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

FPPWPO440A Mapping and Delivery Guide
Troubleshoot and rectify waste paper operations

Version 1.0
Issue Date: April 2024


Qualification -
Unit of Competency FPPWPO440A - Troubleshoot and rectify waste paper operations
Description This unit describes the outcomes required to troubleshoot and rectify waste paper operations in the pulp and paper industry Specific 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 waste paper operations in the pulp and paper industry. This work typically involves complex integrated equipment and continuous operationsThis unit generally applies to those who:identify and analyse causes of faultsrectify plant faultsrectify product quality faults, andrecord and report system performance and product quality datato meet safety, quality and productivity requirementsIt does not include starting up, shutting down or monitoring and controlling waste paper operations
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 analyse causes of faults
  • Causes of faults are identified and analysed within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements
  • Alarms are interpreted to determine fault type and location
  • Sampling and testing results are interpreted to identify variations from specifications or schedule
  • Causes and sources of fault are identified and located
  • Relevant sources of information are accessed and interpreted to assist analysis
       
Element: Rectify plant faults
  • Plant faults are rectified within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements
  • Operator level on-line adjustments are conducted as required
  • Plant is shut down and isolation procedures are implemented prior to fault rectification
  • Faulty plant is isolated, by-passed, repaired or replaced as required
  • Plant is returned to normal operation
  • Verification is communicated to relevant personnel
       
Element: Rectify product quality faults
  • Product quality faults are rectified within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements
  • Quality faults or variations are identified by observation, systematic sampling and testing
  • Test results are interpreted and operations are adjusted to correct faults
  • Faults and causes are rectified if appropriate or recommendations made for further action
  • Out-of-specification product is managed
       
Element: Record and report system performance and product quality data
  • System performance and product quality data is recorded and reported within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements
  • Process variations and faults are recorded
  • Stock production and machine operation faults are recorded
  • Actions undertaken to troubleshoot and rectify faults are recorded
  • 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 waste paper 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 waste paper operations

Access to the full range of equipment involved in integrated continuous manufacturing of waste paper 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 waste paper 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

Uses troubleshooting guides and diagnostic procedures

Demonstrates that stock quality is consistently within specification

Maintains situational awareness in the work area

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

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 waste paper operation 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 waste paper system, processes and associated services sufficient to troubleshoot including:

plant layout

theory of operation

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

relationships between waste paper plant 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

Purpose and operation of reject systems

Purpose and operation of water systems

Purpose and effects of process variables on production and quality

Plant operation and control mechanisms

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 waste paper operation, 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

Waste paper operations may include:

pulping

screening

de-watering

reject systems

System shutdowns may be caused by:

product change

mechanical failures

crash shut

full storage or low supply storage

maintenance shut

process failures

Materials and supplies may include:

waste paper

air

chemicals

broke

steam

water

electricity

Equipment may include:

broke handling systems

fork trucks and front end loaders

cranes

communication equipment and 2-way radios

computer systems

electronic screens and alarms

process control systems

analogue and digital instruments

fully automated, semi-automated, manually operated plant and equipment appropriate to waste paper operations

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 (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

oil or chemical spills and disposal guidelines

plant isolation documentation

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

Material Safety Data Sheets (MSDS)

furnish sheets

tally sheets

process and instrument diagrams

Maintenance may include:

operator level maintenance as per site agreement

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

maintenance services

operational management

Situational awareness may include

awareness of:

traffic

pedestrians

location of equipment

product

hazards

obstruction

unexpected movement

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. 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 faults are identified and analysed within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements 
Alarms are interpreted to determine fault type and location 
Sampling and testing results are interpreted to identify variations from specifications or schedule 
Causes and sources of fault are identified and located 
Relevant sources of information are accessed and interpreted to assist analysis 
Plant faults are rectified within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 
Operator level on-line adjustments are conducted as required 
Plant is shut down and isolation procedures are implemented prior to fault rectification 
Faulty plant is isolated, by-passed, repaired or replaced as required 
Plant is returned to normal operation 
Verification is communicated to relevant personnel 
Product quality faults are rectified within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 
Quality faults or variations are identified by observation, systematic sampling and testing 
Test results are interpreted and operations are adjusted to correct faults 
Faults and causes are rectified if appropriate or recommendations made for further action 
Out-of-specification product is managed 
System performance and product quality data is recorded and reported within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 
Process variations and faults are recorded 
Stock production and machine operation faults are recorded 
Actions undertaken to troubleshoot and rectify faults are recorded 
Relevant information is communicated to appropriate personnel 

Forms

Assessment Cover Sheet

FPPWPO440A - Troubleshoot and rectify waste paper 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

FPPWPO440A - Troubleshoot and rectify waste paper 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: