Application
This unit of competency describes the outcomes required to monitor, control and shut down finishing and converting operations in a pulp or paper manufacturing facility.
The unit applies to production operators and technicians who operate and monitor systems, production and product quality as well as conduct equipment shutdowns. This typically involves working in a facility with complex integrated equipment and continuous operations. Finishing and converting operations describe a range of systems and subsystems, including winding and re-winding, decorating, lotionising, calendaring, water marking, perforating, slitting and cutting, embossing, laminating, folding, printing, bonding, core making, wrapping and packing.
No licensing, legislative 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. Operate and monitor processes and systems | 1.1. Check production requirements at start of shift to plan day's activities considering work health and safety (WHS) regulations, environmental and safe working requirements/practices. 1.2. Confirm planned production requirements are confirmed and communicate to relevant personnel in line with standard operating procedures (SOP). 1.3. Monitor and maintain operations and systems within process parameters consistent with production requirements. 1.4. Interpret and respond to monitoring displays and devices. 1.5. Undertake setup for product change. |
2. Control product quality and production | 2.1. Monitor and control product to production 2.2. Conduct routine observations and assessments on product and system operations. 2.3. Make adjustments to control production and quality requirements. 2.4. Interpret and record test results. 2.5. Communicate changes to product requirements to relevant personnel. |
3. Conduct equipment shutdown | 3.1. Conduct equipment shutdown according to standard operating procedures. 3.2. Communicate shutdown plan with relevant personnel. 3.3. Carry out shutdown procedures. 3.4. Identify and rectify cause of unplanned. 3.5. Record shutdown details. |
4. Record process and system information | 4.1. Record system and production information. 4.2. Record and communicate problems or variations in performance. |
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 evidence that they can:
identify and respond to shutdown causes, at least twice in line with required enterprise intervals
coordinate and plan shutdown activity, at least twice in line with required enterprise intervals
respond to problems associated with plant shutdown and unplanned shutdown to ensure safety quality and production requirements
identify and monitor process control points
implement isolation or lockout procedures
use hand tools
use cleaning equipment
monitor and record production and quality information at required intervals
use electronic and other control systems to control equipment and processes
respond to production needs including output targets, production scheduling, shift requirements, quality requirements, resources and energy use and waste minimisation.
Evidence of Knowledge
A person competent in this unit must be able to demonstrate knowledge of:
finishing and converting operations including winding and re-winding, decorating, lotionising, calendaring, water marking, perforating, slitting and cutting, embossing, laminating, folding, printing, bonding, core making, wrapping and packing
finishing and converting processes, layout and associated services sufficient to monitor, control and shut down finishing and converting operations within level of responsibility
types, causes and effects of finishing and converting plant shutdowns
required responses to all unplanned shutdowns - power outage, mechanical breakdown, blockages, jamming, air supply and control system failure to ensure safety quality and productivity
process and procedures for plant shutdowns and unplanned shutdowns
plant and machinery functions and operations
emergency procedures and responses
sampling and testing process for plant and system operations, and process monitoring - purpose, standards and procedures as per site agreements
finishing and converting equipment and auxiliary systems
equipment setup procedures and adjustments
product types and quality requirements
designated areas for waste.
Assessment Conditions
The following resources must be made available:
access to the full range of equipment and materials involved in integrated continuous manufacturing of finishing and converting operations in a pulp or paper manufacturing facility
electronic control systems which includes portable control devices, touch screens or robotics to control equipment and processes during shutdown operations
applicable work health and safety (WHS) and isolation work place procedures, environmental guidelines and safe working requirements, risks and hazard identification and workplace housekeeping requirements
fully automated, semi-automated, manually operated plant and equipment appropriate to finishing and converting operations
test and diagnostic and cleaning equipment
personal protective equipment required when operating finishing and converting systems
relevant sample workplace documentation, procedures and reports including Standard Operating Procedures (SOP), quality procedures, environmental sustainability requirements/practices, plant manufacturing operating manuals, plant isolation documentation, and safe work documentation.
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. | |
Learning skills to: | identify and action problems. |
Numeracy skills to: | use measuring equipment. |
Oral communication skills to: | respond to problems associated with plant shutdown via radio or telephone and face to face. |
Reading skills to: | read and interpret documentation including SOP, manuals and checklists, drawings, site maps, signage for safety/access interpret production requirements and work instruction interpret instruments, gauges and data recording equipment. |
Writing skills to: | access, navigate and enter computer-based information. prepare written information and enter data to support groups and teams including, emails, incident and other reports, run sheets and data entry. |
Problem solving skills to: | maintain situational awareness in the work area. |
Range Statement
Not Applicable
Sectors
Pulp and Paper Manufacturing