Application
This unit of competency describes the outcomes required to identify, assess and solve systemic problems in the workplace, in the pulp and paper industry.
The unit applies to operators and production technicians who determine and implement a plan to solve systemic problems in the workplace, in a pulp and paper manufacturing facility.
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. Identify and describe the problem | 1.1. Identify and describe the problem within documentation and procedures, work health and safety (WHS) procedures, environmental procedures, standard operating procedures (SOP), and housekeeping requirements. 1.2. Gather information to define the 1.3. Gather information on the effect of the problem on quality or productivity or operations. |
2. Assess the situation and determine actions | 2.1. Take immediate action if safety, quality or productivity are compromised. 2.2. Notify personnel, as required. 2.3. Refer problem to appropriate work group or department. 2.4. Assess and select the most appropriate problem solving methodologies. |
3. Conduct analysis | 3.1. Assemble team for analysis, if required. 3.2. Use selected problem solving methodology. 3.3. Determine possible solutions. 3.4. Conduct quick fixes, if required. 3.5. Determine favoured solutions. |
4. Determine action plan | 4.1. Develop an action plan considering contingencies. 4.2. Document the action plan according to SOP. 4.3. Communicate the action plan to personnel. 4.4. Gain approval for the action plan from appropriate personnel. |
5. Implement plan | 5.1. Identify and organise resources to implement the action plan and consider relevant WHS procedures, environmental procedures, SOP, and housekeeping requirements. 5.2. Schedule plan and communicate to team and other personnel. 5.3. Assist team members, where required. 5.4. Implement the planned changes, to solve the problem, through process adjustments, reporting to an appropriate person or rectifying the problem. |
6. Monitor and evaluate the solution | 6.1. Monitor changes. 6.2. Evaluate the effectiveness of the solution. 6.3. Implement contingency planning, if required. |
7. Document and report changes | 7.1. Finalise and complete report using the required documentation. 7.2. Report the outcome of the solution. 7.3. Communicate the outcome of the solution to team and appropriate 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 evidence that they can:
identify the equipment maintenance, product quality and process inconsistency problems in a pulp or paper mill for at least two of the following operations:
coating systems
handling and preparing primary resources
steam generation
electrical power generation
handling and preparing waste paper for pulp production
waste paper operations
pulping operations
chemical recovery operations
finishing and converting
stock preparation operations
wet end operations
dry end operations
water services
identify the resources needed to address these problems including personnel, equipment, production process, materials or supplies or trouble shooting guides
select and apply suitable problem solving methodologies from the following list, according to the extent of problems:
industry specific methodologies:
e-learning tool
lean
root cause analysis techniques
5 whys
fish bone
sirf roundtable method
cause and effect diagrams
six sigma
Kepner - Tregoe
identify the type and extent of the problem
conduct an analysis and determine a solution
develop and implement an action plan to solve problems in operations
monitor and evaluate the effectiveness of the approach and the implementation of the action plan
report using the required documentation on the solution to the problem.
Evidence of Knowledge
A person competent in this unit must be able to demonstrate knowledge of:
problem solving methodologies which can be applied to common systemic problems with equipment and product quality in a pulp or paper manufacturing facility
documentation and procedures relevant to problem solving, including risk and hazard identification, work health and safety (WHS), quality, environmental (including relevant sustainability requirements and practices), isolation, housekeeping and standard operating procedures.
system, processes and associated services sufficient for problem solving including:
plant layout
theory of operation
causes and effects of adjustments made to equipment and processes
relationships between system, processes and associated services
effects of process variables on production and quality
planning procedures to predict possible solutions for problem solving
monitoring and evaluation processes for problem solving techniques
problem solving reporting requirements according to SOP.
Assessment Conditions
The following resources must be made available:
access to the full range of equipment involved in integrated continuous manufacturing, in a pulp or paper manufacturing facility
personal protective equipment required for working across all areas of a pulp and paper manufacturing facility
maintenance tools and associated equipment
workplace documentation and procedures required for solving systemic problems in a pulp and paper manufacturing plant
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: | undertake calculations to aid testing and sampling for the identification of product or process problems. |
Reading skills to: | read and interpret required documentation, procedures and reports relevant to solving problems. |
Writing skills to: | write clear and detailed reports, using correct technical language, about solving problems. |
Problem solving skills to: | maintain situational awareness in the work area analyse and use sensory information to adjust process to maintain and co-ordinate safety, quality and output. |
Technology skills skills to: | access, navigate and enter computer-based information use electronic and other systems to control equipment and processes as required. |
Range Statement
Not Applicable
Sectors
Pulp and Paper Manufacturing