Monitor, control and shutdown finishing and converting operations Evidence Guide

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Evidence Guide: FPPFCO210A - Monitor, control and shutdown finishing and converting 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

FPPFCO210A - Monitor, control and shutdown finishing and converting operations

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

Operate and monitor processes and systems

Processes and systems are operated and monitored within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements
Production requirements are checked at start of shift to plan day's activities as required
Planned production requirements are confirmed and communicated to relevant personnel
Operations and systems are monitored and maintained within process parameters (range of variables) consistent with production requirements
Monitoring displays and devices are interpreted and responded to
Setup for product change is undertaken as required

Processes and systems are operated and monitored 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 requirements are checked at start of shift to plan day's activities as required

Completed
Date:

Teacher:

Evidence:

Planned production requirements are confirmed and communicated to relevant personnel

Completed
Date:

Teacher:

Evidence:

Operations and systems are monitored and maintained within process parameters (range of variables) consistent with production requirements

Completed
Date:

Teacher:

Evidence:

Monitoring displays and devices are interpreted and responded to

Completed
Date:

Teacher:

Evidence:

Setup for product change is undertaken as required

Completed
Date:

Teacher:

Evidence:

Control product quality and production

Product quality and production is controlled within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements
Product is monitored and controlled to production and quality requirements
Routine observations and assessments are conducted on product and system operations
Adjustments are made to control production and quality requirements
Test results are interpreted and recorded as required
Changes to product requirements are communicated to relevant personnel

Product quality and production is controlled within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements

Completed
Date:

Teacher:

Evidence:

Product is monitored and controlled to production and quality requirements

Completed
Date:

Teacher:

Evidence:

Routine observations and assessments are conducted on product and system operations

Completed
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Evidence:

Adjustments are made to control production and quality requirements

Completed
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Evidence:

Test results are interpreted and recorded as required

Completed
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Evidence:

Changes to product requirements are communicated to relevant personnel

Completed
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Evidence:

Conduct equipment shutdown

Equipment shutdown is conducted within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements
Shutdown plan is communicated with relevant personnel
Shutdown procedures are carried out
Cause of unplanned shutdown is identified and rectified
Shutdown details are recorded as required

Equipment shutdown is conducted within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements

Completed
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Evidence:

Shutdown plan is communicated with relevant personnel

Completed
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Evidence:

Shutdown procedures are carried out

Completed
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Cause of unplanned shutdown is identified and rectified

Completed
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Shutdown details are recorded as required

Completed
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Evidence:

Record process and system information

Recording process and system information is completed within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements
System and production information is recorded
Problems or variations in performance are recorded and communicated

Recording process and system information is completed within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements

Completed
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Teacher:

Evidence:

System and production information is recorded

Completed
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Evidence:

Problems or variations in performance are recorded and communicated

Completed
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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 monitoring, controlling and shutting down finishing and converting operations
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 finishing and converting operations Access to the full range of equipment involved in integrated continuous manufacturing of finishing and converting operations 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 monitoring, controlling and shutting down finishing and converting operations

Reads and interprets required documentation, procedures and reports

Interprets production requirements and work instructions

Interprets instruments, gauges and data recording equipment

Prepares written information and enters data to support groups and teams

Accesses, navigates and enters computer-based information

Identifies and actions problems within level of responsibility

Identifies and monitors process control points

Maintains situational awareness in the work area

Implements isolation or lockout procedures

Identifies and responds appropriately to shutdown causes

Respond to problems associated with plant shutdown and unplanned shutdown to ensure safety quality and productivity

Coordinates and plans shutdown activity

Uses hand tools

Uses cleaning equipment

Perform tests and interprets and record results if required

Uses measuring equipment as required

Operates plant and equipment

Operates high risk (and non-high risk) load shifting equipment as required

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 finishing and converting operations including OHS, environmental including relevant sustainability requirements/practices, SOP, isolation procedures, safe working requirements, risks and hazard identification and housekeeping

Relevant forms of communication

Basic problem-solving techniques consistent with level of responsibility

Working knowledge of finishing and converting operations, 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 (e.g. power outage, mechanical breakdown, blockages, jamming, air supply, 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

Equipment setup procedures and adjustments

Product types and quality requirements

Designated areas for waste

Application of high risk (and non-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 finishing and converting operations, 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
Finishing and converting processes may include:	winding and re-winding decorating lotionising calendering water marking perforating slitting and cutting embossing laminating folding printing bonding core making wrapping and packing
Materials and supplies may include:	parent roll or reel lotion shrink and stretch wraps pallets sheet paper labelling and stencilling wrap paper customer rolls boxes polythene wrap glues cartons strapping printing inks shippers reams signs and labels core board scent rolls
Equipment and systems may include:	separate servo controlled motors and drives electronic sensors and proximity system light curtains category three plus guarding program formatting programmable production configurations pre-set modifiable quick change parts e.g. snap lock reels and winding equipment wrapping and packing equipment guillotine, knives and cutting equipment conveying systems materials handling equipment flexographic printing equipment used for decorating overhead cranes testing and measuring equipment roll grab attachments warehousing equipment warehousing control systems electronic, pneumatic and hydraulic process controls computer systems electronic screens and alarms process control systems analogue and digital instruments fully automated, semi-automated, manually operated plant and equipment appropriate to finishing and converting operations
Auxiliary systems may include:	air lubrication vacuum dust extraction system
Electronic control systems may include:	portable control device 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 (and non-high risk) load shifting licensing requirements
Documentation, procedures and reports may include:	SOP enterprise policies, procedures and guidelines environmental sustainability requirements/practices plant manufacturing operating manuals production schedules production plans production specifications quality certification e.g. ISO quality procedures oil or chemical spills and disposal guidelines plant isolation documentation safe work documentation e.g. plant clearance, job safety analysis, permit systems reference documents on theory of operation of processes and systems vendor manuals checklists Material Safety Data Sheets (MSDS)

Maintenance may include:	operator level maintenance as per site agreement operator maintenance schedules maintenance supplies maintenance systems maintenance suppliers pro-active maintenance strategies e.g. Total Productive Maintenance (TPM), Reliability Centred Maintenance (RCM)
Quality checks and tests may include:	roll density core slippage damaged packaging reel hardness core size colour matching bulk core strength sheet size roll appearance print quality cut quality MD&CD tensile core scenting packaged product stretch roll size perforations product identification warehousing records

Required action in the event of a missing or faulty component may include:	operator level maintenance involvement of maintenance personnel replacement of component communication with appropriate personnel
Actions may include:	process adjustments reporting to authorised person rectifying problem within level of responsibility
Communications may include	interaction with: warehousing personnel internal/external customers and suppliers maintenance services team members operational management statutory authorities
Situational awareness may include	awareness of: traffic pedestrians location of equipment product hazards obstruction unexpected movement
Sensory information may include:	visual sound feel touch smell vibration temperature

Forms of communications 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

NTISthis.com

Evidence Guide: FPPFCO210A - Monitor, control and shutdown finishing and converting operations

Student: __________________________________________________

Signature: _________________________________________________

Tips for gathering evidence to demonstrate your skills

FPPFCO210A - Monitor, control and shutdown finishing and converting operations

Operate and monitor processes and systems

Control product quality and production

Conduct equipment shutdown

Record process and system information

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

Instructions to Assessors

Teacher: ___________________________ Date: _