This unit applies to operators who prepare and operate the woodchip production system in the pulp and paper industry. This work typically involves complex integrated equipment and continuous operations

This unit generally applies to those who:

conduct pre-startup system checks

start up system for production run

monitor and maintain chipping system operation

record and document machine performance and production data, and

conduct a plant shutdown

to meet safety, quality and productivity requirements

It does not include receiving and unloading materials, distributing woodchips or troubleshooting and rectifying primary resource operations

ELEMENT

PERFORMANCE CRITERIA

1. Conduct pre-startup system checks

1.1. Pre-startup system checks are conducted within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements

1.2. External inspection and pre-operational checks of the woodchip system are carried out

1.3. Operator level maintenance schedules are carried out as required

1.4. Isolations are removed in accordance with site procedures if required

1.5. Monitoring devices and alarm systems are confirmed to be operational

1.6. Relevant personnel are notified of impending startup

1.7. Logs to be processed are identified and loaded to ensure correct presentation

2. Start up system for production run

2.1. System for production run is started up within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements

2.2. Equipment, conveyors, transfer system and operational monitoring equipment pre-startup checks are carried out

2.3. Transfer equipment, bins and hoppers are checked to ensure prevention of chip contamination as required

2.4. System is started

2.5. Logs are docked as required

3. Monitor and maintain chipping system operation

3.1. Chipping system operation is monitored and maintained within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements

3.2. Logs and conveyors are monitored to achieve optimum flow

3.3. Supply of logs is co-ordinated and maintained to ensure production requirements are met

3.4. Equipment operation is monitored electronically and visually to ensure operating conditions are continually maintained

3.5. Potential blockage and/or jamming situations are identified and appropriate action is taken to rectify

3.6. Woodchip quality is continually monitored as required

3.7. Woodchip transfer to storage system is monitored and maintained

3.8. Storage levels are monitored and maintained as required

4. Record and document machine performance and production data

4.1. Machine performance and production data is recorded and documented within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements

4.2. Production and quality records are maintained as required

4.3. Data is entered into computer system as required

4.4. Problems or variations are communicated to relevant personnel

5. Conduct a plant shutdown

5.1. Plant shutdown is conducted within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements

5.2. Shutdown plan is communicated with relevant personnel

5.3. Shutdown procedures are carried out

5.4. Cause of uncontrolled shutdown is identified and rectified

5.5. Shutdown details are recorded as required

This describes the skills and knowledge required for this unit.

Required skills

Uses required forms of communication in preparing and operating the woodchip production system

Reads and interprets required documentation, procedures and reports

Prepares written information and enters data to support groups and teams

Accesses, navigates and enters computer-based information

Responds to video and other monitoring devices and alarms

Interprets instruments, gauges and data recording equipment

Identifies and actions problems within level of responsibility

Follows equipment maintenance procedures including recognition, checking, fixing and reporting faults

Identifies and monitors process control points

Maintains situational awareness in the area

Maintains chip quality and machine production rate or schedules

Prepares, starts up, and monitors operations

Follows procedures for woodchip operation

Monitors and maintains waste systems

Coordinates and plans shutdown activity

Responds to problems associated with plant shutdown and uncontrolled shutdown to ensure safety quality and productivity

Sets up equipment or plant to specification as required

Operates high risk (and non-high risk) load shifting equipment as required

Uses measuring equipment as required

Analyses and uses sensory information to adjust process to maintain and co-ordinate 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 woodchip production operations including OHS, environmental including relevant sustainability requirements/practices, SOP, isolation procedures, safe working requirements, risks and hazard identification and housekeeping

Quality standard requirements

Relevant forms of communication

Basic problem-solving techniques consistent with level of responsibility

Equipment fault identification and corrective action

Working knowledge of woodchip production system, area layout and associated services sufficient to carry out docking and debarking processes within level of responsibility

Required responses to all unplanned shutdowns (e.g. power outage, mechanical breakdown, blockages, jamming, air supply, control system failure) to ensure safety quality and productivity

Process and procedures for plant shutdowns and uncontrolled shutdowns

Plant and machinery functions and operations

Emergency procedures and responses

Process and procedures for woodchip production

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 the woodchip production system, within level of responsibility

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 preparing and operating woodchip production systems

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 woodchip production systems

Access to the full range of equipment involved in integrated continuous manufacturing of woodchip production systems 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

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

Materials and supplies may include:

hardwood or softwood logs

supplies

parts

Equipment may include:

chipper

hogger

conveyor feed systems

chipscreens

hydraulic cutting equipment

blades

chainsaws

magnetic detectors

silos

hopper and storage systems

chip spreaders and slingers

front end loader trailer or tipper, articulated loader, tracked dozer/front end loader, forklift, side loader, mobile crane, rigid loader, log loader, straddle truck

fork lift attachments, crane hooks, chains, slings and straps, grabs, winches

docking saw

bark transferring system

debarking machinery

drying ovens

sizing screens

video monitoring

electronic weighing and measuring equipment

computer systems

electronic screens and alarms

process control systems

analogue and digital instrumentation

fully automated, semi-automated, manually operated plant and equipment appropriate to the woodchip production system

Accessories may include:

protective and high visibility safety clothing and equipment

break down tools and equipment

electronic communication equipment

Electronic control systems may include:

Digital Control System (DCS)

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

quality procedures

oil or chemical spills and disposal guidelines

plant isolation documentation

safe work documentation e.g. plant clearance, job safety analysis, permit systems

enterprise policy, procedures and guidelines

environmental sustainability requirements/practices

plant manufacturing operating manuals

work orders

tally sheets

truck delivery dockets

invoices

non-conformance reports

test results and reports

log sheets (production/equipment)

equipment performance data

tonnage, input and conversion

sampling and test reports

Material Safety Data Sheets (MSDS)

process and instrument diagrams

Maintenance may include:

operator level maintenance as per site agreement

operator maintenance schedules

maintenance systems

maintenance suppliers

proactive maintenance strategies e.g. Total Productive Maintenance (TPM), Reliability Centred Maintenance (RCM)

Actions may include:

process adjustments

reporting to authorised person

rectifying problem within level of responsibility

Communications may include

interaction with:

work area personnel

internal/external customers and suppliers

team members

production/service coordinator

maintenance service

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 communication may include:

written e.g. log books, emails, incident and other reports, run sheets, data entry

reading and interpreting documentation e.g. SOP, manuals, checklists, drawings

verbal e.g. radio skills, telephone, face to face, handover

non-verbal e.g. hand signals, alarms, observations

signage e.g. safety, access

This unit contains employability skills