This unit of competency applies to operators or technicians who are responsible for setting up a process for operation and making adjustments to ensure it is operating well.

The unit includes setting up and tuning equipment for startup, job change and equipment changes in preparation for production.

This unit assumes that the person doing the set up has the knowledge and skills to operate the process being set up.

This competency is typically performed by an experienced operator, leading hand or supervisor.

It does NOT include setting up and tuning processes covered by:

PMC553040C Set up and optimise glass forming process

PMC553041C Set up and optimise glass furnace process

PMC553042C Set up and optimise cutting and stacking process.

ELEMENT

PERFORMANCE CRITERIA

1. Prepare for equipment/change parts installation

1.1. Identify all safety and emergency procedures

1.2. Shut down equipment in accordance with procedures/work instructions and manufacturer's specifications

1.3. Isolate equipment according to procedures/work instructions

1.4. Remove ancillary equipment in accordance with procedures/work instructions and manufacturer's specifications

1.5. Complete records and logs for removal of equipment or change parts

2. Prepare the process for production

2.1. Consult the production schedule to determine the product to be manufactured

2.2. Ensure that the raw materials are available as required

2.3. Ensure that the equipment/change parts, ancillaries and fixtures are available as required

2.4. Perform pre-instalment equipment preparation according to procedures/work instructions

2.5. Ensure that the equipment is in a safe condition for use

3. Set up process

3.1. Perform checks and tests to product and equipment specifications

3.2. Ensure alignment of all equipment according to product specifications and procedures/work instructions

3.3. Ensure that process/equipment is set up as required for the production schedule

4. Tune the process

4.1. Monitor operation and compare with standard operating procedures for appropriate operation

4.2. Identify any deviation from standard performance

4.3. Identify the cause of the deviation and take action

4.4. Make adjustments to the equipment settings, process conditions or raw materials to bring production into specification

4.5. Continue monitoring operation and making adjustments until product/equipment is within specification.

5. Respond to problems

5.1. Identify possible routine and non-routine problems in the equipment or process

5.2. Determine problems needing action

5.3. Determine possible fault causes

5.4. Rectify problem using appropriate solution within area of responsibility

5.5. Report problems outside area of responsibility 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 and situations that will lead to out of specification production

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

reading and numeracy to interpret workplace documents and technical information

Required knowledge

Required knowledge includes:

nature of the product

setup and tuning of all equipment

startup and shutdown processes

construction and limitations of the equipment

out of specification situations

quality problems

distinguish between following causes of problems:

raw materials

mechanical

electrical/instrument

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 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:

setup/tuning are completed to specifications and within timeframe

critical process parameters such as temperature and pressures are maintained within limits

quality is monitored to minimise wastage

startup and shutdown occurs first time

signals and alarms are responded to immediately

process measurements are continually made or observed

adjustments made are completed in a timely manner in accordance with work instructions.

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

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

This unit may be assessed concurrently with other relevant 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

Manufactured mineral products

Manufactured mineral products may include:

clay and ceramics

concrete

concrete products

ceramic crucibles

cement

fibre cement

plasterboard

ground minerals

other manufactured mineral products processes

Tools and equipment

Tools and equipment may include:

changeover parts and equipment

computers

measuring and recording equipment

communication equipment

hand tools

safety clothing and equipment

Plant data

Plant data may include:

test results

instrument/control panel information

data from physical senses (sight, sound and hearing)

temperatures, pressures, material flow and discharge rates and effects

variations to chemical reactions/material modifications

Typical problems include:

Typical problems may include:

raw materials feed

equipment alignment

analysis of all plant data including test results, control instrument data and other observations

control of temperature within specification

product quality

equipment speed

taking corrective action

Unit sector

Operational/technical

This unit contains employability skills.