Application
This unit applies to operators who troubleshoot and rectify finishing and converting systems in the pulp and paper industry. This work typically involves complex integrated equipment and continuous operations This unit generally applies to those who: identify and analyse causes of system and quality faults rectify system faults rectify or re-work product with quality faults, and record and report system performance and product quality data to meet safety, quality and productivity requirements It does not include preparing and starting up, monitoring, controlling, or shutting down finishing and converting operations |
Prerequisites
Not Applicable
Elements and Performance Criteria
ELEMENT | PERFORMANCE CRITERIA |
1. Identify and analyse causes of system and quality faults | 1.1. Causes of system and quality faults are identified and analysed within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements 1.2. Control system readouts are monitored to identify process variations 1.3. Trends and warning devices are interpreted to determine fault type and location 1.4. Quality checks are interpreted to identify variations from specifications or schedule 1.5. Cause and source of problem is identified and located 1.6. Relevant sources of information are accessed and interpreted to assist analysis |
2. Rectify system faults | 2.1. System faults are rectified within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 2.2. Equipment is shut down and isolation procedures are implemented prior to fault rectification if required 2.3. Faulty equipment is identified, repaired or replaced 2.4. Faulty equipment is by-passed as required 2.5. Corrective adjustments are made and operator level maintenance requirements are undertaken 2.6. Restoration of machine or system to normal operation is verified and communicated to relevant personnel |
3. Rectify or re-work product with quality faults | 3.1. Product with quality faults is rectified or reworked within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 3.2. Product quality faults or variations are identified by observation, systematic sampling, testing or quality checks 3.3. Quality checks are conducted 3.4. Quality tests are undertaken and results interpreted as required 3.5. Process adjustments are made as required 3.6. Out-of-specification product is actioned as required |
4. Record and report system performance and product quality data | 4.1. System performance and product quality data is recorded and reported within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 4.2. Variations from process specifications are recorded 4.3. Actions undertaken to troubleshoot and rectify faults are recorded 4.4. Indications of performance variation are documented 4.5. Relevant information is communicated to appropriate personnel |
Required Skills
This describes the skills and knowledge required for this unit. |
Required skills |
Identifies, accesses and interprets relevant historical and operational data and information Uses required forms of communication in troubleshooting and rectifying finishing and converting systems Reads and interprets required documentation, procedures and reports Operates communications equipment Interprets instruments, gauges and data recording equipment Interprets troubleshooting guides, operational data, trend analysis and test results Accesses, navigates and enters computer-based information Communicates effectively with personnel to assist with analysis and resolution of operational problems Assists others to identify and resolve operational problems in the workplace Identifies and actions systems, quality and equipment faults within level of responsibility Identifies causes and effects of faults and corrective action on associated processes Selects and uses appropriate troubleshooting methods Takes timely corrective action to maximise safety, quality and productivity Undertakes necessary calculations to aid troubleshooting as required Identifies and monitors process control points Maintains situational awareness in the work area Implements isolation and lockout procedures as required Operates required measuring and testing devices Perform tests and interprets and record results if required Operates high risk (and non-high risk) load shifting equipment as required Analyses and uses sensory information to adjust process to maximise safety, quality and productivity Uses electronic and other control systems to control equipment and processes as required |
Required knowledge |
Procedures, regulations and legislative requirements relevant to finishing and converting system operation including OHS, environmental including relevant sustainability requirements/practices, SOP, isolation procedures, safe working requirements, risks and hazard identification and housekeeping Relevant forms of communication Detailed knowledge of finishing and converting system, processes and associated services sufficient to troubleshoot including: plant layout theory of operation causes and effects of adjustments made to finishing and converting plant and processes relationships between finishing and converting system, processes and associated services An appropriate range of troubleshooting methods Sampling and testing process for plant and system operations, and process monitoring - purpose, standards and procedures as per site agreements Operator level maintenance requirements Application of high risk (and non-high risk) load shifting equipment as required Sensory information that indicates a deviation from standard operating parameters Sufficient knowledge of electronic and other control systems, operation and application to make appropriate adjustments that control finishing and converting systems within level of responsibility |
Evidence Required
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 | |
Critical aspects for assessment and evidence required to demonstrate competency in this unit | Evidence should be relevant to the work. It should satisfy the requirements of the elements and performance criteria and include consideration of: the required knowledge and skills tailored to the needs of the specific workplace applicable OHS regulations, environmental and safe working requirements/practices, SOP and housekeeping requirements applicable aspects of the range statement practical workplace demonstration of skills in troubleshooting and rectifying finishing and converting operations |
