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

PPMRES340 Mapping and Delivery Guide
Troubleshoot and rectify primary resource operations

Version 1.0
Issue Date: April 2024


Qualification -
Unit of Competency PPMRES340 - Troubleshoot and rectify primary resource operations
Description
Employability Skills
Learning Outcomes and Application This unit of competency describes the outcomes required to identify, diagnose and rectify primary resource operations, in a pulp or paper manufacturing facility. The unit applies to senior operators and production specialists who troubleshoot and rectify primary resource operations. This typically involves working in a facility with complex integrated equipment and continuous operations.Licensing, legislative, regulatory, or certification requirements apply to this unit in some states and territories at the time of publication and may differ according to jurisdiction.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.

The following resources must be made available:

access to the full range of equipment required to detect and address faults associated with primary resource operations in a pulp or paper manufacturing facility

applicable work health and safety (WHS) and isolation work place procedures, environmental guidelines and safe working requirements, risks and hazard identification and workplace housekeeping requirements

personal protective equipment required for operating machinery and equipment and fault rectification for the woodchip production system

relevant personnel for the purposes of communicating information

electronic control systems which includes Digital Control System (DCS), touch screens or robotics required to operate the woodchip production system

sample workplace documentation, procedures and reports including SOP, quality procedures, environmental sustainability requirements/practices, plant manufacturing operating manuals, enterprise policies and procedures, oil or chemical spills and disposal guidelines, plant isolation documentation and safe work documentation

Competency is to be assessed in the workplace or in a productive environment that accurately reflects performance in a workplace.

Assessor requirements

Assessors must:

hold the appropriate assessor competency standards as outlined in regulations; and

be able to demonstrate vocational competencies at least to the level being assessed; and

be able to demonstrate how they are continuing to develop their VET knowledge and skills as well as maintaining their industry currency and assessor competence.
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: Identify and diagnose causes of process variation, plant or equipment faults
  • Check and plan work within workplace health and safety (WHS) procedures, risks and hazards identification, environmental sustainability procedures and Standard Operating Procedures (SOP).
  • Interpret visual assessments and machine alarms to determine fault type and location.
  • Undertake routine physical inspections of plant and process to identify faults.
  • Identify and locate causes and sources of process variation, plant or equipmentfaults, using appropriate techniques.
  • Access and analyse relevant historical and operational data to confirm diagnosis.
       
Element: Rectify process variation, plant or equipment faults
  • Initiate emergency stop or shutdown, isolation and lockout procedures prior to fault rectification.
  • Isolate, repair or replace faulty equipment or instrumentation.
  • Implement corrective operational adjustments and operator level maintenance requirements.
  • Restore to normal operations and communicate to relevant personnel.
       
Element: Identify and rectify product quality faults
  • Identify product faults or variations by observation, systematic sampling and testing.
  • Manage out-of-specification production.
  • Check load weight and dimensions to ensure they fall within the capacity of the equipment.
  • Take samples for tests to detect quality faults.
  • Conduct required tests.
  • Interpret test results, adjust operations to correct variations or make recommendations for further action.
       
Element: Record and report troubleshooting activities
  • Document variations from specifications and machine operating faults.
  • Undertake assessment and evaluation of causes of deviations and document corrective actions.
  • Communicate relevant information 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.

ELEMENTS

PERFORMANCE CRITERIA

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold italicised text is used, further information is detailed in the range of conditions.

1. Identify and diagnose causes of process variation, plant or equipment faults

1.1. Check and plan work within workplace health and safety (WHS) procedures, risks and hazards identification, environmental sustainability procedures and Standard Operating Procedures (SOP).

1.2. Interpret visual assessments and machine alarms to determine fault type and location.

1.3. Undertake routine physical inspections of plant and process to identify faults.

1.4. Identify and locate causes and sources of process variation, plant or equipmentfaults, using appropriate techniques.

1.5. Access and analyse relevant historical and operational data to confirm diagnosis.

2. Rectify process variation, plant or equipment faults

2.1. Initiate emergency stop or shutdown, isolation and lockout procedures prior to fault rectification.

2.2. Isolate, repair or replace faulty equipment or instrumentation.

2.3. Implement corrective operational adjustments and operator level maintenance requirements.

2.4. Restore to normal operations and communicate to relevant personnel.

3. Identify and rectify product quality faults

3.1. Identify product faults or variations by observation, systematic sampling and testing.

3.2. Manage out-of-specification production.

3.3. Check load weight and dimensions to ensure they fall within the capacity of the equipment.

3.4. Take samples for tests to detect quality faults.

3.5. Conduct required tests.

3.6. Interpret test results, adjust operations to correct variations or make recommendations for further action.

4. Record and report troubleshooting activities

4.1. Document variations from specifications and machine operating faults.

4.2. Undertake assessment and evaluation of causes of deviations and document corrective actions.

4.3. Communicate relevant information to appropriate personnel.

A person demonstrating competency in this unit must satisfy all of the elements, performance criteria and foundation skills of this unit, and must be able to provide evidence that they can:

troubleshoot and rectify primary resource operations, at least twice in line with required enterprise intervals, where corrective action on addresses equipment and product faults

plan and safely diagnose causes and sources of process variation, plant, equipment and product faults

communicate effectively, through written and verbal means, the corrective actions undertaken

use safety accessories including protective and high visibility, safety clothing and electronic communication equipment when working with primary resource operations.

