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Evidence Guide: MSL975012A - Provide input to production trials

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

 

MSL975012A - Provide input to production trials

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

Prepare for the trial

  1. Clarify trial objectives, specifications, documentation and reporting requirements
  2. Identify the environmental, health, safety, and /or food safety hazards associated with the trial and the recommended control procedures
  3. Determine the availability of resources and the need for any clearances, special safety and storage requirements
  4. Review the recommended trial schedule to identify potential barriers/constraints and develop alternatives as necessary
  5. Communicate and confirm all laboratory requirements with plant operators and personnel in related work areas and functions
Clarify trial objectives, specifications, documentation and reporting requirements

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Identify the environmental, health, safety, and /or food safety hazards associated with the trial and the recommended control procedures

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Determine the availability of resources and the need for any clearances, special safety and storage requirements

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Review the recommended trial schedule to identify potential barriers/constraints and develop alternatives as necessary

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Communicate and confirm all laboratory requirements with plant operators and personnel in related work areas and functions

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Participate in the trial

  1. Reconfirm trial details with all relevant personnel
  2. Identify any last minute changes and delays and make appropriate adjustments
  3. Liaise closely with production personnel to conduct the trial safely and efficiently
  4. Collect required product samples for laboratory analysis and/or reference
  5. Monitor critical process parameters and record required data
  6. Monitor data to identify problems, significant process variations and/or unacceptable product
  7. Recommend changes to production processes as required
  8. Leave plant in condition suitable for routine production to recommence
Reconfirm trial details with all relevant personnel

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Identify any last minute changes and delays and make appropriate adjustments

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Liaise closely with production personnel to conduct the trial safely and efficiently

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Collect required product samples for laboratory analysis and/or reference

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Monitor critical process parameters and record required data

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Monitor data to identify problems, significant process variations and/or unacceptable product

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Recommend changes to production processes as required

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Leave plant in condition suitable for routine production to recommence

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Assess and report trial outcomes

  1. Arrange for, or conduct, testing of product samples to check specifications
  2. Analyse test results and relate properties of product samples to formulation details and processing methods
  3. Identify and investigate out of specification or unacceptable outcomes, as required
  4. Recommend possible modifications and/or opportunities for improvements within limits of role and responsibility
  5. Document and report trial outcomes in accordance with enterprise procedures
Arrange for, or conduct, testing of product samples to check specifications

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Analyse test results and relate properties of product samples to formulation details and processing methods

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Identify and investigate out of specification or unacceptable outcomes, as required

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Recommend possible modifications and/or opportunities for improvements within limits of role and responsibility

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Document and report trial outcomes in accordance with enterprise procedures

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Maintain a safe work environment

  1. Use established safe work practices and personal protective equipment to ensure personal safety and that of other personnel
  2. Minimise the generation of wastes and environmental impacts
  3. Ensure the safe collection of laboratory and hazardous waste for subsequent disposal
  4. Care for and store equipment and reagents as required
Use established safe work practices and personal protective equipment to ensure personal safety and that of other personnel

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Minimise the generation of wastes and environmental impacts

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Ensure the safe collection of laboratory and hazardous waste for subsequent disposal

Completed
Date:

Teacher:
Evidence:

 

 

 

 

 

 

 

Care for and store equipment and reagents 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

Assessors should ensure that candidates can:

analyse trial objectives and specifications to accurately determine resource requirements

liaise with relevant personnel to ensure trials are organised and conducted efficiently

follow all safety requirements on the production floor

work within production constraints, priorities and pressures

communicate effectively with personnel

collect accurate trial data and samples in the time available

recognise, interpret and report problems, atypical situations or unacceptable products

recommend product modifications and improvements within scope of responsibility

report trial outcomes in accordance with enterprise procedures.

Context of and specific resources for assessment

This unit of competency is to be assessed in the workplace or simulated workplace environment.

This unit of competency may be assessed with:

MSL924001A Process and interpret data

relevant MSL974000 series units of competency

relevant MSL975000 series units of competency.

Resources may include:

access to operating plant or pilot plant for duration of trials

trials, sampling and testing enterprise procedures for:

sampling containers and sampling equipment

test equipment, laboratory instruments and reagents.

Method of assessment

The following assessment methods are suggested:

review of trial documentation completed by candidate to ensure quality and timeliness

feedback from personnel involved in trials, supervisors

observation of candidate participating in production trials

oral or written questioning to check underpinning knowledge of trial procedures, sampling and test methods, common causes and remedies for product/processing problems.

In all cases, practical assessment should be supported by questions to assess underpinning knowledge and those aspects of competency which are difficult to assess directly.

Where applicable, reasonable adjustment must be made to work environments and training situations to accommodate ethnicity, age, gender, demographics and disability.

Access must be provided to appropriate learning and/or assessment support when required.

The language, literacy and numeracy demands of assessment should not be greater than those required to undertake the unit of competency in a work like environment.

This competency in practice

Industry representatives have provided the case studies below to illustrate the practical application of this unit of competency and to show its relevance in a workplace setting.

Manufacturing

A new manufacturing plant has been constructed to produce titanium dioxide (TiO2) for use in food and paint manufacture. An experienced laboratory technician is involved in the plant's commissioning process which has been designed by plant engineers. The commissioning involves trial operation of each section of the plant to achieve intermediate products, such as titanium tetra-chloride (TiCl4) of acceptable quality for use in subsequent stages. The technician provides input to the trials by collecting and testing samples, analysing the results and providing regular reports to the engineers. The importance of the technician's work cannot be overestimated. They have to work under tight time deadlines, quality requirements and the overall pressure of commissioning the plant on time and within budget.

