This unit of competency applies to operators who are responsible for operating and maintaining primary annealing equipment within the manufactured mineral products industry.

This unit does NOT include secondary processes involved in reheating of glass for laminating or toughening processes, which are covered by PMC552041C Operate process ovens.

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 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 as per company requirements

1.4. Undertake equipment preparation and prestart checks according to established procedures.

1.5. Undertake pre-startup 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

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

setup and annealing/conditioning process

temperature and temporary and permanent stress

pre-annealing, annealing and post-annealing processes

construction and limitations of the reheating equipment

out of specification situations

quality problems such as:

poor optics

distortion

excessive breakage

non-uniform break pattern

incorrect cross bend

excessive bow

scratches

poor glass shape

distinguish between causes of faults such as:

raw materials/ribbon faults

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 reheating equipment be understood and that the importance of critical material properties, settings and 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. In particular look to see that:

temperatures and stress parameters are maintained within limits

equipment set up is completed in accordance with work instructions

startup and shutdown occur first time

signals and alarms are responded to immediately

process measurements are continually made, observed and interpreted

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 or co-requisite units 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

Finishing equipment

This unit includes finishing equipment applicable to each of the specific areas of glass products manufacture, including:

flat glass

packaging, bottles and jars

Equipment

Equipment may include:

lehr and associated equipment

gas burners

instrumentation

computers

measuring and recording equipment

communication equipment

hand tools

safety clothing and equipment

Typical problems

Typical problems may include:

process problems

equipment problems

quality problems

temperature and strain problems

equipment problems

quality problems

loss of utilities

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.