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Evidence Guide: PMC553040 - Set up and optimise glass forming 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

 

PMC553040 - Set up and optimise glass forming process

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

Prepare for equipment installation

  1. Determine the product to be manufactured
  2. Ensure that the equipment change parts, ancillaries and fixtures are available as required
  3. Perform pre-instalment equipment preparation according to procedures
  4. Ensure that the equipment is in a safe condition for use
Determine the product to be manufactured

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure that the equipment is in a safe condition for use

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Remove current equipment and/or tooling

  1. Identify and implement all safety and emergency procedures
  2. Shut down equipment in accordance with procedures
  3. Isolate equipment in accordance with procedures
  4. Remove ancillary equipment in accordance with procedures
  5. Complete records and logs for removal of current equipment
Identify and implement all safety and emergency procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down equipment in accordance with procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Isolate equipment in accordance with procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Remove ancillary equipment in accordance with procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete records and logs for removal of current equipment

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Install and set up new equipment and/or tooling

  1. Perform required checks and tests prior to installation
  2. Identify any faults in equipment/tooling and take appropriate action
  3. Install and set up appropriate ancillary equipment in accordance with procedures
  4. Set up equipment/tooling as required
  5. Monitor and adjust until production is as required
Perform required checks and tests prior to installation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify any faults in equipment/tooling and take appropriate action

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Install and set up appropriate ancillary equipment in accordance with procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set up equipment/tooling as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor and adjust until production is as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor, interpret data and adjust operation

  1. Monitor process data
  2. Ensure forming equipment start-up function complies with work instructions
  3. Operate glass forming equipment in accordance with procedures
  4. Monitor plant and process and deduce conditions of materials in process and products being made
  5. Take appropriate action to improve process operation
  6. Check that process operation has improved
  7. Monitor and adjust until production is as required
Monitor process data

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure forming equipment start-up function complies with work instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Operate glass forming equipment in accordance with procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Take appropriate action to improve process operation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check that process operation has improved

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor and adjust until production is as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Sample, test and record product data

  1. Sample as required by the product and in line with enterprise requirements
  2. Complete appropriate test to enterprise and client requirements
  3. Identify variations from process parameters and take appropriate action
  4. Measure/graph and record operating parameters, according to enterprise requirements
  5. Record test results as required by procedures
Sample as required by the product and in line with enterprise requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete appropriate test to enterprise and client requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify variations from process parameters and take appropriate action

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Measure/graph and record operating parameters, according to enterprise requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Record test results as required by procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Rectify equipment and quality problems

  1. Identify the range of equipment and quality faults that can occur during the operation
  2. Diagnose possible causes of equipment and quality faults
  3. Rectify cause of equipment failure and quality faults by established enterprise procedures
  4. Identify and rectify equipment failure causes in accordance with established enterprise procedures
  5. Ensure appropriate records and logs of equipment operations are maintained to meet enterprise requirements
  6. Identify non-routine problems and report to designated person
Identify the range of equipment and quality faults that can occur during the operation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Diagnose possible causes of equipment and quality faults

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Rectify cause of equipment failure and quality faults by established enterprise procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure appropriate records and logs 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:

 

 

 

 

 

 

 

Shut down equipment

  1. Shut down equipment in accordance with procedures
  2. Complete appropriate records and logs
  3. Shut down equipment in an emergency situation
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 work instructions
  2. Make sure area is clear and safe for maintenance
  3. Complete all records and logs
Isolate equipment in accordance with work instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Make sure area is clear and safe for maintenance

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete all records and logs

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 installation

1.1

Determine the product to be manufactured

1.2

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

1.3

Perform pre-instalment equipment preparation according to procedures

1.4

Ensure that the equipment is in a safe condition for use

2

Remove current equipment and/or tooling

2.1

Identify and implement all safety and emergency procedures

2.2

Shut down equipment in accordance with procedures

2.3

Isolate equipment in accordance with procedures

2.4

Remove ancillary equipment in accordance with procedures

2.5

Complete records and logs for removal of current equipment

3

Install and set up new equipment and/or tooling

3.1

Perform required checks and tests prior to installation

3.2

Identify any faults in equipment/tooling and take appropriate action

3.3

Install and set up appropriate ancillary equipment in accordance with procedures

3.4

Set up equipment/tooling as required

3.5

Monitor and adjust until production is as required

4

Monitor, interpret data and adjust operation

4.1

Monitor process data

4.2

Ensure forming equipment start-up function complies with work instructions

4.3

Operate glass forming equipment in accordance with procedures

4.4

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

4.5

Take appropriate action to improve process operation

4.6

Check that process operation has improved

4.7

Monitor and adjust until production is as required

4.8

4.9

4.10

5

Sample, test and record product data

5.1

Sample as required by the product and in line with enterprise requirements

5.2

Complete appropriate test to enterprise and client requirements

5.3

Identify variations from process parameters and take appropriate action

5.4

Measure/graph and record operating parameters, according to enterprise requirements

