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Evidence Guide: FPPCPP320A - Prepare and start up coated paper processes

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

 

FPPCPP320A - Prepare and start up coated paper processes

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

Determine production requirements

  1. Production requirements are determined within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements
  2. Production plan is interpreted
  3. Grade specifications and limits are confirmed and communicated to relevant personnel
  4. Process requirements are determined
  5. Process supplies are confirmed available for production
  6. Chemical and material requirements are determined
Production requirements are determined within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Production plan is interpreted

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Grade specifications and limits are confirmed and communicated to relevant personnel

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Process requirements are determined

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Process supplies are confirmed available for production

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Chemical and material requirements are determined

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Inspect and prepare systems for startup

  1. Systems are inspected and prepared for startup within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements
  2. Isolations (if any) are removed
  3. Pre-startup checks on equipment (e.g. coater and supply systems) are completed
  4. Electrical power and process supplies are confirmed as available for production
  5. Chemical/material delivery system is prepared for operation
  6. Operational settings are made and confirmed within specification
  7. Production ready status is confirmed with relevant personnel
  8. Monitoring devices/systems are checked and confirmed operational
  9. Faults are identified and rectified as required
Systems are inspected and prepared for startup within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Isolations (if any) are removed

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Pre-startup checks on equipment (e.g. coater and supply systems) are completed

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Electrical power and process supplies are confirmed as available for production

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Chemical/material delivery system is prepared for operation

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Operational settings are made and confirmed within specification

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Production ready status is confirmed with relevant personnel

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Monitoring devices/systems are checked and confirmed operational

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Faults are identified and rectified as required

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Co-ordinate startup operations

  1. Startup operations are co-ordinated within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements
  2. Equipment startups are co-ordinated for production
  3. System functions are co-ordinated and confirmed by monitoring plant, equipment and control system/display monitors
  4. Process operation status is communicated to relevant personnel
  5. Production startup details are logged, recorded or filed
Startup operations are co-ordinated within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Equipment startups are co-ordinated for production

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

System functions are co-ordinated and confirmed by monitoring plant, equipment and control system/display monitors

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Process operation status is communicated to relevant personnel

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Production startup details are logged, recorded or filed

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Establish and stabilise production and quality processes

  1. Production and quality processes are established and stabilised within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements
  2. Processes are monitored and adjusted to rectify variations from specification
  3. Adjustments/modifications are made to stabilise coating quality within specification
  4. Samples are taken as required to ensure product quality requirements are met
  5. Product tests are verified as within specification, where applicable
  6. Process operation, production and quality data is recorded as required
Production and quality processes are established and stabilised within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Processes are monitored and adjusted to rectify variations from specification

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Adjustments/modifications are made to stabilise coating quality within specification

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Samples are taken as required to ensure product quality requirements are met

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Product tests are verified as within specification, where applicable

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Process operation, production and quality data is recorded as required

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

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

Evidence should be relevant to the work. It should satisfy the requirements of the elements and performance criteria and include consideration of:

the required knowledge and skills tailored to the needs of the specific workplace

applicable OHS regulations, environmental and safe working requirements/practices, SOP and housekeeping requirements

applicable aspects of the range statement

practical workplace demonstration of skills in preparing and starting up coated paper processes

Context of and specific resources for assessment

A workplace assessment must be used to assess:

the application of required knowledge on the job

the application of skills on the job, over time and under a range of typical conditions that may be experienced in coated paper processes

Access to the full range of equipment involved in integrated continuous manufacturing of coated paper processes in a pulp or paper mill is required

Method of assessment

A combination of assessment methods should be used. The following examples are appropriate for this unit:

observation of applied skills and knowledge on the job

workplace demonstrations via a mock-up or simulation that replicate part/s of the job

answers to written or verbal questions about specific skills and knowledge

third-party reports from relevant and skilled personnel

written evidence e.g. log sheet entries, checklist entries, test results

Assessment processes and techniques must be culturally appropriate and in keeping with the language and literacy capacity of the learner and the work being performed. This includes conducting an assessment in a manner that allows thoughts to be conveyed verbally so that the learner can both understand and be understood by the assessor (e.g. use plain English and terminology used on the job)

A holistic assessment with other units relevant to the pulp and paper industry, mill and job role is recommended

Additional information on approaches to assessment for the pulp and paper industry is provided in the Assessment Guidelines for this Training Package

Required Skills and Knowledge

This describes the skills and knowledge required for this unit.

