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

PMC553040 Mapping and Delivery Guide
Set up and optimise glass forming process

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency PMC553040 - Set up and optimise glass forming process
Description
Employability Skills
Learning Outcomes and Application This unit of competency covers the skills and knowledge required to set up and optimise a glass forming process. It applies to forming of glass as typically used in production of flat glass, glass containers and glass fibre products.This unit of competency applies to experienced operators, leading hands, supervisors or those in similar roles who are required to perform shutdown and isolation procedures, prepare and set up equipment, perform changeovers, make adjustments to optimise process, remedy faults/non-conformity and solve problems within area of responsibility. This unit of competency applies to an experienced operator demonstrating theoretical and technical knowledge and well developed skills in situations that require some discretion and judgement. The experienced operator may work alone or as a member of a team or group and will work in liaison with other shift team members, team leader and supervisor, as appropriate.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.

The unit should be assessed holistically and the judgement of competence shall be based on a holistic assessment of the evidence.

The collection of performance evidence:

should occur over a range of situations which include typical disruptions to normal, smooth operation of an operating plant

will typically include a supervisor/third-party report or other evidence, focusing on consistent performance and problem recognition and solving. A supervisor/third-party report must be prepared by someone who has a direct, relevant, current relationship with the person being assessed and who is in a position to form a judgement on workplace performance relevant to the unit of competency

must include the use of an appropriate industrial item/s of equipment requiring demonstration of operation, start-up and shutdown procedures and responding to problems

may use industry-based simulation for all or part of the unit particularly where safety, lack of opportunity or significant cost is an issue.

Assessment should occur in operational workplace situations. Where this is not possible or where personal safety or environmental damage are limiting factors assessment must occur in a sufficiently rigorous simulated environment that reflects realistic operational workplace conditions. This must cover all aspects of workplace performance, including environment, task skills, task management skills, contingency management skills and job role environment skills.

Assessment in a simulated environment should use evidence collected from demonstration of skills and one or more of:

walk-throughs

pilot plant operation

industry-based case studies/scenarios

‘what ifs’.

Knowledge evidence may be collected concurrently with performance evidence (provided a record is kept) or through an independent process such as workbooks, written assessments or interviews (provided a record is kept).

Assessment processes and techniques must be appropriate to the language, literacy and numeracy requirements of the work being performed and the needs of the candidate.

Conditions for assessment must include access to all tools, equipment, materials and documentation required, including relevant workplace procedures, product and manufacturing specifications associated with this unit.

The regulatory framework will be reflected in workplace policies and procedures and is not required to be independently assessed.

Foundation skills are integral to competent performance of the unit and should not be assessed separately.

Assessors must satisfy the assessor competency requirements that are in place at the time of the assessment as set by the VET regulator.

In addition the assessor or anyone acting in subject matter expert role in assessment shall demonstrate both technical competency and currency. If the assessor cannot demonstrate technical competency and currency they shall assess with a subject matter expert who does meet these requirements.

Technical competence can be demonstrated through one or more of:

relevant VET or other qualification/Statement of Attainment

appropriate workplace experience undertaking the type of work being assessed under routine and non-routine conditions

appropriate workplace experience supervising/evaluating the type of work being assessed under routine and non-routine conditions

Currency can be demonstrated through one or more of:

being currently employed undertaking the type of work being assessed

being employed by the organisation undertaking the type of work being assessed and having maintained currency in accordance with that organisation’s policies and procedures

having consulted/had contact with an organisation undertaking the type of work being assessed within the last twelve months, the consultation/contact being related to assessment

conducting on the job training/assessments of the type of work being assessed

being an active member of a relevant professional body and participating in activities relevant to the assessment of this type of work.
Prerequisites/co-requisites
Competency Field Operations
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: Prepare for equipment installation
  • Determine the product to be manufactured
  • Ensure that the equipment change parts, ancillaries and fixtures are available as required
  • Perform pre-instalment equipment preparation according to procedures
  • Ensure that the equipment is in a safe condition for use
       
Element: Remove current equipment and/or tooling
  • Identify and implement all safety and emergency procedures
  • Shut down equipment in accordance with procedures
  • Isolate equipment in accordance with procedures
  • Remove ancillary equipment in accordance with procedures
  • Complete records and logs for removal of current equipment
       
Element: Install and set up new equipment and/or tooling
  • Perform required checks and tests prior to installation
  • Identify any faults in equipment/tooling and take appropriate action
  • Install and set up appropriate ancillary equipment in accordance with procedures
  • Set up equipment/tooling as required
  • Monitor and adjust until production is as required
       
