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Evidence Guide: PMC553000 - Set up and tune a 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

 

PMC553000 - Set up and tune a process

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

Prepare for equipment/change parts installation

  1. Identify all safety and emergency procedures
  2. Shut down equipment in accordance with procedures/work instructions and manufacturer specifications
  3. Isolate equipment according to procedures/work instructions
  4. Remove ancillary equipment in accordance with procedures/work instructions and manufacturer specifications
  5. Complete records and logs for removal of equipment or change parts
Identify all safety and emergency procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down equipment in accordance with procedures/work instructions and manufacturer specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Isolate equipment according to procedures/work instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Remove ancillary equipment in accordance with procedures/work instructions and manufacturer specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete records and logs for removal of equipment or change parts

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare the process for production

  1. Consult the production schedule to determine the product to be manufactured
  2. Ensure that the raw materials are available as required
  3. Ensure that the equipment/change parts, ancillaries and fixtures are available as required
  4. Perform pre-instalment equipment preparation according to procedures/work instructions
  5. Ensure that the equipment is in a safe condition for use
Consult the production schedule to determine the product to be manufactured

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure that the raw materials are available as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure that the equipment/change parts, ancillaries and fixtures are available as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Perform pre-instalment equipment preparation according to procedures/work instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure that the equipment is in a safe condition for use

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set up process

  1. Perform checks and tests to product and equipment specifications
  2. Ensure alignment of all equipment according to product specifications and procedures/work instructions
  3. Ensure that process/equipment is set up as required for the production schedule
Perform checks and tests to product and equipment specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure alignment of all equipment according to product specifications and procedures/work instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure that process/equipment is set up as required for the production schedule

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Tune the process

  1. Monitor operation and compare with standard operating procedures (SOPs) for appropriate operation
  2. Identify any deviation from standard performance
  3. Identify the cause of the deviation and take action
  4. Make adjustments to the equipment settings, process conditions or raw materials to bring production into specification
  5. Continue monitoring operation and making adjustments until product/equipment is within specification
Monitor operation and compare with standard operating procedures (SOPs) for appropriate operation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify any deviation from standard performance

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify the cause of the deviation and take action

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Make adjustments to the equipment settings, process conditions or raw materials to bring production into specification

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Continue monitoring operation and making adjustments until product/equipment is within specification

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Respond to problems

  1. Identify possible routine and non-routine problems in the equipment or process
  2. Determine problems needing action
  3. Determine possible fault causes
  4. Rectify problem using appropriate solution within area of responsibility
  5. Report problems outside area of responsibility to designated person
Identify possible routine and non-routine problems in the equipment or process

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine problems needing action

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine possible fault causes

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Rectify problem using appropriate solution within area of responsibility

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Report problems outside area of responsibility 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 for equipment/change parts installation

1.1

Identify all safety and emergency procedures

1.2

Shut down equipment in accordance with procedures/work instructions and manufacturer specifications

1.3

Isolate equipment according to procedures/work instructions

1.4

Remove ancillary equipment in accordance with procedures/work instructions and manufacturer specifications

1.5

Complete records and logs for removal of equipment or change parts

2

Prepare the process for production

2.1

Consult the production schedule to determine the product to be manufactured

2.2

Ensure that the raw materials are available as required

2.3

Ensure that the equipment/change parts, ancillaries and fixtures are available as required

2.4

Perform pre-instalment equipment preparation according to procedures/work instructions

2.5

Ensure that the equipment is in a safe condition for use

3

Set up process

3.1

Perform checks and tests to product and equipment specifications

3.2

Ensure alignment of all equipment according to product specifications and procedures/work instructions

3.3

Ensure that process/equipment is set up as required for the production schedule

4

Tune the process

4.1

Monitor operation and compare with standard operating procedures (SOPs) for appropriate operation

4.2

Identify any deviation from standard performance

4.3

Identify the cause of the deviation and take action

4.4

Make adjustments to the equipment settings, process conditions or raw materials to bring production into specification

4.5

Continue monitoring operation and making adjustments until product/equipment is within specification

