This unit applies where problem solving occurs over one or more processes and requires an understanding of the characteristics of raw materials and ingredients and processing methods used. It typically applies to the production operator where responsibility for solving problems relating to non-conforming raw materials, ingredients and processes.

ELEMENT

PERFORMANCE CRITERIA

1. Identify and respond to non-conforming ingredients/raw materials

1.1. Non-conformance in raw materials/ingredients is identified and reported according to workplace reporting requirements

1.2. Causes of non-conformance are investigated and reported according to workplace reporting requirements

1.3. Corrective action is determined and implemented within level of responsibility and workplace procedures

1.4. Action is taken to prevent recurrence of non-conformance

1.5. Action is reported according to workplace reporting requirements

2. Identify and respond to non-conforming product and processes

2.1. Processing parameters, stages and changes which occur during processing are monitored

2.2. Non-conformance in processing, handling and/or storage is identified and corrective action taken according to workplace requirements

2.3. Causes of non-conformance relating to processing, handling and/or storage are investigated and reported according to workplace reporting requirements

2.4. Corrective action is determined and implemented within level of responsibility and workplace procedures

2.5. Action is taken to prevent recurrence of non-conformance

2.6. Action is reported according to workplace reporting requirements

2.7. Work is conducted in accordance with workplace environmental guidelines

Required skills

Ability to:

identify requirements of ingredient/raw material characteristics within level of responsibility

follow procedures to identify, remove/isolate and report non-conforming ingredients/materials and/or product according to workplace reporting requirements

determine likely causes of non-conformance of ingredients/raw materials

recognise indicators of unacceptable or non-conforming processing, handling and/or storage outcomes

act promptly to identify, remove/isolate and report non-conforming product and/or processes

access and apply workplace information relating to process troubleshooting

investigate non-conformance to determine likely causes and report findings to appropriate personnel

identify action required to correct non-conformance and implement within level of responsibility

identify action required to prevent or minimise and control recurrence of non-conformance and implement within level of responsibility

complete workplace records, including reporting non-conformance and documenting corrective actions according to workplace recording procedures

conduct tests to confirm raw material/ingredient and/or final product quality characteristics according to enterprise procedures

use oral communication skills/language competence to fulfil the job role as specified by the organisation, including questioning, active listening, asking for clarification and seeking advice from supervisor

work cooperatively within a culturally diverse workforce

Required knowledge

Knowledge of:

basic composition and function of each main raw material/ingredient used, such as awareness of ingredient grades or types

common causes of contamination/unacceptable quality of raw materials/ ingredients

methods used to confirm quality standard, such as accessing information (e.g. certificates of analysis and/or laboratory clearance information)

the effect of variation in raw materials/ingredients on processing stages and final product outcome, including factors likely to cause variation, and scope to adjust or correct for variation at each processing stage

appropriate handling and storage requirements for raw materials/ingredients and final product, and the effect of failing to meet required storage conditions

the changes and reactions that occur through processing stages, including the signs and symptoms of poor/unacceptable processing or equipment operation

factors that affect the shelf-life of product

the inter-relationships between processing stages and the effect of variation in processing parameters on process outcome and on final product, including factors likely to cause variation, and scope to adjust or correct for variation at subsequent process stages

procedures for identifying and isolating non-conforming product

troubleshooting information and techniques

procedures and related documentation required to amend or introduce a new method or procedure, such as short term procedures for amending or updating specifications and processing parameters

reporting requirements and responsibilities

test methods to confirm raw material/ingredient and/or final product quality characteristics where relevant

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

Assessment must be carried out in a manner that recognises the cultural and literacy requirements of the assessee and is appropriate to the work performed. Competence in this unit must be achieved in accordance with food safety standards and regulations.

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

Evidence of ability to:

describe required quality characteristics for raw materials and ingredients

describe required processes to achieve production specifications

identify common non-conforming materials and ingredients and causes

identify common non-conforming processes and causes

determine and undertake corrective action for non-conformances

complete workplace documentation and report non-conformances

apply food safety procedures.

Context of and specific resources for assessment

Assessment must occur in a real or simulated workplace where the assessee has access to:

ingredient/raw materials specifications and related advice, such as certificates of analysis

ingredients/raw materials and final product and related processing equipment and stores areas

troubleshooting information relevant to workplace processes

sampling and test equipment and procedures as required

system for managing and updating workplace documents, such as Standard Operating Procedures (SOPs) and log sheets/processing parameters

reporting and recording system and procedures.

Method of assessment

This unit should be assessed together with core units and other units of competency relevant to the function or work role. Examples could be:

FDFOP2013A Apply sampling procedures

FDFPPL3002A Report on workplace performance

MSL973001A Perform basic tests

PMBQUAL390A Solve problems using quality tools.

Guidance information for assessment

To ensure consistency in one's performance, competency should be demonstrated on more than one occasion over a period of time in order to cover a variety of circumstances, cases and responsibilities, and where possible, over a number of assessment activities.

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.

Policies and procedures

Work is carried out according to company procedures, regulatory and licensing requirements, legislative requirements, and industrial awards and agreements.

Legislative requirements

Legislative requirements are typically reflected in procedures and specifications. Legislation relevant to this industry includes:

the Food Standards Code, including labelling, weights and measures legislation

legislation covering food safety, environmental management, occupational health and safety (OHS), anti-discrimination and equal opportunity

When applied to the pharmaceutical industry, relevant Good Manufacturing Practice (GMP) codes apply in place of the Food Standards Code and reference to food safety is replaced by GMP

Ingredients/raw materials

Ingredients/raw materials are those used to manufacture product

Typical processing and related techniques

Typical processing and related techniques include but are not limited to:

raw materials/ingredient dispensing

preparation

mixing and blending

conditioning

primary and further processing

wrapping

packing and storage

Typical process parameters

Typical process parameters include but are not limited to:

temperature

time

pressure

flow rate

Typical reactions

Typical reactions depend on processing method. Examples include but are not limited to:

gelatinisation and hydration

Problem minimisation

Where recurrence of a problem cannot be prevented, procedures should be established to minimise the likelihood of recurrence and to identify any further incidents

Unit sector

Technical

This unit contains employability skills.