Element: Monitor, interpret data and adjust operation
  • Monitor process data
  • Ensure forming equipment start-up function complies with work instructions
  • Operate glass forming equipment in accordance with procedures
  • Monitor plant and process and deduce conditions of materials in process and products being made
  • Take appropriate action to improve process operation
  • Check that process operation has improved
  • Monitor and adjust until production is as required
       
Element: Sample, test and record product data
  • Sample as required by the product and in line with enterprise requirements
  • Complete appropriate test to enterprise and client requirements
  • Identify variations from process parameters and take appropriate action
  • Measure/graph and record operating parameters, according to enterprise requirements
  • Record test results as required by procedures
       
Element: Rectify equipment and quality problems
  • Identify the range of equipment and quality faults that can occur during the operation
  • Diagnose possible causes of equipment and quality faults
  • Rectify cause of equipment failure and quality faults by established enterprise procedures
  • Identify and rectify equipment failure causes in accordance with established enterprise procedures
  • Ensure appropriate records and logs of equipment operations are maintained to meet enterprise requirements
  • Identify non-routine problems and report to designated person
       
Element: Shut down equipment
  • Shut down equipment in accordance with procedures
  • Complete appropriate records and logs
  • Shut down equipment in an emergency situation
       
Element: Prepare equipment for maintenance
  • Isolate equipment in accordance with work instructions
  • Make sure area is clear and safe for maintenance
  • Complete all records and logs
       
Element: Control hazards
  • Identify hazards from the job to be done
  • Identify other hazards in the work area
  • Assess the risks arising from those hazards
  • Implement measures to control those risks in line with procedures
       


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

Prepare for equipment installation

1.1

Determine the product to be manufactured

1.2

Ensure that the equipment change parts, ancillaries and fixtures are available as required

1.3

Perform pre-instalment equipment preparation according to procedures

1.4

Ensure that the equipment is in a safe condition for use

2

Remove current equipment and/or tooling

2.1

Identify and implement all safety and emergency procedures

2.2

Shut down equipment in accordance with procedures

2.3

Isolate equipment in accordance with procedures

2.4

Remove ancillary equipment in accordance with procedures

2.5

Complete records and logs for removal of current equipment

3

Install and set up new equipment and/or tooling

3.1

Perform required checks and tests prior to installation

3.2

Identify any faults in equipment/tooling and take appropriate action

3.3

Install and set up appropriate ancillary equipment in accordance with procedures

3.4

Set up equipment/tooling as required

3.5

Monitor and adjust until production is as required

4

Monitor, interpret data and adjust operation

4.1

Monitor process data

4.2

Ensure forming equipment start-up function complies with work instructions

4.3

Operate glass forming equipment in accordance with procedures

4.4

Monitor plant and process and deduce conditions of materials in process and products being made

4.5

Take appropriate action to improve process operation

4.6

Check that process operation has improved

4.7

Monitor and adjust until production is as required

4.8

4.9

4.10

5

Sample, test and record product data

5.1

Sample as required by the product and in line with enterprise requirements

5.2

Complete appropriate test to enterprise and client requirements

5.3

Identify variations from process parameters and take appropriate action

5.4

Measure/graph and record operating parameters, according to enterprise requirements

5.5

Record test results as required by procedures

6

Rectify equipment and quality problems

6.1

Identify the range of equipment and quality faults that can occur during the operation

6.2

Diagnose possible causes of equipment and quality faults

6.3

Rectify cause of equipment failure and quality faults by established enterprise procedures

6.4

Identify and rectify equipment failure causes in accordance with established enterprise procedures

6.5

Ensure appropriate records and logs of equipment operations are maintained to meet enterprise requirements

6.6

Identify non-routine problems and report to designated person

7

Shut down equipment

7.1

Shut down equipment in accordance with procedures

7.2

Complete appropriate records and logs

7.3

Shut down equipment in an emergency situation

8

Prepare equipment for maintenance

8.1

Isolate equipment in accordance with work instructions

8.2

Make sure area is clear and safe for maintenance

8.3

Complete all records and logs

9

Control hazards

9.1

Identify hazards from the job to be done

9.2

Identify other hazards in the work area

9.3

Assess the risks arising from those hazards

9.4

Implement measures to control those risks in line with procedures

Must provide evidence that demonstrates knowledge relevant to their job sufficient to operate independently and to solve routine and non-routine problems including knowledge of:

read and interpret procedures, job specifications, production schedules, test results, instruments/control panels, material labels and safety data sheets (SDS)

install and set up equipment to process specifications

perform pre-start checks, start-up/shutdown procedures and isolations

monitor key variables, including:

