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Evidence Guide: FDFGR3003A - Lead flour milling shift operations

Student: __________________________________________________

Signature: _________________________________________________

Tips for gathering evidence to demonstrate your skills

The important thing to remember when gathering evidence is that the more evidence the better - that is, the more evidence you gather to demonstrate your skills, the more confident an assessor can be that you have learned the skills not just at one point in time, but are continuing to apply and develop those skills (as opposed to just learning for the test!). Furthermore, one piece of evidence that you collect will not usualy demonstrate all the required criteria for a unit of competency, whereas multiple overlapping pieces of evidence will usually do the trick!

From the Wiki University

 

FDFGR3003A - Lead flour milling shift operations

What evidence can you provide to prove your understanding of each of the following citeria?

Establish shift operating environment

  1. Identify products and quantities to be produced by mill during shift.
  2. Identify from authorised suppliers the supplier of grain used during shift and the varieties supplied.
  3. Apply required costing and control procedures to achieve set key performance indicators (KPIs).
  4. Establish range of available equipment and any unique design or operating factors.
  5. Identify staffing and work organisation for shift.
  6. Identify any budget and/or budget operating procedures relevant for shift operations.
Identify products and quantities to be produced by mill during shift.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify from authorised suppliers the supplier of grain used during shift and the varieties supplied.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Apply required costing and control procedures to achieve set key performance indicators (KPIs).

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Establish range of available equipment and any unique design or operating factors.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify staffing and work organisation for shift.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify any budget and/or budget operating procedures relevant for shift operations.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor quality during shift

  1. Identify specifications for flour to be produced during shift.
  2. Identify performance indicators and production targets for mill and mill departments during shift.
  3. Supervise testing regime for mill during shift.
  4. Monitor performance against targets and indicators.
  5. Report non-conformances and take appropriate corrective actions.
Identify specifications for flour to be produced during shift.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify performance indicators and production targets for mill and mill departments during shift.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Supervise testing regime for mill during shift.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor performance against targets and indicators.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Report non-conformances and take appropriate corrective actions.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set and supervise grain supply and intake procedures

  1. Supervise grain receival operations including compliance with instructions for rejected deliveries.
  2. Set screening criteria and procedures for re-use of screenings.
  3. Set blending criteria for holding bins/silos.
Supervise grain receival operations including compliance with instructions for rejected deliveries.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set screening criteria and procedures for re-use of screenings.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set blending criteria for holding bins/silos.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set and supervise grain conditioning process and specifications

  1. Specify and communicate grain cleaning requirements to operators.
  2. Set water volume for each grain batch.
  3. Set conditioning time per batch.
  4. Determine any blending and treatment criteria.
  5. Monitor tests and specifications for conditioned grain.
  6. Supervise transfer to storage or mill.
Specify and communicate grain cleaning requirements to operators.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set water volume for each grain batch.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set conditioning time per batch.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine any blending and treatment criteria.

Completed
Date:

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Monitor tests and specifications for conditioned grain.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Supervise transfer to storage or mill.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Supervise production

  1. Identify shift production targets.
  2. Obtain or determine recipes.
  3. Formulate and supervise preparation of grist.
  4. Supervise milling of individual grains.
  5. Set blending requirements including any use of additions and adjuncts.
  6. Allocate production specifications for shift to departments.
  7. Ensure production records are kept.
  8. Monitor production against targets.
Identify shift production targets.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Obtain or determine recipes.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Formulate and supervise preparation of grist.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Supervise milling of individual grains.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set blending requirements including any use of additions and adjuncts.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Allocate production specifications for shift to departments.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure production records are kept.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor production against targets.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Integrate maintenance schedule with shift operations

  1. Identify shift preventative maintenance requirements from maintenance department and/or equipment suppliers.
  2. Supervise equipment monitoring and maintenance responsibilities for operators, maintenance department and other staff.
  3. Identify and approve timing for any regular maintenance activities that will disrupt production.
  4. Supervise breakdown notification and repair procedures.
Identify shift preventative maintenance requirements from maintenance department and/or equipment suppliers.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Supervise equipment monitoring and maintenance responsibilities for operators, maintenance department and other staff.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify and approve timing for any regular maintenance activities that will disrupt production.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Supervise breakdown notification and repair procedures.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Implement risk management procedures

  1. Supervise implementation of OHS and dust control procedures.
  2. Monitor HACCP procedures during shift.
  3. Monitor compliance with environmental and sustainability regulations and targets.
  4. Monitor operations against any required regulatory compliance including required reporting procedures.
Supervise implementation of OHS and dust control procedures.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor HACCP procedures during shift.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor compliance with environmental and sustainability regulations and targets.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor operations against any required regulatory compliance including required reporting procedures.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Provide guidance to other mill employees

  1. Monitor and maintain standard operating procedures.
  2. Supervise any required training for employees during shift operations.
  3. Ensure availability of reference materials.
  4. Implement communication and feedback mechanisms to and from employees.
Monitor and maintain standard operating procedures.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Supervise any required training for employees during shift operations.

