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Evidence Guide: PMC552040 - Operate glass melting process

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

 

PMC552040 - Operate glass melting process

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

Prepare the melting equipment

  1. Establish production program and melting guidelines from the job specifications/work instructions
  2. Conduct furnace pre-start procedures according to enterprise procedure checklist
  3. Ensure furnace start-up function complies with standard operating procedures (SOPs)
  4. Ensure glass melting equipment is operated in accordance with established enterprise procedures
Establish production program and melting guidelines from the job specifications/work instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Conduct furnace pre-start procedures according to enterprise procedure checklist

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure furnace start-up function complies with standard operating procedures (SOPs)

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure glass melting equipment is operated in accordance with established enterprise procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Test furnace back-up equipment

  1. Make sure furnace back-up equipment test schedule is maintained
  2. Conduct back-up equipment test procedures to meet specific enterprise requirements
Make sure furnace back-up equipment test schedule is maintained

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Conduct back-up equipment test procedures to meet specific enterprise requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Melt raw materials

  1. Interpret the molten glass mix and required furnace operation from job specifications
  2. Melt glass and monitor furnace and other operating parameters in accordance with established enterprise procedures
Interpret the molten glass mix and required furnace operation from job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Melt glass and monitor furnace and other operating parameters in accordance with established enterprise procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor and interpret data and adjust operation

  1. Monitor instruments and control panels, and interpret test results for fluctuations, variations and trends
  2. Monitor plant and process and deduce conditions of materials in process and products being made
  3. Determine appropriate action to improve process operation
  4. Adjust furnace controls to ensure glass melt parameters are maintained to job specifications
  5. Check that process operation has improved
  6. Continue analysing data and making adjustments until desired level of process operation is achieved and product is within specifications in accordance with work instructions
Monitor instruments and control panels, and interpret test results for fluctuations, variations and trends

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor plant and process and deduce conditions of materials in process and products being made

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine appropriate action to improve process operation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Adjust furnace controls to ensure glass melt parameters are maintained to job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check that process operation has improved

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Continue analysing data and making adjustments until desired level of process operation is achieved and product is within specifications in accordance with work instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Rectify problems

  1. Identify the range of faults that can occur during the operation
  2. Determine and rectify fault causes in accordance with established enterprise procedures
  3. Identify and rectify equipment failure causes in accordance with established enterprise procedures
  4. Make sure appropriate records and log books of equipment operations are maintained to meet enterprise requirements
  5. Identify non-routine problems and report to designated person
Identify the range of faults that can occur during the operation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine and rectify fault causes in accordance with established enterprise procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify and rectify equipment failure causes in accordance with established enterprise procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Make sure appropriate records and log books of equipment operations are maintained to meet enterprise requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify non-routine problems and report to designated person

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Control hazards

  1. Identify hazards from the job to be done
  2. Identify other hazards in the work area
  3. Assess the risks arising from those hazards
  4. Implement measures to control those risks in line with procedures
Identify hazards from the job to be done

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify other hazards in the work area

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assess the risks arising from those hazards

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Implement measures to control those risks in line with procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Prepare the melting equipment

1.1

Establish production program and melting guidelines from the job specifications/work instructions

1.2

Conduct furnace pre-start procedures according to enterprise procedure checklist

1.3

Ensure furnace start-up function complies with standard operating procedures (SOPs)

1.4

Ensure glass melting equipment is operated in accordance with established enterprise procedures

2

Test furnace back-up equipment

2.1

Make sure furnace back-up equipment test schedule is maintained

2.2

Conduct back-up equipment test procedures to meet specific enterprise requirements

3

Melt raw materials

3.1

Interpret the molten glass mix and required furnace operation from job specifications

3.2

Melt glass and monitor furnace and other operating parameters in accordance with established enterprise procedures

4

Monitor and interpret data and adjust operation

4.1

Monitor instruments and control panels, and interpret test results for fluctuations, variations and trends

4.2

Monitor plant and process and deduce conditions of materials in process and products being made

4.3

Determine appropriate action to improve process operation

4.4

Adjust furnace controls to ensure glass melt parameters are maintained to job specifications

4.5

Check that process operation has improved

4.6

Continue analysing data and making adjustments until desired level of process operation is achieved and product is within specifications in accordance with work instructions

5

Rectify problems

5.1

Identify the range of faults that can occur during the operation

5.2

Determine and rectify fault causes in accordance with established enterprise procedures

5.3

Identify and rectify equipment failure causes in accordance with established enterprise procedures

5.4

Make sure appropriate records and log books of equipment operations are maintained to meet enterprise requirements

5.5

Identify non-routine problems and report to designated person

6

Control hazards

6.1

Identify hazards from the job to be done

6.2

Identify other hazards in the work area

6.3

Assess the risks arising from those hazards

6.4

Implement measures to control those risks in line with procedures

Required Skills and Knowledge

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Prepare the melting equipment

1.1

Establish production program and melting guidelines from the job specifications/work instructions

1.2

Conduct furnace pre-start procedures according to enterprise procedure checklist

1.3

Ensure furnace start-up function complies with standard operating procedures (SOPs)

1.4

Ensure glass melting equipment is operated in accordance with established enterprise procedures

2

Test furnace back-up equipment

2.1

Make sure furnace back-up equipment test schedule is maintained

2.2

Conduct back-up equipment test procedures to meet specific enterprise requirements

