This unit of competency applies to experienced operators, leading hands or supervisors who are responsible for setting up and adjusting glass secondary processes from the requirements as set out in production schedules and specifications. The operator is able to run trials and adjust all of the equipment settings to have the production equipment perform satisfactorily.

This unit does NOT apply to the set up and optimisation of primary glass furnace processes, which is covered by PMC553040C Set up and optimise glass forming process.

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 process for production

1.1. Identify all safety and emergency procedures

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

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

1.4. Ensure that the raw materials are available as required

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

1.6. Complete records and logs for setup of fabrication equipment

2. Set up fabrication process

2.1. Perform checks and tests to product and equipment specifications

2.2. Ensure alignment of all equipment by performing checks and adjustments according to product specifications/work instructions

2.3. Ensure that process and equipment are setup as required for the production schedule

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

3. Monitor, interpret data and adjust operation

3.1. Monitor instruments and control panels, and interpret test results for fluctuations, variations and trends

3.2. Monitor plant and process and deduce conditions of materials in process and products being made

3.3. Determine appropriate action to improve process operation

3.4. Adjust controls to ensure glass parameters are maintained to job specifications

3.5. Check that process operation has improved

3.6. Continue analysing data and making adjustments until desired level of process operation is achieved and product is within specifications in accordance with work instructions

4. Sample, test and record product data

4.1. Carry out sampling procedures appropriate to the product and the test in line with enterprise requirements

4.2. Complete appropriate test to enterprise and client requirements

4.3. Measure/graph and record operating parameters according to enterprise requirements

4.4. Record test results in hard or electronic form as required by standard procedures and work instructions

5. Rectify equipment and quality problems

5.1. Identify the range of equipment and quality faults that can occur during the operation

5.2. Determine and rectify equipment and quality faults causes in accordance with established enterprise procedures

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

5.4. Ensure appropriate records and log books of equipment operations are maintained to meet enterprise requirements

5.5. Identify non-routine problems and rectify within area of responsibility

5.6. Report problems outside area of responsibility to designated person

6. Shut down equipment

6.1. Shut down equipment in accordance with work instructions

6.2. Complete appropriate records and logs

6.3. Shut down equipment in an emergency situation

7. Control hazards

7.1. Identify hazards from the job to be done

7.2. Identify other hazards in the work area

7.3. Assess the risks arising from those hazards

7.4. 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 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:

composition and nature of the glass

setup/changeover and tuning of all equipment

startup and shutdown processes

optimisation of process for yield maximisation

construction and limitations of the equipment

out of specification situations

quality problems such as:

poor optics

excessive breakage

non-uniform break pattern

incorrect cross bend

excessive bow

scratches

poor glass shape

distinguish between causes of problems, such as:

raw material

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. The emphasis should be on the ability to stay out of trouble than on recovery from a disaster.

Consistent performance should be demonstrated. In particular look to see that:

setup/changeover/tuning are completed to specifications

temperature and pressures are maintained within limits

quality is monitored to minimise wastage

startup and shutdown occur first time

early warning signs of equipment/processes needing attention or potential problems are recognised and dealt with in a timely manner

process measurements are continually made or observed

adjustments are completed in a timely manner

the range of possible causes can be identified and the most likely cause determined

appropriate action is taken to ensure a timely return to full performance

obvious problems to related plant areas are recognised and an appropriate contribution made to their solution.

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

Application of equipment

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

flat glass

insulation, glass wool insulation, laminated blankets, roll and boards

fibreglass and glass filaments

packaging, bottles and jars

Tools and equipment

Tools and equipment may include:

secondary process/finishing and associated equipment such as:

CSM line equipment

rovings equipment

robot packer

edge trimmer

choppers

on-line cutting equipment

on-line stacking equipment

curing oven

facing equipment

computers

measuring recording equipment

communication equipment

hand tools

safety clothing and equipment

Process

The process includes:

setting up, monitoring and tuning equipment for optimum performance especially during startup, job change and equipment changes

It does NOT include processes involved with:

scientific glass manufacture

primary manufacturing processes

Typical problems

Typical problems may include:

raw materials supply

equipment alignment

analysis of all plant data

product quality

equipment problems

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

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.