Food processing

The laboratory is notified of an upcoming trial for sour cream using a new starter culture. A technician is assigned to perform the laboratory assessment of the trial. The technician discusses with the production supervisor about when the cream will be cultured. It is agreed that the technician will monitor the fermentation, collect samples, and coordinate testing of the final product. The technician obtains protective footwear and hearing protection to wear while in the production area. On the day of the trial the technician calibrates the process pH meter and monitors the pH of the vat as fermentation progresses. Once the desired pH is reached, the technician advises the production team to commence packing of the product. After collecting samples of the final product from the start, middle and end of packing, the technician records the sample details and distributes the sample for both internal and external laboratory testing. Final product results are collated by the technician, who reports any out of specification results to the quality and production departments.

Required Skills and Knowledge

Required skills

Required skills include:

analysing trial objectives and specifications to accurately determine resource requirements

liaising with relevant personnel to ensure trials are organised and conducted efficiently

following safety requirements

working within production constraints, priorities and pressures

communicating effectively with personnel

collecting accurate trial data and samples in the time available

recognising, interpreting and reporting problems, atypical situations or unacceptable products

recommending product modifications and improvements

reporting trial outcomes in accordance with enterprise procedures

Required knowledge

Required knowledge includes:

trial objectives, laboratory trial requirements, documentation and reporting requirements

recipes/formulations, technical specifications and quality parameters for trial products

effect on product properties of variations in recipes/formulations

product properties, process stages and unit operations involved in the trial

relationship between temperature and viscosity

friction, pumping and fluid flow

expected nature/condition of materials at each process stage

causes and remedies for common processing problems associated with trial products

sampling and test methods for trial products

occupational health and safety (OHS), food safety and /or environmental management procedures relevant to trial

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.

Codes of practice

Where reference is made to industry codes of practice, and/or Australian/international standards, it is expected the latest version will be used

Standards, codes, procedures and/or enterprise requirements

Standards, codes, procedures and/or enterprise requirements may include:

Australian and international standards, such as:

AS ISO 17025-2005 General requirements for the competence of testing and calibration laboratories

AS/NZS ISO 9000 Set:2008 Quality management systems set

Australia New Zealand Food Authority (ANZFA) Code and User Guides

Australia New Zealand Food Standards (ANZFS) Code

Australian code of good manufacturing practice for medicinal products (GMP)

calibration and maintenance schedules

enterprise recording and reporting procedures

equipment startup, operation and shutdown procedures

material safety data sheets (MSDS)

material, production and product specifications

principles of good laboratory practice (GLP)

production and laboratory schedules

quality, equipment and procedures manuals

standard operating procedures (SOPs)

Therapeutic Goods Regulations 1009

Product properties, process stages and unit operations involved in the trial

Product properties, process stages and unit operations involved in the trial may include:

classification of samples (screening and sieving)

milling

mixing

separation (distillation, sieves, filtration, solvent extraction and chromatography)

drying

concentrating

diluting

depositing (injecting, forming and extrusion)

retorting

cooling, freezing, refrigeration and heat transfer

closure (vacuum sealing)

weighing and packaging

materials handling and transport

warehousing

Trial specifications

Trial specifications may include:

product specifications

recipe/formulations

processing parameters

trial size, production target and timeline

trial schedule and resources required

required product samples and tests

analysis of relevant OHS, food safety and environmental hazards and controls

storage requirements

Hazards

Hazards may include:

electric shock

microbiological organisms and agents associated with soil, air and water

solar radiation, dust and noise

chemicals, such as acids, heavy metals, pesticides and hydrocarbons

aerosols from broken centrifuge tubes and pipetting

radiation, such as gamma and X-ray

sharps, broken glassware and hand tools

flammable liquids and gases

cryogenics, such as dry ice and liquid nitrogen

fluids under pressure, such as steam and industrial gases

sources of ignition

disturbance or interruption of services

manual handling, working at heights and working in confined spaces

crushing, entanglement and cuts associated with moving machinery or falling objects

pedestrian and vehicular traffic

Safety procedures and hazard control measures

Safety procedures and hazard control measures may include:

ensuring access to service shut-off points

recognising and observing hazard warnings and safety signs

labelling of samples, reagents, aliquoted samples and hazardous materials

handling and storage of hazardous materials and equipment in accordance with labelling, MSDS and manufacturer's instructions

identifying and reporting operating problems or equipment malfunctions

cleaning and decontaminating equipment and work areas regularly using enterprise procedures

using personal protective clothing and equipment, such as hard hats, hearing protection, gloves, safety glasses, coveralls, gowns, body suits, respirators and safety boots

machinery guards

signage, barriers, flashing lights and traffic control

reporting abnormal emissions, discharges and airborne contaminants, such as noise, light, solids, liquids, water/waste water, gases, smoke, vapour, fumes, odour and particulates to appropriate personnel

Resources

Resources may include:

operators and personnel from affected work areas and functions

production, testing and sampling equipment

enterprise procedures and standard methods for sampling and testing

raw materials/ingredients, packaging components and consumables

trial documentation, such as technical specifications, plant or production line layout, MSDS, trial request and result forms

Occupational health and safety (OHS) and environmental management requirements

OHS and environmental management requirements:

all operations must comply with enterprise OHS and environmental management requirements, which may be imposed through state/territory or federal legislation - these requirements must not be compromised at any time

all operations assume the potentially hazardous nature of samples and require standard precautions to be applied

where relevant, users should access and apply current industry understanding of infection control issued by the National Health and Medical Research Council (NHMRC) and State and Territory Departments of Health