NTISthis.com

Evidence Guide: PMAOPS211B - Operate manufacturing extruders

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

 

PMAOPS211B - Operate manufacturing extruders

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

Start up extruder systems.

  1. Perform pre-start-up checks
  2. Start up individual items of equipment, and the entire extrusion system
  3. Start up system after maintenance
  4. Build up extrusion rate steadily
  5. Produce output at specified rate and quality within minimum time.
Perform pre-start-up checks

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Start up individual items of equipment, and the entire extrusion system

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Start up system after maintenance

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Build up extrusion rate steadily

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Produce output at specified rate and quality within minimum time.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor and control the extrusion process.

  1. Complete routine checks, logs and paperwork
  2. Inspect pellet/granule properties, and recognise and correct problems
  3. Monitor stock levels of feeds and products and take action to maintain production schedule and quality
  4. Adjust plant to achieve required output rate and quality with maximum plant efficiency.
Complete routine checks, logs and paperwork

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Inspect pellet/granule properties, and recognise and correct problems

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor stock levels of feeds and products and take action to maintain production schedule and quality

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Adjust plant to achieve required output rate and quality with maximum plant efficiency.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Change production rates and/or product grade/specification.

  1. Predict from rates and schedule when a transition will be required
  2. Manage transitions smoothly and in a timely manner
  3. Minimise scrap/off grade as a result of a transition.
Predict from rates and schedule when a transition will be required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Manage transitions smoothly and in a timely manner

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Minimise scrap/off grade as a result of a transition.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Carry out maintenance procedures

  1. Isolate extrusion equipment and prepare for maintenance as required
  2. Test safety trips and alarms
  3. Complete minor maintenance according to procedures
  4. Receive plant back from maintenance
  5. Prepare plant for the introduction of polymer and additives
  6. Return plant to operation.
Isolate extrusion equipment and prepare for maintenance as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Test safety trips and alarms

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete minor maintenance according to procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Receive plant back from maintenance

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare plant for the introduction of polymer and additives

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Return plant to operation.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down extrusion systems.

  1. Determine type of shut down required
  2. Give advance warning of shut down where appropriate
  3. Change over individual items of equipment
  4. Shut down individual items of equipment and the entire extrusion system
  5. Perform an emergency shut down when required
  6. Reset trips and alarms after a shut down and leave plant in a condition ready to restart
  7. Shut down for maintenance when required.
Determine type of shut down required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Give advance warning of shut down where appropriate

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Change over individual items of equipment

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down individual items of equipment and the entire extrusion system

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Perform an emergency shut down when required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Reset trips and alarms after a shut down and leave plant in a condition ready to restart

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down for maintenance when required.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Clean extruder.

  1. Identify cleaning requirements
  2. Clean extrusion equipment to requirements according to procedures.
Identify cleaning requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Clean extrusion equipment to requirements according to procedures.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Control hazards.

  1. Identify hazards in work area and with equipment
  2. Assess risks arising from those hazards
  3. Take appropriate action to control risks in accordance with procedures and duty of care.
Identify hazards in work area and with equipment

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assess risks arising from those hazards

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Take appropriate action to control risks in accordance with procedures and duty of care.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Respond to extruder problems.

  1. Monitor plant frequently and critically throughout shift using measured/indicated data and senses (sight, hearing etc) as appropriate.
  2. Recognise operational problems
  3. Analyse cause of operational problems within scope of skill level
  4. Take timely and appropriate action to solve operational problems.
Monitor plant frequently and critically throughout shift using measured/indicated data and senses (sight, hearing etc) as appropriate.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Recognise operational problems

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Analyse cause of operational problems within scope of skill level

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Take timely and appropriate action to solve operational problems.

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, the Range Statement and the Assessment Guidelines for the Training Package.

Overview of assessment

Assessment for this unit of competency will be on an operating plant. The unit will be assessed in as holistic a manner as is practical and may be integrated with the assessment of other relevant units of competency. Assessment will occur over a range of situations which will include disruptions to normal, smooth operation.

Simulation may be required to allow for timely assessment of parts of this unit of competency (eg Elements 3 and 4). Simulation should be based on the actual plant and will include walk-throughs of the relevant competency components. Simulations may also include the use of case studies/scenarios and role plays.

This unit of competency requires a significant body of knowledge which will be assessed through questioning and the use of what-if scenarios both on the plant (during demonstration of normal operations and walk throughs of abnormal operations) and off the plant.

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

Competence must be demonstrated in the ability to recognise and analyse potential situations requiring action and then in implementing appropriate corrective action. The emphasis should be on the ability to stay out of trouble rather than on recovery from a disaster.

Consistent performance should be demonstrated. In particular look to see that:

early warning signs of equipment/processes needing attention or with potential problems are recognised

the range of possible causes can be identified and analysed and the most likely cause determined

appropriate action is taken to ensure a timely return to full performance

obvious problems in related plant areas are recognised and an appropriate contribution made to their solution.

These aspects may be best assessed using a range of scenarios/case studies/what-ifs as the stimulus with a walk through forming part of the response. These assessment activities should include a range of problems, including new, unusual and improbable situations which may have been generated from the past incident history of the plant, incidents on similar plants around the world, hazard analysis activities and similar sources.

Context of and specific resources for assessment

Assessment will require access to an operating plant over an extended period of time, or a suitable method of gathering evidence of operating ability over a range of situations. A bank of scenarios/case studies/what-ifs will be required as will a bank of questions which will be used to probe the reasoning behind the observable actions.

Method of assessment

In all plants it may be appropriate to assess this unit concurrently with relevant teamwork and communication units. For many plants, it might be appropriate for this unit to be assessed with:

PMAOPS210B Operate particulates processing equipment

MSAPMSUP210A Process and record information.

In a major hazard facility, it may be appropriate to assess this unit concurrently with:

MSAPMOHS200A Work safely.

Guidance information for assessment

Assessment processes and techniques must be culturally appropriate and appropriate to the communication ability, language and literacy capacity of the assessee and the work being performed.

Required Skills and Knowledge

This describes the essential skills and knowledge and their level, required for this unit.

Required skills

The ability to distinguish between types and causes of problems as relevant to the practical operation of equipment at the job level.

Required knowledge

A comprehensive understanding of extrusion equipment principles and typical problems to a level needed to control the operation, and recognise and resolve operational problems. In particular it includes a knowledge of:

all items on a schematic of the extruder and the function of each

principles of operation of equipment

physics of operation, including effects of temperature and pressure

properties of materials being extruded

temperature and viscosity effects

isolating a problem to an item of equipment

methods of resolving problems.

This knowledge is required of all major items of equipment which comprise the extrusion system.

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. Add any essential operating conditions that may be present with training and assessment depending on the work situation, needs if the candidate, accessibility of the item, and local industry and regional contexts.

Codes of practice/ standards

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

Context

This competency unit includes all items of equipment and unit operations which form part of the extrusion system. Typically this will include:

additive (including masterbatch) systems

granule/pellet cutting and cooling systems

barrel/head heating and cooling systems.

Problems

It could also include other equipment as well as the extruder itself. It includes the operation of equipment ancillary to the extruder, including that used for adding masterbatch and other additives.

Typical problems include:

knife/blade/cutter adjustment

screen pack preparation and changes

granule/pellet properties not to specification

granule/pellet cooling systems etc.

Procedures

All operations are performed in accordance with procedures.

Health, safety and environment (HSE)

All operations to which this unit applies are subject to stringent health, safety and environment requirements, which may be imposed through State or Federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between Performance Criteria and HSE requirements, the HSE requirements take precedence.