Troubleshoot and rectify finishing and converting systems Evidence Guide

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Evidence Guide: FPPFCO340A - Troubleshoot and rectify finishing and converting systems

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

FPPFCO340A - Troubleshoot and rectify finishing and converting systems

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

Identify and analyse causes of system and quality faults

Causes of system and quality faults are identified and analysed within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements
Control system readouts are monitored to identify process variations
Trends and warning devices are interpreted to determine fault type and location
Quality checks are interpreted to identify variations from specifications or schedule
Cause and source of problem is identified and located
Relevant sources of information are accessed and interpreted to assist analysis

Causes of system and quality faults are identified and analysed within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements

Completed
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Teacher:

Evidence:

Control system readouts are monitored to identify process variations

Completed
Date:

Teacher:

Evidence:

Trends and warning devices are interpreted to determine fault type and location

Completed
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Evidence:

Quality checks are interpreted to identify variations from specifications or schedule

Completed
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Cause and source of problem is identified and located

Completed
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Relevant sources of information are accessed and interpreted to assist analysis

Completed
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Rectify system faults

System faults are rectified within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements
Equipment is shut down and isolation procedures are implemented prior to fault rectification if required
Faulty equipment is identified, repaired or replaced
Faulty equipment is by-passed as required
Corrective adjustments are made and operator level maintenance requirements are undertaken
Restoration of machine or system to normal operation is verified and communicated to relevant personnel

System faults are rectified within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements

Completed
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Equipment is shut down and isolation procedures are implemented prior to fault rectification if required

Completed
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Faulty equipment is identified, repaired or replaced

Completed
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Faulty equipment is by-passed as required

Completed
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Corrective adjustments are made and operator level maintenance requirements are undertaken

Completed
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Restoration of machine or system to normal operation is verified and communicated to relevant personnel

Completed
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Evidence:

Rectify or re-work product with quality faults

Product with quality faults is rectified or reworked within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements
Product quality faults or variations are identified by observation, systematic sampling, testing or quality checks
Quality checks are conducted
Quality tests are undertaken and results interpreted as required
Process adjustments are made as required
Out-of-specification product is actioned as required

Product with quality faults is rectified or reworked within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements

Completed
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Product quality faults or variations are identified by observation, systematic sampling, testing or quality checks

Completed
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Quality checks are conducted

Completed
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Quality tests are undertaken and results interpreted as required

Completed
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Process adjustments are made as required

Completed
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Out-of-specification product is actioned as required

Completed
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Record and report system performance and product quality data

System performance and product quality data is recorded and reported within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements
Variations from process specifications are recorded
Actions undertaken to troubleshoot and rectify faults are recorded
Indications of performance variation are documented
Relevant information is communicated to appropriate personnel

System performance and product quality data is recorded and reported within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements

Completed
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Variations from process specifications are recorded

Completed
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Actions undertaken to troubleshoot and rectify faults are recorded

Completed
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Indications of performance variation are documented

Completed
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Relevant information is communicated to appropriate personnel

Completed
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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 troubleshooting and rectifying 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

Identifies, accesses and interprets relevant historical and operational data and information

Uses required forms of communication in troubleshooting and rectifying finishing and converting systems

Reads and interprets required documentation, procedures and reports

Operates communications equipment

Interprets instruments, gauges and data recording equipment

Interprets troubleshooting guides, operational data, trend analysis and test results

Accesses, navigates and enters computer-based information

Communicates effectively with personnel to assist with analysis and resolution of operational problems

Assists others to identify and resolve operational problems in the workplace

Identifies and actions systems, quality and equipment faults within level of responsibility

Identifies causes and effects of faults and corrective action on associated processes

Selects and uses appropriate troubleshooting methods

Takes timely corrective action to maximise safety, quality and productivity

Undertakes necessary calculations to aid troubleshooting as required

Identifies and monitors process control points

Maintains situational awareness in the work area

Implements isolation and lockout procedures as required

Operates required measuring and testing devices

Perform tests and interprets and record results if required

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

Analyses and uses sensory information to adjust process to maximise 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 system operation including OHS, environmental including relevant sustainability requirements/practices, SOP, isolation procedures, safe working requirements, risks and hazard identification and housekeeping

Relevant forms of communication

Detailed knowledge of finishing and converting system, processes and associated services sufficient to troubleshoot including:

plant layout

theory of operation

causes and effects of adjustments made to finishing and converting plant and processes

relationships between finishing and converting system, processes and associated services

An appropriate range of troubleshooting methods

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

Operator level maintenance requirements

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 systems 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 tensiles 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 reading and interpreting documentation e.g. SOP, manuals, checklists, drawings, data entry 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: FPPFCO340A - Troubleshoot and rectify finishing and converting systems

Student: __________________________________________________

Signature: _________________________________________________

Tips for gathering evidence to demonstrate your skills

FPPFCO340A - Troubleshoot and rectify finishing and converting systems

Identify and analyse causes of system and quality faults

Rectify system faults

Rectify or re-work product with quality faults

Record and report system performance and product quality data

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

Instructions to Assessors

Teacher: ___________________________ Date: _