This unit applies to operators who troubleshoot and rectify primary resource operations 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 diagnose causes of process variation, plant or equipment faults

rectify process variation, plant or equipment faults

identify and rectify product quality faults, and

record and report troubleshooting activities

to meet safety, quality and productivity requirements

It does not include receiving or unloading materials, preparing and operating the woodchip production system or distributing woodchips

ELEMENT

PERFORMANCE CRITERIA

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

1.1. Causes of process variation, plant or equipment faults are identified and diagnosed within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements

1.2. Visual assessments and machine alarms are interpreted to determine fault type and location

1.3. Routine physical inspections of plant and process are made to identify faults

1.4. Causes and sources of process variation, plant or equipment faults are identified and located using appropriate techniques

1.5. Relevant historical data is accessed and analysed to confirm diagnosis

2. Rectify process variation, plant or equipment faults

2.1. Process variation and plant or equipment faults are rectified within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements

2.2. Emergency stop or shutdown, isolation and lockout procedures are initiated prior to fault rectification

2.3. Faulty equipment or instrumentation is isolated and repaired or replaced

2.4. Corrective operational adjustments and operator level maintenance requirements are implemented

2.5. Restoration to normal operation is achieved and communicated to relevant personnel

3. Identify and rectify product quality faults

3.1. Product quality faults are identified and rectified within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements

3.2. Product faults or variations are identified by observation, systematic sampling and testing

3.3. Out-of-specification production is managed

3.4. Samples for a range of tests are undertaken

3.5. Required tests are conducted

3.6. Test results are interpreted and operations are adjusted to correct variations

4. Record and report troubleshooting activities

4.1. Troubleshooting activities are recorded and reported within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements

4.2. Variations from specifications and machine operating faults are documented

4.3. Assessment and evaluation of causes of deviations and corrective actions undertaken are documented

4.4. Relevant information is communicated to the appropriate personnel

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 primary resource operations

Reads and interprets required documentation, procedures and reports

Accesses, navigates and enters computer-based information

Interprets instruments, gauges and data recording equipment

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

Sets up and operates test equipment

Performs tests and interprets and records results if required

Uses measuring equipment as required

Uses routine checking procedures during plant and systems operation

Conducts routine checks during plant and systems operation

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 primary resource operations 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 primary resource operations, processes and associated services 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

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

Types, causes and effects of plant shutdowns

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 primary resource operations, 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 troubleshooting and rectifying primary resource 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 primary resource operations

Access to the full range of equipment involved in integrated continuous manufacturing of primary resource 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

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.

Materials and supplies may include:

hardwood or softwood logs

lapped pulp

waste paper

woodchips

supplies

parts

Equipment may include:

chipper

hogger

conveyor feed systems

chipscreens

hydraulic cutting equipment

blades

chainsaws

magnetic detectors

silos

hopper and storage systems

docking saw

bark transferring systems and debarking machinery

chip spreaders and slingers

trailer or tipper

articulated loader

tracked dozer and front end loader

forklift

side loader

mobile crane

rigid loader

log loader

straddle truck

computer systems

electronic screens and alarms

process control systems

analogue and digital instrumentation

fully automated, semi-automated, manually operated plant and equipment appropriate to primary resource operations

Accessories may include:

protective and high visibility safety clothing and equipment

break down tools and equipment

electronic communication equipment

Testing equipment may include

drying ovens

sizing screens

computer processing equipment

Electronic control systems may include:

Digital Control System (DCS)

touch screens

robotics

Attachments may include:

fork lift attachments

crane hooks

chains

slings and straps

grabs

winches

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

environmental sustainability requirements/practices

plant manufacturing operating manuals

enterprise policy, procedures and guidelines

oil or chemical spills and disposal guidelines

plant isolation documentation

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

weighbridge dockets

work orders

tally sheets

truck delivery dockets

invoices

non-conformance reports

test results and reports

log sheets (production and equipment)

equipment performance data

tonnage, input and conversion

sampling and test reports

Material Safety Data Sheets (MSDS)

pile survey documents

process and instrument diagrams

Maintenance may include:

operator level maintenance as per site agreements

operator maintenance schedules

maintenance systems

maintenance suppliers

pro-active 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 coordinators

maintenance services

operational management

statutory authorities

Situational awareness may include

awareness of:

traffic

pedestrians

location of equipment

product

hazards

obstruction

unexpected movement

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

Sensory information may include:

visual

sound

feel

touch

smell

vibration

temperature

This unit contains employability skills