A person competent in this unit must be able to demonstrate knowledge of:

troubleshooting methods that can be applied across system and quality faults for primary resource operations in the pulp and paper industry

relevant documentation and procedures to troubleshoot primary resource operations in the pulp and paper industry including:

work health and safety (WHS) procedures, including high risk load shifting, licensing requirements, plant clearance, job safety analysis and permit systems

Standard Operating Procedures (SOP)

productivity requirements and quality procedures

environmental sustainability requirements and practices

plant manufacturing operating manuals and plant isolation documentation

enterprise policies and procedures and guidelines

oil or chemical spills and disposal guidelines

weighbridge dockets, work orders, invoices, tally sheets and truck delivery dockets

non-conformance and test results and reports

log sheets (production and equipment) and equipment performance data

tonnage, input and conversion

sampling and test reports

Material Safety Data Sheets (MSDS)

pile survey documents and process and instrument diagrams

processes and associated services of primary resource operations, sufficient to troubleshoot including:

plant layout

theory of operation

causes and effects of adjustments made to primary resource handling plant and processes

relationships between primary resource handling system, processes and associated services

the use of materials and supplies including hardwood or softwood logs, lapped pulp, waste paper, woodchips and parts in primary resource operations

use and purpose of testing equipment including drying ovens, sizing screens and computer processing equipment

appropriate and safe use of attachments including fork lift attachments, crane hooks, chains, slings and straps, grabs and winches

the purpose, standards and procedures as per site agreement, of sampling and testing process for plant and system operations, and process monitoring

types, causes and effects of plant shutdowns on primary resource operations

key features of maintenance systems including operator level maintenance as per site agreements, operator maintenance schedules, maintenance suppliers and pro-active maintenance strategies.

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

PERFORMANCE CRITERIA

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold italicised text is used, further information is detailed in the range of conditions.

1. Identify and diagnose causes of process variation, plant or equipment faults

1.1. Check and plan work within workplace health and safety (WHS) procedures, risks and hazards identification, environmental sustainability procedures and Standard Operating Procedures (SOP).

1.2. Interpret visual assessments and machine alarms to determine fault type and location.

1.3. Undertake routine physical inspections of plant and process to identify faults.

1.4. Identify and locate causes and sources of process variation, plant or equipmentfaults, using appropriate techniques.

1.5. Access and analyse relevant historical and operational data to confirm diagnosis.

2. Rectify process variation, plant or equipment faults

2.1. Initiate emergency stop or shutdown, isolation and lockout procedures prior to fault rectification.

2.2. Isolate, repair or replace faulty equipment or instrumentation.

2.3. Implement corrective operational adjustments and operator level maintenance requirements.

2.4. Restore to normal operations and communicate to relevant personnel.

3. Identify and rectify product quality faults

3.1. Identify product faults or variations by observation, systematic sampling and testing.

3.2. Manage out-of-specification production.

3.3. Check load weight and dimensions to ensure they fall within the capacity of the equipment.

3.4. Take samples for tests to detect quality faults.

3.5. Conduct required tests.

3.6. Interpret test results, adjust operations to correct variations or make recommendations for further action.

4. Record and report troubleshooting activities

4.1. Document variations from specifications and machine operating faults.

4.2. Undertake assessment and evaluation of causes of deviations and document corrective actions.

4.3. Communicate relevant information to appropriate personnel.

Not Applicable
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
Check and plan work within workplace health and safety (WHS) procedures, risks and hazards identification, environmental sustainability procedures and Standard Operating Procedures (SOP). 
Interpret visual assessments and machine alarms to determine fault type and location. 
Undertake routine physical inspections of plant and process to identify faults. 
Identify and locate causes and sources of process variation, plant or equipmentfaults, using appropriate techniques. 
Access and analyse relevant historical and operational data to confirm diagnosis. 
Initiate emergency stop or shutdown, isolation and lockout procedures prior to fault rectification. 
Isolate, repair or replace faulty equipment or instrumentation. 
Implement corrective operational adjustments and operator level maintenance requirements. 
Restore to normal operations and communicate to relevant personnel. 
Identify product faults or variations by observation, systematic sampling and testing. 
Manage out-of-specification production. 
Check load weight and dimensions to ensure they fall within the capacity of the equipment. 
Take samples for tests to detect quality faults. 
Conduct required tests. 
Interpret test results, adjust operations to correct variations or make recommendations for further action. 
Document variations from specifications and machine operating faults. 
Undertake assessment and evaluation of causes of deviations and document corrective actions. 
Communicate relevant information to appropriate personnel. 

Forms

Assessment Cover Sheet

PPMRES340 - Troubleshoot and rectify primary resource 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

PPMRES340 - Troubleshoot and rectify primary resource 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: