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

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 for production

1.1. Set up line in accordance with work instructions

1.2. Determine product formation requirements from the production program

1.3. Conduct equipment pre-startup procedure and visual checks according to enterprise procedure check list

1.4. Ensure required change parts are in place

1.5. Set up and configure equipment startup functions to comply with standard operating procedures

1.6. Ensure equipment is safe to use

2. Operate forming equipment

2.1. Start up equipment in accordance with work instructions

2.2. Operate equipment to produce product of required shape, dimensions and consistency

2.3. Monitor equipment conditions and adjust to ensure correct product quality

2.4. Monitor and adjust material properties as required

2.5. Record production data as required

3. Rectify routine problems

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

3.2. Determine and rectify fault causes by established enterprise procedures/work instructions

3.3. Identify and rectify equipment failure causes in accordance with accordance with established enterprise procedures

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

4. Shut down equipment

4.1. Ensure line is clear of all product and left in a safe manner for startup

4.2. Determine and rectify fault causes in accordance with procedures/work instructions

4.3. Clean work area

4.4. Complete appropriate records and logs

4.5. Shut down equipment in an emergency situation

5. Prepare equipment for cleaning and maintenance

5.1. Isolate equipment in accordance with work instructions

5.2. Remove any remaining product or materials safely

5.3. Ensure the area is clear and safe for cleaning or maintenance

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 and taking appropriate action

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 equipment

reading and numeracy to interpret workplace documents and technical information

Required knowledge

Required knowledge includes:

composition and nature of products being manufactured

startup and shutdown processes

construction and limitations of the equipment

identification of required adjustments to keep process within specifications

identification of out of specification situations

distinguish between causes of faults such as:

raw material

equipment adjustment setup

maintenance issues

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 forming 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:

process and equipment are operated in accordance with work instructions and process parameters

quality is monitored to minimise wastage

startup and shutdown occur first time

signals and alarms are responded to immediately

process measurements and tests are continually made, observed and interpreted

all OHS requirements are followed.

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

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

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

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

Operations

This unit of competency includes the operation of items of equipment where the operator is expected to demonstrate an understanding of the process and the equipment operation. The processes covered by this unit include:

fibre cement board

plaster board

machine cornices

Tools and equipment

Tools and equipment may include:

curing ovens

transfer machines

scoring

plasterboard liner unwinders/burners

setting belts

forming plates/dams

mixers

pizza cutters/blades

hand tools

safety clothing and equipment

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.