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Evidence Guide: FDFOP2040A - Operate a heat treatment process

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

 

FDFOP2040A - Operate a heat treatment process

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

Prepare the heat treatment process for operation

  1. Materials are confirmed and available to meet operating requirements
  2. Cleaning and maintenance requirements and status are identified and confirmed
  3. Processing/operating parameters are entered as required to meet safety and production requirements
  4. Equipment performance is checked and adjusted as required
  5. Pre-start checks are carried out as required by workplace requirements
Materials are confirmed and available to meet operating requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Cleaning and maintenance requirements and status are identified and confirmed

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Processing/operating parameters are entered as required to meet safety and production requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Equipment performance is checked and adjusted as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Pre-start checks are carried out as required by workplace requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Operate and monitor the heat treatment process

  1. The process is started and operated according to workplace procedures
  2. Equipment is monitored to identify variation in operating conditions
  3. Variation in equipment operation is identified and maintenance requirements are reported according to workplace reporting requirements
  4. The process is monitored to confirm that temperature specifications are met
  5. Out-of-specification product/process outcomes are identified, rectified and/or reported to maintain the process within specification
  6. The work area is maintained according to housekeeping standards
  7. Work is conducted in accordance with workplace environmental guidelines
  8. Workplace records are maintained according to workplace recording requirements
The process is started and operated according to workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Equipment is monitored to identify variation in operating conditions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Variation in equipment operation is identified and maintenance requirements are reported according to workplace reporting requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

The process is monitored to confirm that temperature specifications are met

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Out-of-specification product/process outcomes are identified, rectified and/or reported to maintain the process within specification

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

The work area is maintained according to housekeeping standards

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Work is conducted in accordance with workplace environmental guidelines

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Workplace records are maintained according to workplace recording requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down the heat treatment process

  1. The appropriate shutdown procedure is identified
  2. The process is shut down according to workplace procedures
  3. Maintenance requirements are identified and reported according to workplace reporting requirements
The appropriate shutdown procedure is identified

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

The process is shut down according to workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Maintenance requirements are identified and reported according to workplace reporting requirements

Completed
Date:

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:

conduct pre-start checks on machinery used for heat treatment

start, operate, monitor and adjust process equipment to achieve required quality outcomes

take corrective action in response to typical faults and inconsistencies

complete workplace records as required

apply safe work practices and identify OHS hazards and controls

safely shut down equipment

apply food safety procedures.

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

information on equipment capacity and operating parameters

production schedule/batch instructions

specifications, control points and processing parameters

heat treatment process and related equipment and services

materials to be heat treated

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:

FDFOP2003A Clean equipment in place

FDFOP2004A Clean and sanitise equipment

FDFOP2011A Conduct routine maintenance

FDFOP2013A Apply sampling procedures

FDFOP2030A Operate a process control interface

MSL973001A Perform basic tests.

Guidance information for assessment

To ensure consistency in one's 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

Ability to:

access workplace information to identify heat treatment requirements

select, fit and use personal protective clothing and/or equipment

confirm supply of necessary materials and services

prepare materials as required

conduct pre-start checks, such as inspecting equipment condition to identify any signs of wear, selecting appropriate settings and/or related parameters, cancelling isolation or lockouts as required, confirming that equipment is clean and correctly configured for processing requirements,positioning sensors and controls correctly, ensuring any scheduled maintenance has been carried out, and confirming that all safety guards are in place and operational

start, operate, monitor and adjust the heat treatment process and equipment to achieve required outcomes, including monitoring control points and conducting inspections as required to confirm process remains within specification, such as:

time and temperature

pressure

flow rates

flow diversion

monitor supply and flow of materials to and from the process

take corrective action in response to out-of-specification results

respond to and/or report equipment failure within level of responsibility

locate emergency stop functions on equipment

follow isolation and lock out/tag out procedures as required to take process and related equipment off-line in preparation for cleaning and/or maintenance within level of responsibility

demonstrate procedure to clean and sanitise equipment

complete workplace records as required

maintain work area to meet housekeeping standards

control related holding and cooling stages according to enterprise procedures

use process control systems according to enterprise procedures

conduct routine maintenance according to enterprise procedures

conduct product/batch changeovers according to enterprise procedures

collect samples and conduct tests according to enterprise procedures

use oral communication skills/language competence to fulfil the job role as specified by the organisation, including questioning, active listening, asking for clarification and seeking advice from supervisor

work cooperatively within a culturally diverse workforce

Required knowledge

Knowledge of:

purpose and basic principles of heat treatment, including the effect of heat treatment on product and on microbiological characteristics

the relationship between time, temperature and pressure in the heat treatment process, such as associated holding and cooling profiles according to product requirements

basic operating principles of equipment, such as main equipment components, types and characteristics of heating mediums used, status and purpose of guards, equipment operating capacities and applications, and the purpose and location of sensors and related feedback instrumentation

the flow of the heat treatment process and the effect of product output on downstream processes

quality characteristics required of the heat treated product

effect of raw material characteristics on the heat treatment process, such as variation in viscosity/texture, microbial load and acidity

heat treatment requirements for food to be treated, such as low and/or high acid foods

operating requirements and parameters and corrective action required where operation is outside specified operating parameters

typical equipment faults and related causes, including signs and symptoms of faulty equipment and early warning signs of potential problems

methods used to monitor the heat treatment process, such as inspecting, measuring and testing as required by the process

inspection or test points (control points) in the process and the related procedures and recording requirements

contamination/food safety risks associated with the process and related control measures

common causes of variation and corrective action required

operational health and safety (OHS) hazards and controls, including the limitations of protective clothing and equipment relevant to the work process

requirements of different shutdowns as appropriate to the process and workplace production requirements, including emergency and routine shutdowns and procedures to follow in the event of a power outage

isolation, lock out and tag out procedures and responsibilities

procedures and responsibility for reporting production and performance information

cleaning and sanitation procedures

environmental issues and controls relevant to the heat treatment process, including waste/rework collection and handling procedures related to the process

basic operating principles of process control, where relevant, including the relationship between control panels and systems and the physical equipment

product/process changeover procedures and responsibilitieswhere relevant

routine maintenance procedures where relevant

sampling and testing associated with process monitoring and controlwhere relevant

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.

Policies and procedures

Work is carried out according to company policies and procedures, regulatory and licensing requirements, legislative requirements, and industrial awards and agreements

Legislative requirements

Legislative requirements are typically reflected in procedures and specifications. Legislation relevant to this industry includes:

the Food Standards Code, including labelling, weights and measures legislation

legislation covering food safety, environmental management, occupational health and safety, anti-discrimination and equal opportunity

When applied to the pharmaceutical industry, relevant Good Manufacturing Practice (GMP) codes apply in place of the Australian Food Standards Code and reference to food safety is replaced by GMP

Workplace information

Workplace information may include:

standard operating procedures (SOPs)

specifications

production schedules and instruction,

manufacturers' advice

standard forms and reports

Heat treatment equipment

Heat treatment equipment may include:

pumps

heat exchangers

holding and cooling stages

filters and clarifiers

direct steam injection equipment

Operation of equipment and processes

Operation of equipment and processes may require:

the use of process control panels and systems

Shutdown procedures

Shutdown procedures may include:

cleaning (in some cases cleaning may be carried out by a dedicated cleaning crew)

Services

Services may need to be confirmed. These depend on the nature of the process. Typical examples include:

power

steam

water

vacuum

compressed and instrumentation air