating the woodchip production system or distributing woodchips
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 alarms are interpreted to determine fault type and location Routine physical inspections of plant and process are made to identify faults Causes and sources of process variation, plant or equipment faults are identified and located using appropriate techniques Relevant historical data is accessed and analysed to confirm diagnosis
Element: Rectify process variation, plant or equipment faults	Process variation and plant or 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 operator level 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 production is managed Samples for a range of tests are 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 specifications and machine operating faults are documented Assessment and evaluation of causes of deviations and corrective actions undertaken are documented Relevant information is communicated to the 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 primary resource operations
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 primary resource operations Access to the full range of equipment involved in integrated continuous manufacturing of primary resource operations 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 primary resource operations

Reads and interprets required documentation, procedures and reports

Accesses, navigates and enters computer-based information

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

Sets up and operates test equipment

Performs tests and interprets and records results if required

Uses measuring equipment as required

Uses routine checking procedures during plant and systems operation

Conducts routine checks during plant and systems operation

Operates high risk (and non-high risk) load shifting equipment, as required

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 primary resource operations 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 primary resource operations, processes and associated services sufficient to troubleshoot including:

plant layout

theory of operation

causes and effects of adjustments made to primary resource handling plant and processes

relationships between primary resource handling system, processes and associated services

An appropriate range of troubleshooting methods

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

Types, causes and effects of plant shutdowns

Application of high risk (and non-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 primary resource operations, 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.
Materials and supplies may include:	hardwood or softwood logs lapped pulp waste paper woodchips supplies parts
Equipment may include:	chipper hogger conveyor feed systems chipscreens hydraulic cutting equipment blades chainsaws magnetic detectors silos hopper and storage systems docking saw bark transferring systems and debarking machinery chip spreaders and slingers trailer or tipper articulated loader tracked dozer and front end loader forklift side loader mobile crane rigid loader log loader straddle truck computer systems electronic screens and alarms process control systems analogue and digital instrumentation fully automated, semi-automated, manually operated plant and equipment appropriate to primary resource operations
Accessories may include:	protective and high visibility safety clothing and equipment break down tools and equipment electronic communication equipment
Testing equipment may include	drying ovens sizing screens computer processing equipment
Electronic control systems may include:	Digital Control System (DCS) touch screens robotics
Attachments may include:	fork lift attachments crane hooks chains slings and straps grabs winches
Legislation, regulatory, licensing and certification requirements may include:	OHS and environmental requirements (local, state and commonwealth) activity or task specific high risk (and non-high risk) load shifting licensing requirements
Documentation, procedures and reports may include:	SOP quality procedures environmental sustainability requirements/practices plant manufacturing operating manuals enterprise policy, procedures and guidelines oil or chemical spills and disposal guidelines plant isolation documentation safe work documentation e.g. plant clearance, job safety analysis, permit systems weighbridge dockets work orders tally sheets truck delivery dockets invoices non-conformance reports test results and reports log sheets (production and equipment) equipment performance data tonnage, input and conversion sampling and test reports Material Safety Data Sheets (MSDS) pile survey documents process and instrument diagrams
Maintenance may include:	operator level maintenance as per site agreements operator maintenance schedules maintenance systems maintenance suppliers pro-active 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: work area personnel internal/external customers and suppliers team members production/service coordinators maintenance services 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 alarms are interpreted to determine fault type and location
Routine physical inspections of plant and process are made to identify faults
Causes and sources of process variation, plant or equipment faults are identified and located using appropriate techniques
Relevant historical data is accessed and analysed to confirm diagnosis
Process variation and plant or 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 operator level 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 production is managed
Samples for a range of tests are 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 specifications and machine operating faults are documented
Assessment and evaluation of causes of deviations and corrective actions undertaken are documented
Relevant information is communicated to the appropriate personnel

Forms

Assessment Cover Sheet

FPPRES340A - Troubleshoot and rectify primary resource operations

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

FPPRES340A - Troubleshoot and rectify primary resource operations

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:

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

FPPRES340A Mapping and Delivery Guide Troubleshoot and rectify primary resource operations

Version 1.0 Issue Date: April 2024

Evidence Required

Submission Requirements

Assessment Tasks

Observation Checklist

Forms

Assessment Cover Sheet

FPPRES340A - Troubleshoot and rectify primary resource operations

Assessment task 1: [title]

Assessment Record Sheet

FPPRES340A - Troubleshoot and rectify primary resource operations

FPPRES340A Mapping and Delivery Guide
Troubleshoot and rectify primary resource operations

Version 1.0
Issue Date: April 2024