PPMCPP210
Monitor and control coated paper processes


Application

This unit of competency describes the outcomes required to monitor and maintain coated paper processes, ensure product quality and record and report production data.

This unit applies to production support workers who work in a pulp or paper manufacturing facility in the coated paper area. This typically involves working in a facility with complex integrated equipment and continuous operations.

No licensing, legislative, regulatory, or certification requirements apply to this unit at the time of publication.


Elements and Performance Criteria

ELEMENTS

PERFORMANCE CRITERIA

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold italicised text is used, further information is detailed in the range of conditions.

1. Monitor and maintain process

1.1. Check production requirements at start of shift and plan daily work activities in line with organisational safety and standard operating procedures.

1.2. Confirm operational status by inspection, observation and other information.

1.3. Maintain process supplies to meet production requirements.

1.4. Monitor process to ensure coating system operations are within specification.

1.5. Identify, rectify or report routine variations from specification.

1.6. Monitor and maintain process levels to maintain productivity requirements.

1.7. Complete routine preventative maintenance in line with maintenance schedules.

2. Control product quality

2.1. Monitor and maintain product to quality requirements.

2.2. Conduct routine visual observations and assessments on product and system operations.

2.3. Sample and test product quality and interpret and record results to ensure production requirements are maintained.

2.4. Adjust system operation to rectify out-of-specification product and maintain productivity requirements.

3. Record and report product and process data

3.1. Interpret production data and enter into recording system.

3.2. Communicate problems or variations with process, product or equipment to relevant personnel.

Evidence of Performance

A person demonstrating competency in this unit must satisfy all of the elements, performance criteria and foundation skills of this unit, and must be able to provide sufficient evidence of the ability to:

monitor and control coated paper processes, at least twice in line with required enterprise intervals, with individual production requirements for each period

complete routine maintenance on equipment at specified intervals

complete records for system operation, production outcomes and equipment faults at least twice, in line with required enterprise intervals.


Evidence of Knowledge

A person competent in this unit must be able to demonstrate knowledge of:

system layout for coated paper processing plant

purpose, features and operation of coated paper process plant, operating parameters and allowable variations

operation and application of electronic and other control systems

key features of the full range of processes involved in controlling coated paper production

purpose of, and processes for sampling and testing product quality, plant and system operations

quality requirements for different types of coated paper

methods used to monitor coating system operations against specified system parameters

effect of process adjustments on product quality and productivity during monitoring and operation

safe handling of materials and chemicals

organisational procedures including:

standard operating procedures specific to coated paper processes

workplace health and safety with particular emphasis on equipment lock out, use of personal protective equipment and handling hazardous substances

communication reporting lines

recording and reporting system operation, production outcomes and equipment faults.


Assessment Conditions

The following resources must be made available:

access to the full range of tools and equipment involved in integrated continuous manufacturing of coated paper processes in a pulp or paper manufacturing facility

machines, equipment and resources specific to coated paper operations including electronic control systems which includes Digital Control System (DCS), touch screens or robotics

consumables which can be chemicals and polymers, additives, labels, felts and base paper

maintenance tools and equipment and consumables for coated paper process plant

personal protective equipment suitable for operating coated paper process plant

maintenance schedules for coated paper process plant

template documents for recording system operation and production outcomes

organisational workplace health and safety and standard operating procedures

relevant personnel for the purposes of communicating information.

Competency is to be assessed in the workplace or in a productive environment that accurately reflects performance in a workplace.

Assessor requirements

Assessors must:

hold the appropriate assessor competency standards as outlined in regulations; and

be able to demonstrate vocational competencies at least to the level being assessed; and

be able to demonstrate how they are continuing to develop their VET knowledge and skills as well as maintaining their industry currency and assessor competence.


Foundation Skills

This section describes those core and employment skills that are essential to performance and are not explicit in the performance criteria.

Numeracy skills to:

interpret basic numerical settings on instruments, gauges and data recording equipment

monitor, assess and interpret production data

record basic numerical data for test results and production outcomes.

Oral communication skills to:

provide clear basic information about problems or variations with process, products and equipment.

Reading skills to:

interpret:

workplace health and safety and standard operating procedures

maintenance schedules.

Writing skills to:

complete accurate basic records for system operation and production outcomes.

Problem solving skills to:

use and assess sensory information (sight, sound, touch, smell, vibration, temperature) to adjust process to maximise safety, quality and productivity.


Range Statement

Not Applicable


Sectors

Pulp and Paper Manufacturing