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Evidence Guide: PMC553010C - Process raw meal into product

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

 

PMC553010C - Process raw meal into product

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

Prepare for processing

  1. Notify/keep informed all relevant people about the current status operations and any intention to make changes
  2. Perform all pre-start checks in accordance with standard operating procedures
  3. Set up and configure equipment startup function complying with procedures
  4. Check plant/equipment settings against operating parameters as identified in standard operating procedures
  5. Load raw materials in accordance with work instructions
  6. Start up plant/equipment in accordance with procedures
Notify/keep informed all relevant people about the current status operations and any intention to make changes

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Perform all pre-start checks in accordance with standard operating procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set up and configure equipment startup function complying with procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check plant/equipment settings against operating parameters as identified in standard operating procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Load raw materials in accordance with work instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Start up plant/equipment in accordance with procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Process raw meal

  1. Commence/continue process operations in accordance with specified operating procedures
  2. Monitor and check against target parameters instrument/ control panels for variations, fluctuations or trends
  3. Maximise throughput of system while meeting quality target parameters
  4. Check and adjust ancillary equipment as required
Commence/continue process operations in accordance with specified operating procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor and check against target parameters instrument/ control panels for variations, fluctuations or trends

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Maximise throughput of system while meeting quality target parameters

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check and adjust ancillary equipment as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Distribute product to storage

  1. Monitor and perform necessary adjustments to discharge rate and temperature as required
  2. Monitor the distribution transport system for efficiency and spillages and take appropriate action as required
  3. Monitor the distribution of product to the correct storage area and level of product in that area, and redirect as required
Monitor and perform necessary adjustments to discharge rate and temperature as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor the distribution transport system for efficiency and spillages and take appropriate action as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor the distribution of product to the correct storage area and level of product in that area, and redirect as required

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. Follow through items initiated until final resolution has occurred
  6. 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:

 

 

 

 

 

 

 

Follow through items initiated until final resolution has occurred

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Report problems outside area of responsibility to designated person

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down equipment

  1. Ensure line is clear of all product and left ready for startup
  2. Shut down equipment in accordance with procedures
  3. Complete appropriate records and logs
  4. Shut down equipment in an emergency situation
Ensure line is clear of all product and left ready for startup

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down equipment in accordance with procedures

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 procedures
  2. Remove any broken materials safely
  3. Ensure area is clear and safe for maintenance
Isolate equipment in accordance with procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Remove any broken materials safely

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure area is clear and safe for maintenance

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Control hazards

  1. Identify hazards in kiln work area
  2. Assess the risks arising from those hazards
  3. Implement measures to control those risks in line with procedures and duty of care
Identify hazards in kiln 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 and duty of care

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 process 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:

temperatures are maintained within limits

quality is monitored to minimise wastage

process measurements are continually made or observed.

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.

Individual enterprises may choose to add prerequisites and co-requisites relevant to their processes.

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 variance from specifications and standard operating procedures and determining an appropriate action that is consistent with operating guidelines

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 process

reading and numeracy to interpret workplace documents and technical information

Required knowledge

Required knowledge includes:

operation procedures of the kiln and kiln system

kiln chemistry, chemistry and physics of cement/lime making processes (as appropriate)

isolation procedures

operational processes and functions, including startup and shutdown processes

composition and nature of raw materials and finished product

construction and limitations of the equipment

out of specification situations

material feed, cooling and distribution systems

distinguish between causes of faults such as:

equipment fault

variations in raw materials

variations in feed rates and preparation

kiln quality and optimisation practices

types of kiln fuels and reactions

acceptable ranges of variations

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

Equipment and operations

Equipment and operations may include:

instrument panels (local)

measuring and recording equipment

communication equipment

hand tools

emergency stop buttons and lanyards

personal protective equipment

grinding mills

pneumatic conveying systems

slurry pumps

dust collectors

mixing and blending silos

vibrating screens

kilns

bulk storage silos

heat recovery systems

Typical problems

Typical problems may include:

equipment malfunctions

temperature fluctuations

quality of product

material/feed variations

spillages and leakages

inaccuracies in blending and proportioning of raw materials

out of specification moisture content of raw materials/slurry

variations in temperature, time and cooling rates

variations in feed rates or quantities

vibration

Occupational health and safety (OHS)

The identification and control of hazards and the application of OHS are to be in accordance with current, applicable legislation and regulations, and company procedures. All work is carried out at all times in accordance with these requirements