Required skills

Uses required forms of communication in preparing and starting up coated paper processes

Communicates operational requirements clearly to relevant personnel

Reads and interprets required documentation, procedures and reports

Prepares written information and data to support groups and teams

Accesses, navigates and enters computer-based information

Monitors, analyses and interprets data

Interprets instruments, gauges and data recording equipment

Interprets control systems and display monitors in accordance with SOP and other specifications

Responds to control systems and display alarms in accordance with SOP

Confirms production ready status with team members and relevant personnel

Identifies and actions problems within level of responsibility

Responds to faults of process flow-through systems if required

Responds to faults of plant if required

Identifies and monitors process control points

Maintains situational awareness in the work area

Takes samples, conducts tests and interprets and records results if required

Uses measuring equipment as required

Calculates performance measures

Determines coating production requirements (e.g. sheet, coating chemicals)

Conducts checks to ensure availability of sheet, coating chemicals and electrical power

Conducts checks to ensure space availability for coated sheet where applicable

Ensures isolations are removed according to SOP

Conducts pre-startup checks of plant and equipment including instrumentation

Inputs operational settings (e.g. set points) in preparation for startup in accordance with SOP

Activates and confirms operation of coating system according to SOP

Operates high risk load shifting equipment as required

Makes process control adjustments to stabilise production and obtain product quality

Conducts routine maintenance checks

Analyses and uses sensory information to adjust process to maintain and co-ordinate safety, quality and productivity

Uses electronic and other control systems to control equipment and processes as required

Required knowledge

Procedures, regulations and legislative requirements relevant to coated paper processes including OHS, environmental including relevant sustainability requirements/practices, SOP, isolation procedures, safe working requirements, risks and hazard identification and housekeeping

Relevant forms of communication

Information provided on the production specification sheet

Navigation of computer control system displays

Relationships within the coating area members and with the area's suppliers and customers

Basic problem-solving techniques consistent with level of responsibility

Cause and effect of operational equipment faults

Working knowledge of coated paper processes, system layout and associated services sufficient to carry out startup activities within level of responsibility

Sampling and testing process for plant and system operations and process monitoring - purpose, standards and procedures as per site agreements

Purpose of each of the steps in the preparation of the coating system for production

Purpose of each component of the coating system

Purpose and location of the coating chemical supply system

Critical control points of the preparation for startup procedure

Purpose of the process controls and how changes affect the production variables

Critical control points of the startup procedure

Critical control points of the monitoring process during startup

Awareness of high risk load shifting equipment, as required

Sensory information that indicates a deviation from standard operating parameters

Sufficient knowledge of electronic and other control systems, operation and application to make appropriate adjustments that control coated paper processes, within level of responsibility

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.

Productivity requirements may include:

energy efficiency

waste minimisation

evaporation minimisation, including landfill and waste water reduction

environmentally safe waste disposal

consideration of resource utilisation, including fibre efficiency

minimising delays

chemical recovery maximisation

meeting key performance indicators

line speed

handovers

quality checks

meeting output targets i.e. net tonnes per employee per annum

machine/process time availability i.e. time the machine or process is making product

machine/process production rate

Coated paper processes may include:

tail feed systems

chemical and material batching

laminating and coating

splicing

clay plant operation

calender

pre-reeler operations

super calendering

monitoring systems

rewindering

drying systems

internal unloading

combine rollers

testing

Materials and supplies may include:

chemicals and polymers

power

water

additives

steam

labels

felts

equipment

gas

accessories (parts)

air

base paper

Equipment may include:

coater

splicer

pre-reelers

crimpers

calender

super-calender

parent rolls and reels

cranes

pigment

coating makedown plant

starch cooker

slitter

computer systems

electronic screens and alarms

process control systems

analogue and digital instrumentation

fully, automated, semi-automated, manually operated plant and equipment appropriate to the coated paper process

Electronic control systems may include:

Digital Control System (DCS)

touch screens

robotics

Legislation, regulatory, licensing and certification requirements may include:

OHS and environmental requirements (local, state and commonwealth)

activity or task specific high risk licensing requirements

Documentation, procedures and reports may include:

SOP

quality procedures

environmental sustainability requirements/practices

plant manufacturing operating manuals

enterprise policies and procedures

Material Safety Data Sheets (MSDS)

oil or chemical spills and disposal guidelines

plant isolation documentation

safe work documentation e.g. plant clearance, job safety analysis, permit systems

product specifications and schedules

maintenance logs

job sheets

site agreements

safety instructions

process and instrument diagrams

machine manuals

troubleshooting guides

incidents reports

Maintenance may include:

operator level maintenance as per site agreements

operator maintenance schedules

maintenance systems

maintenance suppliers

proactive maintenance strategies e.g. Total Productive Maintenance (TPM), Reliability Centred Maintenance (RCM)

Actions may include:

process adjustments

reporting to authorised person

rectifying problem within level of responsibility

Communications may include

interaction with:

internal/external customers and suppliers

team members

production/service co-ordinators

maintenance services

operator support personnel

operational management

statutory authorities

Situational awareness may include

awareness of:

traffic

pedestrians

location of equipment

product

hazards

obstruction

unexpected movement

Forms of communication may include:

written e.g. log books, emails, incident and other reports, run sheets, data entry

reading and interpreting documentation e.g. SOP, manuals, checklists, drawings

verbal e.g. radio skills, telephone, face to face, handover

non-verbal e.g. hand signals, alarms, observations

signage e.g. safety, access

Sensory information may include:

visual

sound

feel

touch

smell

vibration

temperature