Completed
Date:

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Ensure availability of reference materials.

Completed
Date:

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Implement communication and feedback mechanisms to and from employees.

Completed
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Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

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

Assessment must be carried out in a manner that recognises the cultural and literacy requirements of the assessee and is appropriate to the work performed. Competence in this Unit must be achieved in accordance with food safety standards and regulations.

Critical aspects for assessment and evidence required to demonstrate competency in this Unit

Evidence of ability to:

interpret production requirements and grain tests for desirable mill settings

assist employees with conduct and interpretation of grain and flour tests

match grain receival, screening and storage processes to production requirements during shift

prepare or supervise production of grists according to recipes

set and manage milling and blending operations

supervise dust control, HACCP and OHS procedures during shift operations.

Context of and specific resources for assessment

Assessment must occur in a real or simulated workplace where the assessee has access to:

personal protective clothing and equipment

work procedures, including advice on safe work practices, food safety, quality and environmental requirements

equipment manuals including operating parameters

specifications, control points and processing parameters

break and reduction roll process and related equipment and services

conditioned grain suitable for the break and reduction roll process

sampling schedules and test procedures and equipment as required

documentation and recording requirements and procedures

cleaning procedures, materials and equipment as required.

Method of assessment

This Unit should be assessed together with core Units and other Units of Competency relevant to the function or work role. Examples could be:

FDFOP3001A Control contaminants and allergens in the workplace

FDFGR3004A Control mill processes and performance

FDFOP3003A Operate inter related processes in a production system.

Guidance information for assessment

To ensure consistency of performance, competency should be demonstrated on more than one occasion over a period of time in order to cover a variety of circumstances, cases and responsibilities, and where possible, over a number of assessment activities.

Required Skills and Knowledge

Required skills include:

Ability to:

identify typical flours including semolina, and other mill products

identify grain types and main grain varieties

liaise with other departments on flour product requirements

calculate:

water required to achieve target moisture content

extraction rate on:

dirty wheat basis

clean wheat basis

total production basis

protein loss for each grist

milling gains/losses

integrate OHS, HACCP and dust control procedures with mill operations

communicate production requirements and technical information to other employees.

Required knowledge includes:

Knowledge of:

differences in types of milling processes including differences in milling of different grains, varieties and milling for flour or for semolina

process and purpose of flour milling including:

opening of grain to enable removal of endosperm

separation of bran

grinding of endosperm to flour

sifting of ground stock to:

remove oversize endosperm particles

remove flour

remove any bran and endosperm that has not been ground

kibbling

middlings and semolina process

methods used to establish the most economic grist for a particular flour, i.e. the balancing of flour specification, grain availability, cost of grain available etc.

financial impacts of mill performance/settings

principles of preventative maintenance including failure mode effects analysis (FMEA)

food safety, food labelling and other regulations affecting flour mills

grain varieties and specifications

flour types and specifications

food labelling regulations relevant to flour products

HACCP principles and procedures

dust control procedures

OHS standards and requirements

environmental regulations.

Range Statement

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.

Mill

The term mill is used to refer to the whole mill site including the actual milling equipment, equipment used for associated processes, and transport, warehouse, maintenance, testing and administration facilities.

Grain

Grain refers to all edible grains that can be milled for flour, semolina and other grain based food and non-food products. Examples of grains covered by this Unit include wheat, rye, spelt, triticale, oats, corn and barley.

Grist

Grist is a blend that may be made from a single wheat (or other grain) or be produced from a combination of wheats (or other grains).

Mill testing regime

The mill testing regime refers to the determination of:

range of tests required per product

test locations e.g. operator tests, on site laboratory tests and externally conducted tests

test frequency/sampling rate

criteria for acceptance/rejection/re-test

reporting requirements

training required by employees to conduct tests.

Mill performance

Mill performance is the production of the maximum amount of flour to required specifications in the most efficient and profitable way. Indicators of mill performance may include:

mill gain or loss

extraction rate

flour production per shift and other selected periods.

HACCP Plan

The detailed establishment and implementation of a mill HACCP plan is not included in this Unit. However establishing and supervising compliance with the HACCP plan is included.

Production records will usually include:

capacity per hour or per 24 hours to first break

output per hour of final flour

extraction rate

moisture content of flour/grain

water absorption of flour

protein content of flour

colour grade.