installation and performance of equipment/tooling

process parameters

yield

energy utilisation

variations

fluctuations

trends

material properties/chemical reactions

product integrity and general conformance to specification

use tests, process data and own senses to monitor plant and maximise performance

make adjustments to equipment settings, process conditions and/or raw materials to bring production into specification

identify hazards and apply relevant hazard controls

apply safety procedures

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

distinguish between causes of problems, including:

instrument failure/malfunction

electrical/mechanical failure/malfunction

wrong readings

material variations/contamination

process abnormalities

procedural errors

atmospheric conditions

recognise and prioritise problems requiring action

resolve routine and non-routine problems

communicate effectively with team/work group and supervisors

complete workplace records

calculate and interpret process conditions, performance and trends.

Must provide evidence that demonstrates knowledge relevant to their job sufficient to operate independently and to solve routine and non-routine problems, including knowledge of:

principles of glass forming process

functions, limitations and principles of operation of glass forming and ancillary equipment being used

impact of variations in equipment settings, process conditions and raw materials on product quality, production output and optimisation of process

factors which may affect product quality or production output and appropriate remedies

physics and chemistry relevant to the equipment/process/materials

importance of atmospheric conditions and effect on process

characteristics of materials being processed and their behaviour in relation to process conditions and stages of production

quality requirements at each stage of production

common adjustments in process variables and their impact on product quality and production output

start-up and shutdown processes

routine and non-routine problems that may arise, the range of possible causes and appropriate actions

organisation procedures relevant to the work environment/job role

hierarchy of control

hazards that may arise in the job/work environment and:

their possible causes

potential consequences

appropriate risk controls.

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

Prepare for equipment installation

1.1

Determine the product to be manufactured

1.2

Ensure that the equipment change parts, ancillaries and fixtures are available as required

1.3

Perform pre-instalment equipment preparation according to procedures

1.4

Ensure that the equipment is in a safe condition for use

2

Remove current equipment and/or tooling

2.1

Identify and implement all safety and emergency procedures

2.2

Shut down equipment in accordance with procedures

2.3

Isolate equipment in accordance with procedures

2.4

Remove ancillary equipment in accordance with procedures

2.5

Complete records and logs for removal of current equipment

3

Install and set up new equipment and/or tooling

3.1

Perform required checks and tests prior to installation

3.2

Identify any faults in equipment/tooling and take appropriate action

3.3

Install and set up appropriate ancillary equipment in accordance with procedures

3.4

Set up equipment/tooling as required

3.5

Monitor and adjust until production is as required

4

Monitor, interpret data and adjust operation

4.1

Monitor process data

4.2

Ensure forming equipment start-up function complies with work instructions

4.3

Operate glass forming equipment in accordance with procedures

4.4

Monitor plant and process and deduce conditions of materials in process and products being made

4.5

Take appropriate action to improve process operation

4.6

Check that process operation has improved

4.7

Monitor and adjust until production is as required

4.8

4.9

4.10

5

Sample, test and record product data

5.1

Sample as required by the product and in line with enterprise requirements

5.2

Complete appropriate test to enterprise and client requirements

5.3

Identify variations from process parameters and take appropriate action

5.4

Measure/graph and record operating parameters, according to enterprise requirements

5.5

Record test results as required by procedures

6

Rectify equipment and quality problems

6.1

Identify the range of equipment and quality faults that can occur during the operation

6.2

Diagnose possible causes of equipment and quality faults

6.3

Rectify cause of equipment failure and quality faults by established enterprise procedures

6.4

Identify and rectify equipment failure causes in accordance with established enterprise procedures

6.5

Ensure appropriate records and logs of equipment operations are maintained to meet enterprise requirements

6.6

Identify non-routine problems and report to designated person

7

Shut down equipment

7.1

Shut down equipment in accordance with procedures

7.2

Complete appropriate records and logs

7.3

Shut down equipment in an emergency situation

8

Prepare equipment for maintenance

8.1

Isolate equipment in accordance with work instructions

8.2

Make sure area is clear and safe for maintenance

8.3

Complete all records and logs

9

Control hazards

9.1

Identify hazards from the job to be done

9.2

Identify other hazards in the work area

9.3

Assess the risks arising from those hazards

9.4

Implement measures to control those risks in line with procedures

This field allows for 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.

Regulatory framework

The latest version of all legislation, regulations, industry codes of practice and Australian/international standards, or the version specified by the local regulatory authority, must be used.

Applicable legislation, regulations, standards and codes of practice include:

health, safety and environmental (HSE) legislation, regulations and codes of practice relevant to the workplace, equipment and production processes and hazardous materials

Australian/international standards relevant to the materials being used and products being made

any relevant licence and certification requirements.