3

Melt raw materials

3.1

Interpret the molten glass mix and required furnace operation from job specifications

3.2

Melt glass and monitor furnace and other operating parameters in accordance with established enterprise procedures

4

Monitor and interpret data and adjust operation

4.1

Monitor instruments and control panels, and interpret test results for fluctuations, variations and trends

4.2

Monitor plant and process and deduce conditions of materials in process and products being made

4.3

Determine appropriate action to improve process operation

4.4

Adjust furnace controls to ensure glass melt parameters are maintained to job specifications

4.5

Check that process operation has improved

4.6

Continue analysing data and making adjustments until desired level of process operation is achieved and product is within specifications in accordance with work instructions

5

Rectify problems

5.1

Identify the range of faults that can occur during the operation

5.2

Determine and rectify fault causes in accordance with established enterprise procedures

5.3

Identify and rectify equipment failure causes in accordance with established enterprise procedures

5.4

Make sure appropriate records and log books of equipment operations are maintained to meet enterprise requirements

5.5

Identify non-routine problems and report to designated person

6

Control hazards

6.1

Identify hazards from the job to be done

6.2

Identify other hazards in the work area

6.3

Assess the risks arising from those hazards

6.4

Implement measures to control those risks in line with procedures

Evidence required to demonstrate competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria and demonstrate the ability to:

read and interpret, job sheets, procedures, instruments/control panels, test results, material labels and safety information

perform pre-start procedures

conduct back-up equipment test procedures to schedule

analyse test results and control instrument data to identify fluctuations, variations and trends in process variables

monitor key variables, including:

temperature

material flow and discharge rates

fuel source

melt quality

product integrity and general conformance to specification

operate and adjust the equipment to meet product quality and production output specifications

identify hazards and apply relevant hazard controls

apply safety procedures

apply housekeeping procedures

recognise out-of-specification products, process problems and materials faults

recognise routine and non-routine problems

identify when the operator is able to rectify problems, when assistance is required and who is the appropriate source for assistance

take action to resolve problems or report them to appropriate personnel

distinguish between possible causes of routine problems, including:

raw material variations

equipment malfunctions

electrical/instrument malfunctions

process abnormalities

communicate effectively with team/work group and supervisors

complete workplace records

do basic arithmetical manipulations, including additions, subtractions, divisions, fractions and percentages.

Must provide evidence that demonstrates knowledge relevant to their job sufficient to operate under routine only supervision and to solve routine problems, including knowledge of:

principles of glass melting process

control philosophy of process

functions, limitations and principles of operation of melting equipment

composition and nature of the glass

critical material properties, settings and readings

combustion fundamentals

test procedures and schedule

basic physics, and where appropriate chemistry, relevant to the equipment/process/materials

the potential effects of variations in raw materials and equipment operation in relation to quality of product

factors which may affect product quality or production output and appropriate remedies

start-up and shutdown processes

routine problems, their probable causes and relevant corrective actions

organisation procedures relevant to the work environment/job role

hierarchy of control

hazards that may arise in the job/work environment and:

their possible causes

potential consequences

appropriate risk controls.

Range Statement

This field allows for different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.

Regulatory framework

The latest version of all legislation, regulations, industry codes of practice and Australian/international standards, or the version specified by the local regulatory authority, must be used.

Applicable legislation, regulations, standards and codes of practice include:

health, safety and environmental (HSE) legislation, regulations and codes of practice relevant to the workplace, equipment and production processes and hazardous materials

Australian/international standards relevant to the materials being used and products being made

any relevant licence and certification requirements.

All operations to which this unit applies are subject to stringent HSE requirements, which may be imposed through state/territory or federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between performance criteria and such requirements the legislative requirements take precedence.

Procedures

All operations must be performed in accordance with relevant procedures.

Procedures are written, verbal, visual, computer-based or in some other form, and include one or any combination of:

job cards

emergency procedures

work instructions

SOPs

safe work method statements (SWMS)

formulas/recipes

batch sheets

temporary instructions

any similar instructions provided for the smooth running of the plant.

Tools and equipment

Tools and equipment include:

furnaces

measuring and recording equipment

ancillary equipment that is integral to the process.

Problems

Routine problems must be resolved by applying known solutions.

Routine problems are predictable and include one or more of:

raw materials feed

change of fuel source

variations in furnace temperature

variations in melt quality.

Known solutions are drawn from one or more of:

procedures

training

remembered experience.

Non-routine problems must be reported according to according to relevant procedures.

Hazards

Hazards must be identified and controlled. Identifying hazards requires consideration of:

high temperatures

smoke, dust, vapours or other atmospheric hazards

weight, shape, volume of materials to be handled

hazardous products and materials

sharp edges, protrusions or obstructions

slippery surfaces, spills or leaks

electricity

gas

gases and liquids under pressure

noise

rotational equipment or vibration

plant services (steam, condensate, cooling water, etc)

structural hazards

equipment failures

machinery, equipment and product mass

limited head spaces or overhangs

working at heights

working in restricted or confined spaces

other hazards that might arise.

Records and reports

Records include one or more of:

log books/sheets

electronic records

job/work sheets

other records used for the smooth running of the plant.

Reports include one or more of:

paper or electronic-based logs and reports

verbal/radio reports

reporting items found which require action.