5

Respond to problems

5.1

Identify possible routine and non-routine problems in the equipment or process

5.2

Determine problems needing action

5.3

Determine possible fault causes

5.4

Rectify problem using appropriate solution within area of responsibility

5.5

Report problems outside area of responsibility 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 for equipment/change parts installation

1.1

Identify all safety and emergency procedures

1.2

Shut down equipment in accordance with procedures/work instructions and manufacturer specifications

1.3

Isolate equipment according to procedures/work instructions

1.4

Remove ancillary equipment in accordance with procedures/work instructions and manufacturer specifications

1.5

Complete records and logs for removal of equipment or change parts

2

Prepare the process for production

2.1

Consult the production schedule to determine the product to be manufactured

2.2

Ensure that the raw materials are available as required

2.3

Ensure that the equipment/change parts, ancillaries and fixtures are available as required

2.4

Perform pre-instalment equipment preparation according to procedures/work instructions

2.5

Ensure that the equipment is in a safe condition for use

3

Set up process

3.1

Perform checks and tests to product and equipment specifications

3.2

Ensure alignment of all equipment according to product specifications and procedures/work instructions

3.3

Ensure that process/equipment is set up as required for the production schedule

4

Tune the process

4.1

Monitor operation and compare with standard operating procedures (SOPs) for appropriate operation

4.2

Identify any deviation from standard performance

4.3

Identify the cause of the deviation and take action

4.4

Make adjustments to the equipment settings, process conditions or raw materials to bring production into specification

4.5

Continue monitoring operation and making adjustments until product/equipment is within specification

5

Respond to problems

5.1

Identify possible routine and non-routine problems in the equipment or process

5.2

Determine problems needing action

5.3

Determine possible fault causes

5.4

Rectify problem using appropriate solution within area of responsibility

5.5

Report problems outside area of responsibility 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 procedures, job specifications, production schedules, test results, instruments/control panels, material labels and materials data safety sheets

set up equipment to process specifications

perform pre-start checks, start-up/shutdown procedures and isolations

monitor key variables, including:

operating temperatures

pressure

material flow

discharge rates

material properties/chemical reactions

cycle time

output rate

product integrity and general conformance to specification

use data and own senses to monitor plant and maximise performance

make adjustments to equipment settings, process conditions and/or raw materials to bring production into specification

identify hazards and apply relevant hazard controls

apply safety procedures

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

distinguish between causes of problems, including:

instrument failure/malfunction

electrical/mechanical failure/malfunction

wrong readings

raw material variations/contamination

process abnormalities

procedural errors

recognise and prioritise problems requiring action

resolve routine and non-routine problems

communicate effectively with team/work group and supervisors

complete workplace records

calculate and interpret process conditions, performance and trends.

Must provide evidence that demonstrates knowledge relevant to their job sufficient to operate independently and to solve routine and non-routine problems, including knowledge of:

functions, limitations and principles of operation of the equipment used in the process

impact of variations in equipment settings, process conditions and raw materials on product quality and production output

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

basic physics and chemistry relevant to the equipment/process/materials

characteristics of materials being processed and their behaviour in relation to process conditions and stages of production

quality requirements at each stage of production

common adjustments in process variables and their impact on product quality and production output

start-up and shutdown processes

routine and non-routine problems that may arise, the range of possible causes and appropriate 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:

manufacturer's technical information

job cards

drawings

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.

Hazards

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

heat, 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.

Problems

Routine and non-routine problems must be resolved.

Routine problems are predictable and have known solutions and include one or more of:

variations in raw materials feed

equipment alignment

out-of-specification settings (e.g. temperature and speed)

product quality problems.

Non-routine problems are unexpected problems or variations of previous problems.

Non-routine problems must be resolved by applying operational knowledge to develop new solutions, either individually or in collaboration with relevant experts, to:

determine problems needing action

determine possible fault causes

develop solutions to problems which do not have a known solution

follow through items initiated until final resolution has occurred

report problems outside area of responsibility to designated person.

Operational knowledge includes one or more of:

procedures

training

technical information, such as journals and engineering specifications

remembered experience

relevant knowledge obtained from appropriate people.

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.