5.5

Record test results as required by procedures

6

Rectify equipment and quality problems

6.1

Identify the range of equipment and quality faults that can occur during the operation

6.2

Diagnose possible causes of equipment and quality faults

6.3

Rectify cause of equipment failure and quality faults by established enterprise procedures

6.4

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

6.5

Ensure appropriate records and logs of equipment operations are maintained to meet enterprise requirements

6.6

Identify non-routine problems and report to designated person

7

Shut down equipment

7.1

Shut down equipment in accordance with procedures

7.2

Complete appropriate records and logs

7.3

Shut down equipment in an emergency situation

8

Prepare equipment for maintenance

8.1

Isolate equipment in accordance with work instructions

8.2

Make sure area is clear and safe for maintenance

8.3

Complete all records and logs

9

Control hazards

9.1

Identify hazards from the job to be done

9.2

Identify other hazards in the work area

9.3

Assess the risks arising from those hazards

9.4

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 installation

1.1

Determine the product to be manufactured

1.2

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

1.3

Perform pre-instalment equipment preparation according to procedures

1.4

Ensure that the equipment is in a safe condition for use

2

Remove current equipment and/or tooling

2.1

Identify and implement all safety and emergency procedures

2.2

Shut down equipment in accordance with procedures

2.3

Isolate equipment in accordance with procedures

2.4

Remove ancillary equipment in accordance with procedures

2.5

Complete records and logs for removal of current equipment

3

Install and set up new equipment and/or tooling

3.1

Perform required checks and tests prior to installation

3.2

Identify any faults in equipment/tooling and take appropriate action

3.3

Install and set up appropriate ancillary equipment in accordance with procedures

3.4

Set up equipment/tooling as required

3.5

Monitor and adjust until production is as required

4

Monitor, interpret data and adjust operation

4.1

Monitor process data

4.2

Ensure forming equipment start-up function complies with work instructions

4.3

Operate glass forming equipment in accordance with procedures

4.4

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

4.5

Take appropriate action to improve process operation

4.6

Check that process operation has improved

4.7

Monitor and adjust until production is as required

4.8

4.9

4.10

5

Sample, test and record product data

5.1

Sample as required by the product and in line with enterprise requirements

5.2

Complete appropriate test to enterprise and client requirements

5.3

Identify variations from process parameters and take appropriate action

5.4

Measure/graph and record operating parameters, according to enterprise requirements

5.5

Record test results as required by procedures

6

Rectify equipment and quality problems

6.1

Identify the range of equipment and quality faults that can occur during the operation

6.2

Diagnose possible causes of equipment and quality faults

6.3

Rectify cause of equipment failure and quality faults by established enterprise procedures

6.4

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

6.5

Ensure appropriate records and logs of equipment operations are maintained to meet enterprise requirements

6.6

Identify non-routine problems and report to designated person

7

Shut down equipment

7.1

Shut down equipment in accordance with procedures

7.2

Complete appropriate records and logs

7.3

Shut down equipment in an emergency situation

8

Prepare equipment for maintenance

8.1

Isolate equipment in accordance with work instructions

8.2

Make sure area is clear and safe for maintenance

8.3

Complete all records and logs

9

Control hazards

9.1

Identify hazards from the job to be done

9.2

Identify other hazards in the work area

9.3

Assess the risks arising from those hazards

9.4

Implement measures to control those risks in line with procedures

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:

read and interpret procedures, job specifications, production schedules, test results, instruments/control panels, material labels and safety data sheets (SDS)

install and set up equipment to process specifications

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

monitor key variables, including:

installation and performance of equipment/tooling

process parameters

yield

energy utilisation

variations

fluctuations

trends

material properties/chemical reactions

product integrity and general conformance to specification

use tests, process 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

material variations/contamination

process abnormalities

procedural errors

atmospheric conditions

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:

principles of glass forming process

functions, limitations and principles of operation of glass forming and ancillary equipment being used

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

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

physics and chemistry relevant to the equipment/process/materials

importance of atmospheric conditions and effect on process

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

standard operating procedures (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:

raw materials supply

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.

Tools and equipment

Tools and equipment include:

glass forming equipment as used to make one or more of:

flat glass

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

fibreglass or glass filaments

packaging, bottles or jars

ancillary equipment that is integral to the process

measuring and recording equipment.