Context of and specific resources for assessment | A workplace assessment must be used to assess: the application of required knowledge on the job the application of skills on the job, over time and under a range of typical conditions that may be experienced in finishing and converting operations Access to the full range of equipment involved in integrated continuous manufacturing of finishing and converting operations in a pulp or paper mill is required |
Method of assessment | A combination of assessment methods should be used. The following examples are appropriate for this unit: observation of applied skills and knowledge on the job workplace demonstrations via a mock-up or simulation that replicate part/s of the job answers to written or verbal questions about specific skills and knowledge third-party reports from relevant and skilled personnel written evidence e.g. log sheet entries, checklist entries, test results Assessment processes and techniques must be culturally appropriate and in keeping with the language and literacy capacity of the learner and the work being performed. This includes conducting an assessment in a manner that allows thoughts to be conveyed verbally so that the learner can both understand and be understood by the assessor (e.g. use plain English and terminology used on the job) A holistic assessment with other units relevant to the pulp and paper industry, mill and job role is recommended Additional information on approaches to assessment for the pulp and paper industry is provided in the Assessment Guidelines for this Training Package |
Range Statement
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. | |
Productivity requirements may include: | energy efficiency waste minimisation evaporation minimisation, including landfill and waste water reduction environmentally safe waste disposal consideration of resource utilisation, including fibre efficiency minimising delays chemical recovery maximisation meeting key performance indicators line speed handovers quality checks meeting output targets i.e. net tonnes per employee per annum machine/process time availability i.e. time the machine or process is making product machine/process production rate |
Finishing and converting processes may include: | winding and re-winding decorating lotionising calendering water marking perforating slitting and cutting embossing laminating folding printing bonding core making wrapping and packing |
Materials and supplies may include: | parent roll or reel lotion shrink and stretch wraps pallets sheet paper labelling and stencilling wrap paper customer rolls boxes polythene wrap glues cartons strapping printing inks shippers reams signs and labels core board scent rolls |
Equipment and systems may include: | separate servo controlled motors and drives electronic sensors and proximity system light curtains category three plus guarding program formatting programmable production configurations pre-set modifiable quick change parts e.g. snap lock reels and winding equipment wrapping and packing equipment guillotine, knives and cutting equipment conveying systems materials handling equipment flexographic printing equipment used for decorating overhead cranes testing and measuring equipment roll grab attachments warehousing equipment warehousing control systems electronic, pneumatic and hydraulic process controls computer systems electronic screens and alarms process control systems analogue and digital instruments fully automated, semi-automated, manually operated plant and equipment appropriate to finishing and converting operations |
Auxiliary systems may include: | air lubrication vacuum dust extraction system |
Electronic control systems may include: | portable control device touch screens robotics |
Legislation, regulatory, licensing and certification requirements may include: | OHS and environmental requirements (local, state and commonwealth) activity or task specific high risk (and non-high risk) load shifting licensing requirements |
Documentation, procedures and reports may include: | SOP enterprise policies, procedures and guidelines environmental sustainability requirements/practices plant manufacturing operating manuals production schedules production plans production specifications quality certification e.g. ISO quality procedures oil or chemical spills and disposal guidelines plant isolation documentation safe work documentation e.g. plant clearance, job safety analysis, permit systems reference documents on theory of operation of processes and systems vendor manuals checklists Material Safety Data Sheets (MSDS) |
Maintenance may include: | operator level maintenance as per site agreement operator maintenance schedules maintenance supplies maintenance systems maintenance suppliers pro-active maintenance strategies e.g. Total Productive Maintenance (TPM), Reliability Centred Maintenance (RCM) |
Quality checks and tests may include: | roll density core slippage damaged packaging reel hardness core size colour matching bulk core strength sheet size roll appearance print quality cut quality MD&CD tensiles core scenting packaged product stretch roll size perforations product identification warehousing records |
Required action in the event of a missing or faulty component may include: | operator level maintenance involvement of maintenance personnel replacement of component communication with appropriate personnel |
Actions may include: | process adjustments reporting to authorised person rectifying problem within level of responsibility |
Communications may include | interaction with: warehousing personnel internal/external customers and suppliers maintenance services team members operational management statutory authorities |
Situational awareness may include | awareness of: traffic pedestrians location of equipment product hazards obstruction unexpected movement |
Sensory information may include: | visual sound feel touch smell vibration temperature |
Forms of communications may include: | written e.g. log books, emails, incident and other reports, run sheets reading and interpreting documentation e.g. SOP, manuals, checklists, drawings, data entry verbal e.g. radio skills, telephone, face to face, handover non-verbal e.g. hand signals, alarms, observations signage e.g. safety, access |
Sectors
Not Applicable
Employability Skills
This unit contains employability skills |
Licensing Information
Refer to Unit Descriptor