This unit of competency applies to operators who are responsible for operating, monitoring and maintaining float forming equipment within the manufactured mineral products industry.

This competency includes the operation of all ancillary equipment.

This competency is typically performed by operators working either independently or as part of a work team. At all times they would be liaising with other members of the team.

ELEMENT

PERFORMANCE CRITERIA

1. Prepare forming equipment

1.1. Interpret job specifications and set up the appropriate equipment in accordance with work instructions

1.2. Check materials stocks for quality and quantity suitable for production

1.3. Prepare all consumables for production

1.4. Undertake equipment preparation and checks according to established procedures

2. Operate forming equipment

2.1. Start up equipment in accordance with work instructions

2.2. Form glass by directing product flow in accordance with work instructions and safety requirements

2.3. Ensure forming processing equipment is operated in accordance with established enterprise procedures

3. Monitor and record forming equipment operation

3.1. Monitor equipment to ensure that quality specifications are met

3.2. Make operation adjustments according to established procedures to maintain product quality

3.3. Conduct product sampling and quality control checks according to enterprise procedures to maintain forming specifications

3.4. Monitor application of size over glass fibres to ensure quality specifications are met

3.5. Use and observe ancillary equipment and safety procedures in accordance with enterprise requirements

3.6. Document and maintain records and production results according to enterprise requirements

3.7. Identify and report processing problems to a designated person for rectification

4. Rectify routine problems

4.1. Identify the range of faults that can occur during the operation

4.2. Determine and rectify fault causes in accordance with procedures

4.3. Identify and rectify equipment failure causes in accordance with procedures

4.4. Ensure appropriate records and log books of equipment operations are maintained to meet procedures

4.5. Identify non-routine problems and report to designated person

5. Control hazards

5.1. Identify hazards from the job to be done

5.2. Identify other hazards in the work area

5.3. Assess the risks arising from those hazards

5.4. Implement measures to control those risks in line with procedures

Required skills

Required skills include:

recognising process conditions which will lead to out of specification production

implementing the enterprise's standard procedures and work instructions and relevant regulatory requirements within appropriate time constraints and in a manner relevant to the operation of the process and equipment

reading and numeracy to interpret workplace documents and technical information

Required knowledge

Required knowledge includes:

composition and nature of the glass

startup and shutdown processes

construction and limitations of the equipment

out of specification situations

importance of safety procedures and personal protective equipment (PPE)

quality problems which may include:

broken packs

mixed and damaged material

double winding

forming positions

break and stoppages

poor glass quality

distinguish between causes of faults such as:

raw materials

equipment

types of defects/faults

electrical/instrumental

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

The unit will be assessed in as holistic a manner as is practical and may be integrated with the assessment of other relevant units of competency.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

It is essential that the equipment and operating parameters be understood and that the importance of critical material properties 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. In particular look to see that:

equipment setup is completed in accordance with work instructions

signals and alarms are responded to immediately

process measurements are continually made, observed and interpreted

operating supply levels are maintained

equipment problems are identified and responded to immediately

quality is maintained to customer specifications.

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

Context of and specific resources for assessment

Assessment will require access to an operating plant over an extended period of time, or a suitable method of gathering evidence of operating ability over a range of situations.

Assessment will occur over a range of situations which will include disruptions to normal, smooth operation.

Simulation or case studies/scenarios may be required to allow for timely assessment of parts of this unit of competency. Simulation should be based on the actual plant and will include 'walk-throughs' of the relevant competency components. A bank of scenarios/case studies/what ifs and questions will be required to probe the reasoning behind observable actions.

Method of assessment

In all plants it may be appropriate to assess this unit concurrently with relevant teamwork and communication units.

Individual enterprises may choose to add prerequisites and co-requisites relevant to their processes.

Guidance information for assessment

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

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.

Procedures

All operations are performed in accordance with standard procedures and work instructions

Equipment

Equipment may include:

forming equipment

size application equipment

communication equipment

hand tools

safety clothing and equipment

Typical problems

Typical problems may include:

winding and sliver problems

equipment problems including condition and cleaning of equipment

quality problems

Occupational health and safety (OHS)

All operations are subject to stringent OHS requirements and these must not be compromised at any time. Where there is an apparent conflict between performance criteria and OHS requirements, the OHS requirements take precedence

Unit sector

Operational/technical

This unit contains employability skills.