Application of this unit

This competency requires the application of detailed operational and process knowledge, including the principles of operation of equipment, and the chemistry and/or physics and/or biology/biochemistry of changes to materials occurring during processing. It embodies a significant breadth and depth of technical knowledge and process understanding.

Assessment of this competency should ensure that the applicant can apply this knowledge to a process, and should typically rely on the applicant undertaking, or leading, a significant process improvement project.

This competency is typically performed by a senior operator, team leader or frontline manager.

Prerequisites

This unit has prerequisites of

MSAPMSUP390A Use structured problem solving tools

This describes the essential skills and knowledge and their level required for this unit.

Knowledge and understanding of the:

equipment,

processes

systems

sufficient to

identify hazards associated with the process

recognise opportunities to improve and/or enhance the quality of performance of the plant.

This knowledge needs to include:

the relevant technical theory of the plant area

an in depth understanding across the entire plant area

the organisation standard procedures and work instructions

relevant regulatory requirements, including those related to OHS risk control as appropriate to process/plant area optimisation.

Competence includes the ability to:

apply analytical skills which enable corrective or optimal conditions to prevail

identify and control hazards by applying the hierarchy of control as part of the optimisation process

interpret information and make appropriate process control decisions.

Competence includes the ability to distinguish between:

optimum and marginal performance of the plant

effective and marginal performance corrections and actions.

as is relevant to the practical operation of all major equipment/process/systems within the area.

Optimising process systems requires application of detailed operational and process knowledge to address issues such as:

starting material quality

yield maximisation

throughput maximisation

energy efficiency

use of utilities

labour utilisation

overall cost

efficient use of equipment

reducing downtime

minimisation of waste and rework

improved workplace layout and workflow.

Language, literacy and numeracy requirements

This unit requires the ability to communicate at all levels about what may be complex technical matters. It also requires the ability to evaluate complex information and sort often conflicting information into useful and distracting and to rank/prioritise information.

Writing is required to the level of reading and interpreting technical information, developing and modifying plans and procedures and interpreting relevant regulatory requirements.

Numeracy is required to the level of analysing product/process performance data, interpreting process condition information and deriving useful information from technical brochures, papers and similar. Calculation will be required to assist this and to determine priorities for optimisation plans (ie benefit/cost or other quantitative criteria)

The Evidence Guide provides advice on assessment and must be read in conjunction with the Performance Criteria, Required Skills and Knowledge, the Range Statement and the Assessment Guidelines for this Training Package.

Overview of assessment

A holistic approach should be taken to the assessment.

Assessors must be satisfied that the person can consistently perform the unit as a whole, as defined by the Elements, Performance Criteria and skills and knowledge.

Competence must be demonstrated in the ability to analyse and evaluate current production performance, and develop and implement plans to optimise process systems.

While the technician is expected to take a lead technical role, and to demonstrate competence as defined above, optimisation is rarely undertaken by an individual alone and liaison with all relevant stakeholders is an expected part of this competency.

Where the assessee does not currently possess evidence of competency in MSASUP390A Use structured problem solving tools, it may be coassessed with this unit.

Criticalaspects for assessment and evidence required to demonstrate competency in this unit

It is essential that the equipment/process/system be understood in depth and that the importance of critical material properties/settings/readings is known. Competence must be demonstrated in the ability to recognise and analyse potential situations requiring action and then in implementing appropriate corrective action.

Consistent performance should be demonstrated. For example, look to see that:

non-routine problems are recognised and defined

hazards are identified and controlled by applying the hierarchy of control

possible causes of complex problems are identified based on experience and the use of analytical techniques in solving the problem, including identifying variations and cause, separating single problems from multiple problems and the recognition of recurring problems

fundamental cause of process or equipment faults is determined

corrective/preventative actions are developed to avoid recurrence of the problem and optimise the condition of the process, plant and equipment

product quality and uniformity are maintained.

Competence must be demonstrated in the operation of all ancillary equipment to the level required for this competency unit.

Competence also includes the ability to implement improvements within appropriate time constraints and in a manner relevant to the operation of the equipment, processes and systems.

Context of assessment

Competence in this unit may be assessed by:

observation over time in a processing plant allowing for adequate assessment of operation under all normal and a range of abnormal conditions. Where this is not practical, additional assessment techniques must be used.

using a suitable simulation and/or a range of case studies/scenarios

undertaking a specific project based in the plant

a combination of these techniques.

Method of assessment

In all cases it is expected that practical assessment will be combined with targeted questioning to assess the underpinning knowledge and theoretical assessment will be combined with appropriate practical/simulation or similar assessment. Assessors need to be aware of any cultural issues that may affect responses to questions.

Assessment processes and techniques must be culturally appropriate and appropriate to the oracy, language and literacy capacity of the assessee and the work being performed.

Specific resources for assessment

This section should be read in conjunction with the Range Statement for this unit of competency. Resources required include suitable access to an operating plant or equipment that allows for appropriate and realistic simulation. A bank of case studies/scenarios and questions will also be required to the extent that they form part of the assessment method. Questioning may take place either in the workplace, or in an adjacent, quiet facility such as an office or lunchroom. No other special resources are required.

Access must be provided to appropriate learning and/or assessment support when required. Where applicable, physical resources should include equipment modified for people with disabilities.

The Range Statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Add any 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.

Where reference is made to industry codes of practice, and/or Australian/international standards, the latest version must be used.

Context

This unit describes the work conducted by senior operators, team leaders or front line managers who optimise process systems as part of their work function. It includes all items of equipment and unit operations which form part of the production process of a complete area.

Typical problems will require the application of detailed operational and process knowledge over the entire production/manufacturing area, including the principles of operation of the equipment and the chemistry, physics, biology and/or biochemistry of the changes to materials occurring within that area.

All operations are performed in accordance with organisation procedures, licensing requirements, legislative requirements and industrial awards and agreements.

Procedures

All operations are performed in accordance with procedures. Procedures means all relevant workplace procedures, work instructions, temporary instructions and relevant industry and government codes and standards. These may include or have been prepared from/to comply with:

industry codes of practice

materials safety data sheets

equipment manuals

equipment start up, operation and shut down procedures

calibration and maintenance schedules

quality manuals and procedures

organisation recording and reporting procedures

production and laboratory schedules

material, production and product specifications.

Data/records

Historical data/records may include:

hazard logs

incident reports

maintenance records

product non-conformance reports

production records.

Implementing change

Requirements to implement change may include:

changes to procedures

training of operators

equipment modifications

ensuring all HSE requirements are addressed.

Relevant/appropriate personnel

Relevant/appropriate personnel may include:

managers

OHS representatives and OHS committee.

Relevant information

Relevant information logged to include:

modifications to plant or equipment

modifications to procedures or practices.

Sources of information

Sources of information may include:

hazard logs

incident reports

maintenance records

work practices

procedures

industry journals

equipment supplier information

industry best practice information.

Health, Safety and Environment (HSE)

All operations to which this unit applies are subject to stringent health, safety and environment requirements, which may be imposed through State or Federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between Performance Criteria and HSE requirements, the HSE requirements take precedence.

Not applicable.

EmployabilitySkills

This unit contains employability skills.

Not applicable.