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

PMC553080B Mapping and Delivery Guide
Set up and optimise finishing process

Version 1.0
Issue Date: March 2024


Qualification -
Unit of Competency PMC553080B - Set up and optimise finishing process
Description This unit of competency covers setting up and optimising the finishing process for a flat sheet manufacturing process such as fibre board or plasterboard. It involves monitoring and interpreting process data, adjusting processes, completing quality and fault finding inspections and monitoring stock.
Employability Skills This unit contains employability skills.
Learning Outcomes and Application This unit of competency applies to operators who are responsible for setting up, monitoring and tuning equipment or processes to optimise performance, including the rectification of non-routine equipment and quality problems.This competency is typically performed by operators working either independently or as part of a work team. At all times they would be liaising with other members of the team.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.
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: Prepare the process for production
  • Identify all safety and emergency procedures
  • Shut down all equipment in accordance with work instructions and manufacturer's specifications
  • Consult the production schedule to determine the product to be manufactured
  • Ensure that the raw materials are available as required
  • Ensure that the equipment change parts, ancillaries and fixtures are available as required
  • Complete records and logs for setup of finishing equipment
       
Element: Set up finishing process
  • Perform checks and tests to product and equipment specifications
  • Ensure alignment of all equipment by performing checks and adjustments according to product specifications/work instructions
  • Ensure that process and equipment is setup as required for the production schedule
  • Ensure that the equipment is in a safe condition for use
       
Element: Monitor, interpret data and adjust operation
  • Monitor instruments and control panels, and interpret test results for fluctuations, variations and trends
  • Monitor plant and process and deduce conditions of materials in process and products being made
  • Determine appropriate action to improve process operation
  • Adjust controls to ensure product parameters are maintained to job specifications
  • Check that process operation has improved
  • Continue analysing data and making adjustments until desired level of process operation is achieved and product is within specifications in accordance with work instructions
       
Element: Sample, test and record product data
  • Carry out sampling procedures appropriate to the product and the test in line with enterprise requirements
  • Complete appropriate test to enterprise and client requirements
  • Measure/graph and record operating parameters, according to enterprise requirements
  • Record test results in hard or electronic form as required by standard procedures and work instructions
       
Element: Rectify equipment and quality problems
  • Identify the range of equipment and quality faults that can occur during the operation
  • Determine and rectify equipment and quality fault causes in accordance with established enterprise procedures
  • Identify and rectify equipment failure causes in accordance with established enterprise procedures
  • Make sure appropriate records and log books of equipment operations are maintained to meet enterprise requirements
  • Identify non-routine problems and rectify within area of responsibility
  • Report problems outside area of responsibility to designated person
       
Element: Shut down equipment
  • Shut down equipment in accordance with work instructions
  • Complete appropriate records and logs
  • Shut down equipment in an emergency situation
       
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.

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

The unit will be assessed in as holistic a manner as is practical and may be integrated with the assessment of other relevant units of competency.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

It is essential that the equipment be understood and that the importance of critical material properties, settings and readings is known. Competence must be demonstrated in the ability to recognise and analyse potential situations requiring action and then in implementing appropriate corrective action. The emphasis should be on the ability to stay out of trouble rather than on recovery from a disaster.

Consistent performance should be demonstrated. In particular look to see that:

setup/changeover/tuning are completed to specifications

plant conditions are maintained within limits

quality is monitored to minimise wastage

startup and shutdown occur first time

early warning signs of equipment/processes needing attention or potential problems are recognised and dealt with in a timely manner

process measurements are continually made or observed

adjustments are completed in a timely manner

the range of possible causes can be identified and the most likely cause determined

appropriate action is taken to ensure a timely return to full performance

obvious problems to related plant areas are recognised and an appropriate contribution made to their solution.

Competence must be demonstrated in the operation of all ancillary equipment to the level required for this unit of competency.

Context of and specific resources for assessment

Assessment will require access to an operating plant over an extended period of time, or a suitable method of gathering evidence of operating ability over a range of situations.

Assessment will occur over a range of situations which will include disruptions to normal, smooth operation.

