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

FPPSPR210A Mapping and Delivery Guide
Monitor and control stock preparation systems

Version 1.0
Issue Date: March 2024


Qualification -
Unit of Competency FPPSPR210A - Monitor and control stock preparation systems
Description This unit describes the outcomes required to monitor and control stock preparation systems in the pulp and paper industryGeneral 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 monitor and control stock preparation systems in the pulp and paper industry. This work typically involves complex integrated equipment and continuous operationsThis unit generally applies to those who:monitor and control process and systemscontrol quality of stock, chemicals and waterconduct product grade change, and record process and system informationto meet safety, quality and productivity requirementsIt does not include starting up, shutting down or troubleshooting and rectifying stock preparation systems
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: Monitor and control process and systems
  • Process and systems are monitored and controlled within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements
  • Production requirements are checked at start of shift to plan day's activities as required
  • Operational status is confirmed by inspection, observations and other information
  • Process supplies are maintained and controlled to meet production requirements
  • Systems are monitored to ensure stock preparation systems are within parameters
  • Process and system variations from operating parameters are identified, rectified and/or reported
  • Operator level preventative maintenance is undertaken as required
  • Changes to machine operations are communicated to relevant personnel
  • Stock systems are monitored and adjusted during stock-off situations as required
       
Element: Control quality of stock, chemicals and water
  • Quality of stock, chemicals and water is controlled within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements
  • Quality of stock, chemical and water is monitored and controlled within parameters
  • Test samples are taken and test results are interpreted and recorded as required
  • Adjustments are made to ensure quality requirements are met
  • Routine observations and assessments are conducted on product and system operations
  • Changes to product requirements are communicated to relevant personnel
       
Element: Conduct product grade change
  • Product grade changes are conducted within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements
  • Product grade change is completed within OHS, SOP, environmental and safe working requirements and practices
  • Grade change requirements are determined and planned
  • Run out of stock, chemicals and water systems are coordinated and completed as required
  • Flushing, draining and cleaning of stock, chemicals and water systems are completed as required
  • Process set ups/adjustments are implemented to meet new grade requirements
  • Raw materials and supplies required for new grade requirements are staged ready for use
  • Stock, chemicals and water systems startups are coordinated and implemented for new grade requirements as required
  • Grade change is coordinated and implemented on the run as required
       
Element: Record process and system information
  • Recording process and system information is completed within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements
  • Systems and production information is recorded
  • Problems or variations in performance are recorded and communicated
       


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 the monitoring and controlling of stock preparation systems

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 stock preparation systems

Access to the full range of equipment involved in integrated continuous manufacturing of stock preparation systems 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

Uses required forms of communication in monitoring and controlling stock preparation systems

Reads and interprets required documentation, procedures and reports

Interprets instruments, gauges and data recording equipment

Accesses, navigates and enters computer-based information

Identifies and actions problems within level of responsibility

Interprets and plans grade change requirements

Co-ordinates and conducts grade changes

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

Uses measuring equipment as required

Identifies and monitors process control points

Maintains situational awareness in the work area

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

Analyses and uses sensory information to adjust process to maintain 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 stock preparation systems including OHS, environmental including relevant sustainability requirements/practices, SOP, isolation procedures, safe working requirements, risks and hazard identification and housekeeping

Relevant forms of communication

Basic problem-solving techniques consistent with level of responsibility

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

Stock preparation in-process tests and procedures

Working knowledge of stock preparation plant, processes, layout and associated services including operating parameters, variation and associated adjustments within level of responsibility

Grade requirements

Quality requirements

Materials and supplies and how they influence paper properties

Grade change processes and coordination

Timing for materials and supplies run out

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 stock preparation systems, 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

Systems and functions involved in stock preparation may include:

refining systems

blending system

proportioning system

broke system

stock chests

water chests

cleaning system

water recovery system

chemical and additive plants

bale handler

broke baler

wire coiler

Materials and supplies may include:

water

stock

compressed air

chemicals

additives

steam

baled pulp

Equipment may include:

refiners

pumps

valves

chests

agitators

pulpers

screens

cleaners

showers

disc deckers

consistency controllers

screw press

water recovery equipment

computer systems

electronic screens and alarms

process control systems

fully automated, semi-automated, manually operated plant and equipment appropriate to stock preparation systems

Electronic control systems may include:

Digital Control System (DCS)

touch screens

robotics

Hazards and risks involved in stock preparation may include:

steam and/or gas leaks

fires

nip points

compressed air

hot surfaces

electrical

entanglement

slip hazards/falls

energy

pressures

chemicals

fumes

confined spaces

dust

Legislation, regulatory, licensing and certification requirements may include:

OHS and environmental requirements (local, state and commonwealth)

as applicable, activity or task specific high risk (and non-high risk) load shifting licensing requirements

Documentation, procedures and reports may include:

SOP

site policy and procedures

environmental sustainability requirements/practices

plant manufacturing operating manuals

confined space requirements

vendor documentation

reference manual

grade specifications

quality procedures

oil or chemical spills and disposal guidelines

plant isolation documentation

housekeeping

safe work documentation e.g. plant clearance, job safety analysis, permit systems

maintenance logs

job sheets

operating log

production instructions

Materials Safety Data Sheets (MSDS)

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

interactions with:

team members

production/service co-ordinators

internal/external customers and suppliers

maintenance services

operational management

statutory authorities

Situational awareness may include

awareness of:

traffic

pedestrians

location of equipment

product

hazards

obstructions

unexpected movement

Sensory information may include:

visual

sound

feel

touch

smell

vibration

temperature

Forms of communications may include:

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

reading and interpreting documentation e.g. standard operating procedures, 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

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
Process and systems are monitored and controlled within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements 
Production requirements are checked at start of shift to plan day's activities as required 
Operational status is confirmed by inspection, observations and other information 
Process supplies are maintained and controlled to meet production requirements 
Systems are monitored to ensure stock preparation systems are within parameters 
Process and system variations from operating parameters are identified, rectified and/or reported 
Operator level preventative maintenance is undertaken as required 
Changes to machine operations are communicated to relevant personnel 
Stock systems are monitored and adjusted during stock-off situations as required 
Quality of stock, chemicals and water is controlled within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 
Quality of stock, chemical and water is monitored and controlled within parameters 
Test samples are taken and test results are interpreted and recorded as required 
Adjustments are made to ensure quality requirements are met 
Routine observations and assessments are conducted on product and system operations 
Changes to product requirements are communicated to relevant personnel 
Product grade changes are conducted within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 
Product grade change is completed within OHS, SOP, environmental and safe working requirements and practices 
Grade change requirements are determined and planned 
Run out of stock, chemicals and water systems are coordinated and completed as required 
Flushing, draining and cleaning of stock, chemicals and water systems are completed as required 
Process set ups/adjustments are implemented to meet new grade requirements 
Raw materials and supplies required for new grade requirements are staged ready for use 
Stock, chemicals and water systems startups are coordinated and implemented for new grade requirements as required 
Grade change is coordinated and implemented on the run as required 
Recording process and system information is completed within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 
Systems and production information is recorded 
Problems or variations in performance are recorded and communicated 

Forms

Assessment Cover Sheet

FPPSPR210A - Monitor and control stock preparation systems
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

FPPSPR210A - Monitor and control stock preparation systems

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: