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Evidence Guide: PMC552049 - Operate on-line stacking and assembly equipment

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

 

PMC552049 - Operate on-line stacking and assembly equipment

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

Prepare the flat glass processing equipment for production

  1. Set up line in accordance with job specifications
  2. Transfer glass to conveyor
  3. Conduct flat glass processing equipment pre-start procedure and visual checks according to enterprise procedure checklist
  4. Set up and configure flat glass processing equipment to ensure start-up function complies with standard operating procedures (SOPs)
  5. Load and separate glass in accordance with work instructions
Set up line in accordance with job specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Transfer glass to conveyor

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Conduct flat glass processing equipment pre-start procedure and visual checks according to enterprise procedure checklist

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set up and configure flat glass processing equipment to ensure start-up function complies with standard operating procedures (SOPs)

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Load and separate glass in accordance with work instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Operate flat glass processing equipment

  1. Identify customer requirements and set minimum parameters in accordance with batch sheets
  2. Start up equipment in accordance with work instructions
  3. Ensure flat glass processing equipment is operated in accordance with established enterprise procedures
Identify customer requirements and set minimum parameters in accordance with batch sheets

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Start up equipment in accordance with work instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure flat glass processing equipment is operated in accordance with established enterprise procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor, adjust and record flat glass processing equipment operation

  1. Monitor equipment performance in accordance with work instructions and manufacturer specifications
  2. Monitor product for non-conformance to customer specifications
  3. Adjust and control equipment to ensure correct product quality
  4. Complete final inspection checks
  5. Complete appropriate records and logs
Monitor equipment performance in accordance with work instructions and manufacturer specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor product for non-conformance to customer specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Adjust and control equipment to ensure correct product quality

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete final inspection checks

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete appropriate records and logs

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Rectify routine problems

  1. Identify the range of faults that can occur during the operation
  2. Determine and rectify fault causes in accordance with procedures
  3. Identify and rectify equipment failure causes in accordance with procedures
  4. Ensure appropriate records and log books of equipment operations are maintained to meet procedures
  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 procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify and rectify equipment failure causes in accordance with procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure appropriate records and log books of equipment operations are maintained to meet procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify non-routine problems and report to designated person

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down equipment

  1. Ensure line is clear of all product and left in a safe manner for shutdown
  2. Shut down equipment in accordance with work instructions
  3. Complete appropriate records and logs
  4. Shut down equipment in an emergency situation
Ensure line is clear of all product and left in a safe manner for shutdown

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down equipment in accordance with work instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete appropriate records and logs

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down equipment in an emergency situation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare equipment for maintenance

  1. Isolate equipment in accordance with work instructions
  2. Remove any broken glass safely
  3. Make sure area is clear and safe for maintenance
Isolate equipment in accordance with work instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Remove any broken glass safely

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Make sure area is clear and safe for maintenance

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 flat glass processing equipment for production

1.1

Set up line in accordance with job specifications

1.2

Transfer glass to conveyor

1.3

Conduct flat glass processing equipment pre-start procedure and visual checks according to enterprise procedure checklist

1.4

Set up and configure flat glass processing equipment to ensure start-up function complies with standard operating procedures (SOPs)

1.5

Load and separate glass in accordance with work instructions

2

Operate flat glass processing equipment

2.1

Identify customer requirements and set minimum parameters in accordance with batch sheets

2.2

Start up equipment in accordance with work instructions

2.3

Ensure flat glass processing equipment is operated in accordance with established enterprise procedures

3

Monitor, adjust and record flat glass processing equipment operation

3.1

Monitor equipment performance in accordance with work instructions and manufacturer specifications

3.2

Monitor product for non-conformance to customer specifications

3.3

Adjust and control equipment to ensure correct product quality

3.4

Complete final inspection checks

3.5

Complete appropriate records and logs

4

Rectify routine problems

4.1

Identify the range of faults that can occur during the operation

4.2

Determine and rectify fault causes in accordance with procedures

4.3

Identify and rectify equipment failure causes in accordance with procedures

4.4

Ensure appropriate records and log books of equipment operations are maintained to meet procedures

4.5

Identify non-routine problems and report to designated person

5

Shut down equipment

5.1

Ensure line is clear of all product and left in a safe manner for shutdown

5.2

Shut down equipment in accordance with work instructions

5.3

Complete appropriate records and logs

5.4

Shut down equipment in an emergency situation

6

Prepare equipment for maintenance

6.1

Isolate equipment in accordance with work instructions

6.2

Remove any broken glass safely

6.3

Make sure area is clear and safe for maintenance

7

Control hazards

7.1

Identify hazards from the job to be done

7.2

Identify other hazards in the work area

7.3

Assess the risks arising from those hazards

7.4

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 flat glass processing equipment for production

1.1

Set up line in accordance with job specifications

1.2

Transfer glass to conveyor

1.3

Conduct flat glass processing equipment pre-start procedure and visual checks according to enterprise procedure checklist

1.4

Set up and configure flat glass processing equipment to ensure start-up function complies with standard operating procedures (SOPs)

1.5

Load and separate glass in accordance with work instructions

2

Operate flat glass processing equipment

2.1

Identify customer requirements and set minimum parameters in accordance with batch sheets

2.2

Start up equipment in accordance with work instructions

2.3

Ensure flat glass processing equipment is operated in accordance with established enterprise procedures

3

Monitor, adjust and record flat glass processing equipment operation

3.1

Monitor equipment performance in accordance with work instructions and manufacturer specifications

3.2

Monitor product for non-conformance to customer specifications

3.3

Adjust and control equipment to ensure correct product quality

3.4

Complete final inspection checks

3.5

Complete appropriate records and logs

4

Rectify routine problems

4.1

Identify the range of faults that can occur during the operation

4.2

Determine and rectify fault causes in accordance with procedures

4.3

Identify and rectify equipment failure causes in accordance with procedures

4.4

Ensure appropriate records and log books of equipment operations are maintained to meet procedures

4.5

Identify non-routine problems and report to designated person

5

Shut down equipment

5.1

Ensure line is clear of all product and left in a safe manner for shutdown

5.2

Shut down equipment in accordance with work instructions

5.3

Complete appropriate records and logs

5.4

Shut down equipment in an emergency situation

6

Prepare equipment for maintenance

6.1

Isolate equipment in accordance with work instructions

6.2

Remove any broken glass safely

6.3

Make sure area is clear and safe for maintenance

7

Control hazards

7.1

Identify hazards from the job to be done

7.2

Identify other hazards in the work area

7.3

Assess the risks arising from those hazards

7.4

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, material labels and safety information

perform pre-start procedures

set up and configure equipment and materials

monitor key variables, including:

temperature

product integrity and general conformance to specification

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

start up and shut down the annealing equipment

identify hazards and apply relevant hazard controls

apply safety 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 faults, 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:

functions, limitations and principles of operation of flat glass processing equipment

composition and nature of the glass

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:

one or more of:

flat glass processing equipment

glass assembly equipment

on-line stacking equipment

ancillary equipment that is integral to the process

measuring/recording equipment.

Problems

Routine problems must be resolved by applying known solutions.

Routine problems are predictable and include one or more of:

glass jamming or kicking sideways

temperature problems

quality problems, such as:

scars

moisture content

shelling

venting

curing

thickness.

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.