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Evidence Guide: PMC552040C - 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

 

PMC552040C - 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-startup procedure according to enterprise procedure checklist
  3. Ensure furnace startup function complies with standard operating procedures
  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-startup procedure according to enterprise procedure checklist

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure furnace startup function complies with standard operating procedures

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

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

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.

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

It is essential that the melting equipment be understood and that the importance of critical material properties, settings and readings is known.

Competence must be demonstrated in the ability to recognise and analyse potential situations requiring action and then in implementing appropriate corrective action.

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

importance of critical material properties, settings and readings is identified

process and equipment are operated in accordance with work instructions and process parameters

temperatures are maintained within limits

melt quality is monitored to minimise wastage

start up and shut down occur first time

change in utilities (gas/power/diesel) is responded to immediately

signals and alarms are responded to immediately

process measurements and tests are continually made, observed and interpreted

melt quality is maintained to customer specifications.

Competence must be demonstrated in the operation of all ancillary equipment to the level required for this unit of competency.

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.

Assessment will occur over a range of situations which will include disruptions to normal, smooth operation.

Simulation or case studies/scenarios may be required to allow for timely assessment of parts of this unit of competency. Simulation should be based on the actual plant and will include 'walk-throughs' of the relevant competency components. A bank of scenarios/case studies/what ifs and questions will be required to probe the reasoning behind observable actions.

Method of assessment

In all plants it may be appropriate to assess this unit concurrently with relevant teamwork and communication units.

It may be appropriate to assess this unit concurrently with:

MSAPMSUP292A Sample and test materials and product.

Guidance information for assessment

Assessment processes and techniques must be culturally appropriate and appropriate to the language and literacy capacity of the candidate and the work being performed.

Required Skills and Knowledge

Required skills

Required skills include

recognising process conditions which will lead to out of specification production and taking appropriate action

implementing the enterprise's standard procedures and work instructions and relevant regulatory requirements within appropriate time constraints and in a manner relevant to the operation of the melting equipment

reading and numeracy to interpret workplace documents and technical information

Required knowledge

Required knowledge includes:

composition and nature of the glass

startup and shutdown processes

construction and limitations of the melting equipment and conditions

combustion fundamentals

out of specification situations

physics and chemistry (where appropriate) of process

principles of operation of process

control philosophy of process

distinguish between causes of faults such as:

raw material

mechanical

electrical/instrument

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.

Procedures

All operations are performed in accordance with standard procedures and work instructions

Melting equipment

This unit includes melting equipment applicable to each of the specific areas of glass products manufacture. These may include:

flat glass

insulation, glass wool insulation, laminated blankets, roll and boards

fibreglass and glass filaments

packaging, bottles and jars

Tools and equipment

Tools and equipment may include:

furnaces and associated equipment

gas stations

computers

measuring and recording equipment

communication equipment

hand tools

safety clothing and equipment

Process and products

Process and products include:

melting, refining and conditioning of raw material, including frit and other recycled glass materials, to produce glass for forming processes

It does NOT include processes involved with:

scientific glass

secondary processes

the softening of already made glass

Plant data

Plant data includes:

test results

instrument/control panel information

data from physical senses (sight, sound and hearing)

temperatures, pressures, material flow and discharge rates and effects

variations to chemical reactions/material modifications

Typical problems

Typical problems may include:

raw materials feed

alternative fuel sources

analysis of all plant data including test results, control instrument data and other observations

control of furnace temperature within specifications

surveillance of melt quality

taking corrective action

Occupational health and safety (OHS)

All operations are subject to stringent OHS requirements and these must not be compromised at any time. Where there is an apparent conflict between performance criteria and OHS requirements, the OHS requirements take precedence.