Simulation or case studies/scenarios may be required to allow for timely assessment of parts of this unit of competency. Simulation should be based on the actual plant and will include 'walk-throughs' of the relevant competency components. A bank of scenarios/case studies/what ifs and questions will be required to probe the reasoning behind observable actions.

Method of assessment

Individual enterprises may choose to add prerequisites and co-requisites relevant to their processes.

In all plants it may be appropriate to assess this unit concurrently with relevant teamwork and communication units.

Guidance information for assessment

Assessment processes and techniques must be culturally appropriate and appropriate to the language and literacy capacity of the candidate and the work being performed.


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.

Required skills

Required skills include:

recognising process conditions that will lead to out of specification production

implementing enterprise's standard procedures and work instructions and relevant regulatory requirements in a manner relevant to the operation of the process

reading and numeracy to interpret workplace documents and technical information

Required knowledge

Required knowledge includes:

composition and nature of the product

setup/changeover and tuning of all equipment

startup and shutdown processes

optimisation of process for yield maximisation

construction and limitations of the equipment

out of specification situations

quality problems such as poor optics, excessive breakage, non-uniform break pattern, incorrect cross bend, excessive bow, scratches or poor glass shape

distinguish between causes of problems, such as:

raw material

mechanical

electrical/instrument

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.

Procedures

All operations are performed in accordance with standard procedures and work instructions

Equipment

This competency unit includes equipment applicable to finishing flat sheet product such as:

sanding

sealing

priming

rebating

Tools and equipment

Tools and equipment may include:

finishing and associated equipment

computers

measuring and recording equipment

communication equipment

hand tools

safety clothing and equipment

Process

The process includes:

setting up, monitoring and tuning equipment for optimum performance especially during startup, job change and equipment changes

Typical problems

Typical problems may include:

raw materials supply

equipment alignment

analysis of all plant data

product quality

equipment problems

Plant data

Plant data may include:

test results

instrument/control panel information

data from physical senses (sight, sound and hearing)

temperatures, pressures, material flow and discharge rates and effects

variations to chemical reactions/material modifications

Occupational health and safety (OHS)

All operations are subject to stringent OHS requirements and these must not be compromised at any time. Where there is an apparent conflict between performance criteria and OHS requirements, the OHS requirements take precedence

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
Identify all safety and emergency procedures 
Shut down all equipment in accordance with work instructions and manufacturer's specifications 
Consult the production schedule to determine the product to be manufactured 
Ensure that the raw materials are available as required 
Ensure that the equipment change parts, ancillaries and fixtures are available as required 
Complete records and logs for setup of finishing equipment 
Perform checks and tests to product and equipment specifications 
Ensure alignment of all equipment by performing checks and adjustments according to product specifications/work instructions 
Ensure that process and equipment is setup as required for the production schedule 
Ensure that the equipment is in a safe condition for use 
Monitor instruments and control panels, and interpret test results for fluctuations, variations and trends 
Monitor plant and process and deduce conditions of materials in process and products being made 
Determine appropriate action to improve process operation 
Adjust controls to ensure product parameters are maintained to job specifications 
Check that process operation has improved 
Continue analysing data and making adjustments until desired level of process operation is achieved and product is within specifications in accordance with work instructions 
Carry out sampling procedures appropriate to the product and the test in line with enterprise requirements 
Complete appropriate test to enterprise and client requirements 
Measure/graph and record operating parameters, according to enterprise requirements 
Record test results in hard or electronic form as required by standard procedures and work instructions 
Identify the range of equipment and quality faults that can occur during the operation 
Determine and rectify equipment and quality fault causes in accordance with established enterprise procedures 
Identify and rectify equipment failure causes in accordance with established enterprise procedures 
Make sure appropriate records and log books of equipment operations are maintained to meet enterprise requirements 
Identify non-routine problems and rectify within area of responsibility 
Report problems outside area of responsibility to designated person 
Shut down equipment in accordance with work instructions 
Complete appropriate records and logs 
Shut down equipment in an emergency situation 
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

PMC553080B - Set up and optimise finishing 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

PMC553080B - Set up and optimise finishing 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: