Application
This unit of competency covers the skills and knowledge required to operate annealing equipment to form glass products from a melting furnace and ancillary equipment that is integral to the process.
This unit of competency applies to operators who are required to set up annealing equipment, monitor and adjust the equipment, undertake routine checks and identify and rectify routine problems.
This unit of competency applies to an individual working alone or as part of a team or group and working in liaison with other shift team members, team leader and supervisor, as appropriate.
No licensing, legislative or certification requirements apply to this unit at the time of publication.
Elements and Performance Criteria
Elements describe the essential outcomes. | Performance criteria describe the performance needed to demonstrate achievement of the element. | ||
1 | Prepare the annealing equipment | 1.1 | Identify the location and function of annealing equipment |
1.2 | Interpret job specifications and set up the appropriate line/equipment | ||
1.3 | Check that the quality and quantity of input glass is suitable for production run according to company requirements | ||
1.4 | Undertake equipment preparation and pre-start checks according to established procedures. | ||
1.5 | Undertake pre-start checks in accordance with procedures | ||
2 | Start up and shut down annealing equipment | 2.1 | Complete the steps for setting up and preparing to start annealing equipment in normal and abnormal situations |
2.2 | Complete the steps preparing for shutting down annealing equipment in normal and abnormal situations | ||
2.3 | Start up the annealing equipment as required | ||
2.4 | Shut down the annealing equipment as required | ||
3 | Operate annealing equipment | 3.1 | Operate annealing equipment to ensure quality specifications are met |
3.2 | Make operation adjustments according to established procedures and ensure product quality and specifications are maintained | ||
3.3 | Use and observe ancillary equipment and safety procedures in accordance with enterprise requirements | ||
3.4 | Document and maintain records and production results according to enterprise requirements | ||
4 | Monitor, adjust and record annealing operation | 4.1 | Monitor equipment operation to maintain product quality and specifications |
4.2 | Measure and record operating parameters according to enterprise requirements | ||
4.3 | Conduct product sampling and quality control checks according to standard procedures to ensure and maintain annealing specifications | ||
4.4 | Adjust annealing equipment controls to ensure glass parameters are maintained to job specifications | ||
4.5 | Record results in accordance with work instructions | ||
5 | Rectify routine problems | 5.1 | Identify the range of faults that can occur during the operation |
5.2 | Determine and rectify fault causes in accordance with procedures | ||
5.3 | Identify and rectify equipment failure causes in accordance with procedures | ||
5.4 | Ensure appropriate records and log books of equipment operations are maintained to meet procedures | ||
5.5 | Identify non-routine problems and report to designated person | ||
6 | Control hazards | 6.1 | Identify hazards from the job to be done |
6.2 | Identify other hazards in the work area | ||
6.3 | Assess the risks arising from those hazards | ||
6.4 | Implement measures to control those risks in line with procedures | ||
Evidence of Performance
Evidence required to demonstrate competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria and demonstrate the ability to:
read and interpret job sheets, procedures, instruments/control panels, test results, material labels and safety information
perform pre-start procedures
monitor key variables, including:
ribbon quality
dimensions
temperature and stress parameters
product integrity and general conformance to specification
operate and adjust the equipment to meet product quality and production output specifications
start up and shut down the annealing equipment
identify hazards and apply relevant hazard controls
apply safety procedures
recognise out-of-specification products, process problems and materials faults
recognise routine and non-routine problems
identify when the operator is able to rectify problems, when assistance is required and who is the appropriate source for assistance
take action to resolve problems or report them to appropriate personnel
distinguish between possible causes of routine problems, including:
raw material variations
equipment malfunctions
electrical/instrument malfunctions
process abnormalities
communicate effectively with team/work group and supervisors
complete workplace records
do basic arithmetical manipulations, including additions, subtractions, divisions, fractions and percentages.
Evidence of Knowledge
Must provide evidence that demonstrates knowledge relevant to their job sufficient to operate under routine only supervision and to solve routine problems, including knowledge of:
principles of pre-annealing, annealing and post-annealing processes
functions, limitations and principles of operation of the equipment
composition and nature of the glass
critical material properties, settings and readings
basic physics, and where appropriate chemistry, relevant to the equipment/process/materials
the potential effects of variations in raw materials and equipment operation in relation to quality of product
factors which may affect product quality or production output and appropriate remedies
start-up and shutdown processes
routine problems, their probable causes and relevant corrective actions
organisation procedures relevant to the work environment/job role
hierarchy of control
hazards that may arise in the job/work environment and:
their possible causes
potential consequences
appropriate risk controls.
Assessment Conditions
The unit should be assessed holistically and the judgement of competence shall be based on a holistic assessment of the evidence.
The collection of performance evidence:
should occur over a range of situations which include typical disruptions to normal, smooth operation of an operating plant
will typically include a supervisor/third-party report or other evidence, focusing on consistent performance and problem recognition and solving. A supervisor/third-party report must be prepared by someone who has a direct, relevant, current relationship with the person being assessed and who is in a position to form a judgement on workplace performance relevant to the unit of competency
must include the use of an appropriate industrial item/s of equipment requiring demonstration of operation, start-up and shutdown procedures and responding to problems
may use industry-based simulation for all or part of the unit particularly where safety, lack of opportunity or significant cost is an issue.
Assessment should occur in operational workplace situations. Where this is not possible or where personal safety or environmental damage are limiting factors assessment must occur in a sufficiently rigorous simulated environment that reflects realistic operational workplace conditions. This must cover all aspects of workplace performance, including environment, task skills, task management skills, contingency management skills and job role environment skills.
Assessment in a simulated environment should use evidence collected from demonstration of skills and one or more of:
walk-throughs
pilot plant operation
industry-based case studies/scenarios
‘what ifs’.
Knowledge evidence may be collected concurrently with performance evidence (provided a record is kept) or through an independent process such as workbooks, written assessments or interviews (provided a record is kept).
Assessment processes and techniques must be appropriate to the language, literacy and numeracy requirements of the work being performed and the needs of the candidate.
Conditions for assessment must include access to all tools, equipment, materials and documentation required, including relevant workplace procedures, product and manufacturing specifications associated with this unit.
The regulatory framework will be reflected in workplace policies and procedures and is not required to be independently assessed.
Foundation skills are integral to competent performance of the unit and should not be assessed separately.
Assessors must satisfy the assessor competency requirements that are in place at the time of the assessment as set by the VET regulator.
In addition the assessor or anyone acting in subject matter expert role in assessment shall demonstrate both technical competency and currency. If the assessor cannot demonstrate technical competency and currency they shall assess with a subject matter expert who does meet these requirements.
Technical competence can be demonstrated through one or more of:
relevant VET or other qualification/Statement of Attainment
appropriate workplace experience undertaking the type of work being assessed under routine and non-routine conditions
appropriate workplace experience supervising/evaluating the type of work being assessed under routine and non-routine conditions
Currency can be demonstrated through one or more of:
being currently employed undertaking the type of work being assessed
being employed by the organisation undertaking the type of work being assessed and having maintained currency in accordance with that organisation’s policies and procedures
having consulted/had contact with an organisation undertaking the type of work being assessed within the last twelve months, the consultation/contact being related to assessment
conducting on the job training/assessments of the type of work being assessed
being an active member of a relevant professional body and participating in activities relevant to the assessment of this type of work.
Foundation Skills
This section describes those required skills (language, literacy and numeracy) that are essential to performance.
Foundation skills essential to performance are explicit in the performance criteria of this unit of competency.
Range Statement
This field allows for different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included. | |
Regulatory framework | The latest version of all legislation, regulations, industry codes of practice and Australian/international standards, or the version specified by the local regulatory authority, must be used. Applicable legislation, regulations, standards and codes of practice include: health, safety and environmental (HSE) legislation, regulations and codes of practice relevant to the workplace, equipment and production processes and hazardous materials Australian/international standards relevant to the materials being used and products being made any relevant licence and certification requirements. All operations to which this unit applies are subject to stringent HSE requirements, which may be imposed through state/territory or federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between performance criteria and such requirements the legislative requirements take precedence. |
Procedures | All operations must be performed in accordance with relevant procedures. Procedures are written, verbal, visual, computer-based or in some other form, and include one or any combination of: job cards emergency procedures work instructions standard operating procedures (SOPs) safe work method statements (SWMS) formulas/recipes batch sheets temporary instructions any similar instructions provided for the smooth running of the plant. |
Tools and equipment | Tools and equipment include: lehr ancillary equipment that is integral to the process measuring and recording equipment. |
Problems | Routine problems must be resolved by applying known solutions. Routine problems are predictable and include one or more of: process problems equipment problems temperature and strain problems loss of utilities quality problems, such as: poor optics distortion excessive breakage non-uniform break pattern incorrect cross bend excessive bow scratches poor glass shape. Known solutions are drawn from one or more of: procedures training remembered experience. Non-routine problems must be reported according to according to relevant procedures. |
Hazards | Hazards must be identified and controlled. Identifying hazards requires consideration of: high temperatures smoke, dust, vapours or other atmospheric hazards weight, shape, volume of materials to be handled hazardous products and materials sharp edges, protrusions or obstructions slippery surfaces, spills or leaks electricity gas gases and liquids under pressure noise rotational equipment or vibration plant services (steam, condensate, cooling water, etc) structural hazards equipment failures machinery, equipment and product mass limited head spaces or overhangs working at heights working in restricted or confined spaces other hazards that might arise. |
Records and reports | Records include one or more of: log books/sheets electronic records job/work sheets other records used for the smooth running of the plant. Reports include one or more of: paper or electronic-based logs and reports verbal/radio reports reporting items found which require action. |
Sectors
Not applicable
Competency Field
Operations