All operations to which this unit applies are subject to stringent HSE requirements, which may be imposed through state/territory or federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between performance criteria and such requirements the legislative requirements take precedence.

Procedures

All operations must be performed in accordance with relevant procedures.

Procedures are written, verbal, visual, computer-based or in some other form, and include one or any combination of:

manufacturer's technical information

job cards

drawings

emergency procedures

work instructions

standard operating procedures (SOPs)

safe work method statements (SWMS)

formulas/recipes

batch sheets

temporary instructions

any similar instructions provided for the smooth running of the plant.

Hazards

Hazards must be identified and controlled. Identifying hazards requires consideration of:

heat, smoke, dust, vapours or other atmospheric hazards

weight, shape, volume of materials to be handled

hazardous products and materials

sharp edges, protrusions or obstructions

slippery surfaces, spills or leaks

electricity

gas

gases and liquids under pressure

noise

rotational equipment or vibration

plant services (steam, condensate, cooling water, etc)

structural hazards

equipment failures

machinery, equipment and product mass

limited head spaces or overhangs

working at heights

working in restricted or confined spaces

other hazards that might arise

Problems

Routine and non-routine problems must be resolved.

Routine problems are predictable and have known solutions and include one or more of:

raw materials supply

equipment alignment

out-of-specification settings (e.g. temperature and speed)

product quality problems.

Non-routine problems are unexpected problems or variations of previous problems.

Non-routine problems must be resolved by applying operational knowledge to develop new solutions, either individually or in collaboration with relevant experts, to:

determine problems needing action

determine possible fault causes

develop solutions to problems which do not have a known solution

follow through items initiated until final resolution has occurred

report problems outside area of responsibility to designated person.

Operational knowledge includes one or more of:

procedures

training

technical information, such as journals and engineering specifications

remembered experience

relevant knowledge obtained from appropriate people.

Records and reports

Records include one or more of:

log books/sheets

electronic records

job/work sheets

other records used for the smooth running of the plant.

Reports include one or more of:

paper or electronic-based logs and reports

verbal/radio reports

reporting items found which require action.

Tools and equipment

Tools and equipment include:

glass forming equipment as used to make one or more of:

flat glass

insulation, glass wool insulation, laminated blankets or roll and boards

fibreglass or glass filaments

packaging, bottles or jars

ancillary equipment that is integral to the process

measuring and recording equipment.

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
Determine the product to be manufactured 
Ensure that the equipment change parts, ancillaries and fixtures are available as required 
Perform pre-instalment equipment preparation according to procedures 
Ensure that the equipment is in a safe condition for use 
Identify and implement all safety and emergency procedures 
Shut down equipment in accordance with procedures 
Isolate equipment in accordance with procedures 
Remove ancillary equipment in accordance with procedures 
Complete records and logs for removal of current equipment 
Perform required checks and tests prior to installation 
Identify any faults in equipment/tooling and take appropriate action 
Install and set up appropriate ancillary equipment in accordance with procedures 
Set up equipment/tooling as required 
Monitor and adjust until production is as required 
Monitor process data 
Ensure forming equipment start-up function complies with work instructions 
Operate glass forming equipment in accordance with procedures 
Monitor plant and process and deduce conditions of materials in process and products being made 
Take appropriate action to improve process operation 
Check that process operation has improved 
Monitor and adjust until production is as required 
Sample as required by the product and in line with enterprise requirements 
Complete appropriate test to enterprise and client requirements 
Identify variations from process parameters and take appropriate action 
Measure/graph and record operating parameters, according to enterprise requirements 
Record test results as required by procedures 
Identify the range of equipment and quality faults that can occur during the operation 
Diagnose possible causes of equipment and quality faults 
Rectify cause of equipment failure and quality faults by established enterprise procedures 
Identify and rectify equipment failure causes in accordance with established enterprise procedures 
Ensure appropriate records and logs of equipment operations are maintained to meet enterprise requirements 
Identify non-routine problems and report to designated person 
Shut down equipment in accordance with procedures 
Complete appropriate records and logs 
Shut down equipment in an emergency situation 
Isolate equipment in accordance with work instructions 
Make sure area is clear and safe for maintenance 
Complete all records and logs 
Identify hazards from the job to be done 
Identify other hazards in the work area 
Assess the risks arising from those hazards 
Implement measures to control those risks in line with procedures 

Forms

Assessment Cover Sheet

PMC553040 - Set up and optimise glass forming process
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

PMC553040 - Set up and optimise glass forming process

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: