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

MSFGG4007 Mapping and Delivery Guide
Manage glass processing plant shutdown and re-start

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency MSFGG4007 - Manage glass processing plant shutdown and re-start
Description
Employability Skills
Learning Outcomes and Application This unit of competency covers the coordination of the shutdown and re-starting of a glass production or processing plant in a safe and efficient manner due to a planned or an unplanned shutdown or emergency situation. It does not apply to individual plant operators shutting down individual production units or following directions during a shutdown and would typically be exercised by the leading plant technician on a shift. This unit requires the exercise of discretion as the plant technician's responses are governed by the cause of the shutdown and the plant's responses to that. It requires the coordination of all personnel involved in the shutdown to ensure it happens in as orderly a fashion as possible and that the plant is left in the best condition possible for a quick re-start. No licensing, legislative or certification requirements apply to this unit at the time of publication.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.

Assessors must:

hold training and assessment competencies as determined by the National Skills Standards Council (NSSC) or its successors

have vocational competency in the furnishing industry at least to the level being assessed with broad industry knowledge and experience, usually combined with a relevant industry qualification

be familiar with the current skills and knowledge used and have relevant, current experience in the furnishing industry.

Assessment methods must confirm consistency of performance over time rather than a single assessment event and in a range of workplace relevant contexts.

Assessment must be by observation of relevant tasks with questioning on underpinning knowledge and, where applicable, multimedia evidence, supervisor’s reports, projects and work samples.

Assessment is to be conducted on single units of competency or in conjunction with other related units of competency. Foundation skills are integral to competent performance in the unit and should not be assessed separately.

Assessment must occur on the job or in a workplace simulated facility with relevant process, equipment, materials, work instructions and deadlines.

Access is required to control systems for glass processing plant and equipment, workplace documentation, procedures and job requirements.
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: Manage shutdown sequence
  • Glass plant safety systems are checked and verified to ensure that the unit has been made safe
  • The reason for, or cause of, the plant shutdown is identified by troubleshooting the system and utilising all available data and information systems
  • Confirmation of the identified shutdown is obtained from operators to verify both the nature and the reliability of the shutdown
  • Procedures are initiated to rectify the fault or shutdown cause through either repair of the operational fault or readjustment before returning the system to start-up status
       
Element: Conduct start-up process
  • All start-up permissives are satisfied prior to start-up process being commenced
  • Start-up is conducted according to procedures and in a safe and efficient manner, ensuring a return to normal operation is achieved
       
Element: Document shutdown and start-up process
  • All logs and workplace documentation relating to the shutdown/start-up process are completed ensuring all details, actions and responses are accurately recorded
  • Any further ongoing production problems are recorded and reported to appropriate persons or authority
       


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.

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Manage shutdown sequence

1.1

Glass plant safety systems are checked and verified to ensure that the unit has been made safe

1.2

The reason for, or cause of, the plant shutdown is identified by troubleshooting the system and utilising all available data and information systems

1.3

Confirmation of the identified shutdown is obtained from operators to verify both the nature and the reliability of the shutdown

1.4

Procedures are initiated to rectify the fault or shutdown cause through either repair of the operational fault or readjustment before returning the system to start-up status

2

Conduct start-up process

2.1

All start-up permissives are satisfied prior to start-up process being commenced

2.2

Start-up is conducted according to procedures and in a safe and efficient manner, ensuring a return to normal operation is achieved

3

Document shutdown and start-up process

3.1

All logs and workplace documentation relating to the shutdown/start-up process are completed ensuring all details, actions and responses are accurately recorded

3.2

Any further ongoing production problems are recorded and reported to appropriate persons or authority

Consistently:

recognise early warning signs of equipment/processes needing attention or with potential problems

determine and analyse the range of possible plant problem causes and the most likely cause

take appropriate action to ensure a timely return to full performance

recognise obvious problems in related plant areas and make an appropriate contribution made to their solution

Shutdown and re-start a glass processing plant safety and efficiently

Communicate ideas and information to enable confirmation of work requirements and specifications and the reporting of work outcomes and problems

Avoid backtracking, work flow interruptions or wastage

Work with others and in a team by recognising dependencies and using cooperative approaches to optimise work flow and productivity

Principles of operation of glass processing plant/equipment

Interactions between plant units within the entire plant

The architecture and location of the glass process/production equipment

Specific glass plant process operations

Interactions between glass plant items/processes

Glass product specifications and tolerances

Hierarchy of control and basis of control for glass plant/s

Communication protocols (e.g. radio, phone, computer, paper and permissions/authorities)

Routine glass processing plant problems, faults and their resolution

Relevant alarms and actions

Complex process drawings (e.g. piping and instrumentation diagrams (P&ID), probability of failure on demand (PFD), and cause and effect)

Plant process idiosyncrasies

Correct methods of starting, stopping, operating and controlling glass processing plants

Corrective action appropriate to the problem cause

Function and troubleshooting of major glass processing plant components and their problems

Process control philosophies and strategies

Emergency shutdown procedures

Physics, chemistry and mathematics relevant to the process

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.

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Manage shutdown sequence

1.1

Glass plant safety systems are checked and verified to ensure that the unit has been made safe

1.2

The reason for, or cause of, the plant shutdown is identified by troubleshooting the system and utilising all available data and information systems

1.3

Confirmation of the identified shutdown is obtained from operators to verify both the nature and the reliability of the shutdown

1.4

Procedures are initiated to rectify the fault or shutdown cause through either repair of the operational fault or readjustment before returning the system to start-up status

2

Conduct start-up process

2.1

All start-up permissives are satisfied prior to start-up process being commenced

2.2

Start-up is conducted according to procedures and in a safe and efficient manner, ensuring a return to normal operation is achieved

3

Document shutdown and start-up process

3.1

All logs and workplace documentation relating to the shutdown/start-up process are completed ensuring all details, actions and responses are accurately recorded

3.2

Any further ongoing production problems are recorded and reported to appropriate persons or authority

Specifies different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included. Range is restricted to essential operating conditions and any other variables essential to the work environment.

Reasons for glass processing plant shutdown include:

planned (e.g. for maintenance or other planned work)

unplanned (e.g. in response to a plant upset or equipment failure)

emergency (e.g. in response to an automatic shutdown sequence or plant trip)

Shutdown includes:

shutdown 'to cold' (e.g. complete plant shutdown and purging of all process materials from equipment)

short shutdown to allow minor work 'warm shutdown' (e.g. partial shutdown, with retention of some or all of process materials)

managing a plant trip and restart 'hot shutdown' (e.g. short duration shutdown in response to a plant upset or trip)

Shutdown actions include:

coordinating the shift team

implementing emergency procedures

using the permit to work system (for repairs required)

performing all operations according to procedures

Relevant personnel include:

panel technicians

outside technicians

technicians seconded to a shutdown role

other relevant personnel

Work health and safety (WHS) requirements include:

Commonwealth, state or territory legislation and regulations

organisational safety policies and procedures

the use of personal protective equipment and clothing

firefighting equipment

first aid equipment

hazard and risk control and elimination of hazardous materials and substances

manual handling, including lifting and carrying

Appropriate action includes:

determining problems needing action

determining possible fault causes

rectifying problem using appropriate solution within area of responsibility

following through items initiated until final resolution has occurred

reporting problems outside area of responsibility to designated person

Procedures include:

work instructions

standard operating procedures

formulas/recipes

batch sheets

temporary instructions

any instructions provided for the smooth running of the plant

written, verbal or computer-based procedures

Glass plant/equipment include:

glass laminating plant

glass toughening plant

insulated glass plant

glass silvering plant

glass printing plant

cutting (including water jet), seaming, edge grinding and computer numerically controlled (CNC) milling

Organisational requirements include:

legal, organisational and site guidelines, policies and procedures relating to own role and responsibility

quality assurance

procedural manuals

quality and continuous improvement processes and standards

WHS procedures

emergency and evacuation

ethical standards

recording and reporting

access and equity principles and practices

equipment use, maintenance and storage

environmental management (waste disposal, recycling and re-use guidelines)

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
Glass plant safety systems are checked and verified to ensure that the unit has been made safe 
The reason for, or cause of, the plant shutdown is identified by troubleshooting the system and utilising all available data and information systems 
Confirmation of the identified shutdown is obtained from operators to verify both the nature and the reliability of the shutdown 
Procedures are initiated to rectify the fault or shutdown cause through either repair of the operational fault or readjustment before returning the system to start-up status 
All start-up permissives are satisfied prior to start-up process being commenced 
Start-up is conducted according to procedures and in a safe and efficient manner, ensuring a return to normal operation is achieved 
All logs and workplace documentation relating to the shutdown/start-up process are completed ensuring all details, actions and responses are accurately recorded 
Any further ongoing production problems are recorded and reported to appropriate persons or authority 

Forms

Assessment Cover Sheet

MSFGG4007 - Manage glass processing plant shutdown and re-start
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

MSFGG4007 - Manage glass processing plant shutdown and re-start

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: