Application
This unit applies to operators who monitor and control stock preparation systems in the pulp and paper industry. This work typically involves complex integrated equipment and continuous operations This unit generally applies to those who: monitor and control process and systems control quality of stock, chemicals and water conduct product grade change, and record process and system information to meet safety, quality and productivity requirements It does not include starting up, shutting down or troubleshooting and rectifying stock preparation systems |
Prerequisites
Not Applicable
Elements and Performance Criteria
ELEMENT | PERFORMANCE CRITERIA |
1. Monitor and control process and systems | 1.1. Process and systems are monitored and controlled within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements 1.2. Production requirements are checked at start of shift to plan day's activities as required 1.3. Operational status is confirmed by inspection, observations and other information 1.4. Process supplies are maintained and controlled to meet production requirements 1.5. Systems are monitored to ensure stock preparation systems are within parameters 1.6. Process and system variations from operating parameters are identified, rectified and/or reported 1.7. Operator level preventative maintenance is undertaken as required 1.8. Changes to machine operations are communicated to relevant personnel 1.9. Stock systems are monitored and adjusted during stock-off situations as required |
2. Control quality of stock, chemicals and water | 2.1. Quality of stock, chemicals and water is controlled within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 2.2. Quality of stock, chemical and water is monitored and controlled within parameters 2.3. Test samples are taken and test results are interpreted and recorded as required 2.4. Adjustments are made to ensure quality requirements are met 2.5. Routine observations and assessments are conducted on product and system operations 2.6. Changes to product requirements are communicated to relevant personnel |
3. Conduct product grade change | 3.1. Product grade changes are conducted within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 3.2. Product grade change is completed within OHS, SOP, environmental and safe working requirements and practices 3.3. Grade change requirements are determined and planned 3.4. Run out of stock, chemicals and water systems are coordinated and completed as required 3.5. Flushing, draining and cleaning of stock, chemicals and water systems are completed as required 3.6. Process set ups/adjustments are implemented to meet new grade requirements 3.7. Raw materials and supplies required for new grade requirements are staged ready for use 3.8. Stock, chemicals and water systems startups are coordinated and implemented for new grade requirements as required 3.9. Grade change is coordinated and implemented on the run as required |
4. Record process and system information | 4.1. Recording process and system information is completed within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 4.2. Systems and production information is recorded 4.3. Problems or variations in performance are recorded and communicated |
Required Skills
This describes the skills and knowledge required for this unit. |
Required skills |
Uses required forms of communication in monitoring and controlling stock preparation systems Reads and interprets required documentation, procedures and reports Interprets instruments, gauges and data recording equipment Accesses, navigates and enters computer-based information Identifies and actions problems within level of responsibility Interprets and plans grade change requirements Co-ordinates and conducts grade changes Takes samples, conducts tests, interprets and records results as required Uses measuring equipment as required Identifies and monitors process control points Maintains situational awareness in the work area Operates high risk (and non-high risk) load shifting equipment as required Analyses and uses sensory information to adjust process to maintain 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 stock preparation systems including OHS, environmental including relevant sustainability requirements/practices, SOP, isolation procedures, safe working requirements, risks and hazard identification and housekeeping Relevant forms of communication Basic problem-solving techniques consistent with level of responsibility Sampling and testing process for plant and system operations, and process monitoring - purpose, standards and procedures as per site agreements Stock preparation in-process tests and procedures Working knowledge of stock preparation plant, processes, layout and associated services including operating parameters, variation and associated adjustments within level of responsibility Grade requirements Quality requirements Materials and supplies and how they influence paper properties Grade change processes and coordination Timing for materials and supplies run out 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 stock preparation 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 the monitoring and controlling of stock preparation 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 stock preparation systems Access to the full range of equipment involved in integrated continuous manufacturing of stock preparation 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 |
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 | |
Systems and functions involved in stock preparation may include: | refining systems blending system proportioning system broke system stock chests water chests cleaning system water recovery system chemical and additive plants bale handler broke baler wire coiler | |
Materials and supplies may include: | water stock compressed air chemicals additives steam baled pulp | |
Equipment may include: | refiners pumps valves chests agitators pulpers screens cleaners showers disc deckers consistency controllers screw press water recovery equipment computer systems electronic screens and alarms process control systems fully automated, semi-automated, manually operated plant and equipment appropriate to stock preparation systems | |
Electronic control systems may include: | Digital Control System (DCS) touch screens robotics | |
Hazards and risks involved in stock preparation may include: | steam and/or gas leaks fires nip points compressed air hot surfaces electrical entanglement slip hazards/falls energy pressures chemicals fumes confined spaces dust | |
Legislation, regulatory, licensing and certification requirements may include: | OHS and environmental requirements (local, state and commonwealth) as applicable, activity or task specific high risk (and non-high risk) load shifting licensing requirements | |
Documentation, procedures and reports may include: | SOP site policy and procedures environmental sustainability requirements/practices plant manufacturing operating manuals confined space requirements vendor documentation reference manual grade specifications quality procedures oil or chemical spills and disposal guidelines plant isolation documentation housekeeping safe work documentation e.g. plant clearance, job safety analysis, permit systems maintenance logs job sheets operating log production instructions Materials Safety Data Sheets (MSDS) 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 | interactions with: team members production/service co-ordinators internal/external customers and suppliers maintenance services operational management statutory authorities | |
Situational awareness may include | awareness of: traffic pedestrians location of equipment product hazards obstructions 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, data entry reading and interpreting documentation e.g. standard operating procedures, 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 |
Sectors
Not Applicable
Employability Skills
This unit contains employability skills |
Licensing Information
Refer to Unit Descriptor