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Evidence Guide: PMC553041 - Set up and optimise glass furnace 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

 

PMC553041 - Set up and optimise glass furnace process

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

Remove current equipment and/or tooling

  1. Identify all safety and emergency procedures
  2. Shut down furnace and ancillary equipment in accordance with work instructions and manufacturer specifications
  3. Conduct tests and checks on equipment/tooling prior to removal in accordance with work instructions
  4. Remove current equipment/tooling in accordance with work instructions and manufacturer specifications
  5. Complete records and logs for removal
Identify all safety and emergency procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down furnace and ancillary equipment in accordance with work instructions and manufacturer specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Conduct tests and checks on equipment/tooling prior to removal in accordance with work instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Remove current equipment/tooling in accordance with work instructions and manufacturer specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete records and logs for removal

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Install and set up new equipment and/or tooling

  1. Perform checks and tests prior to installation
  2. Identify any faults in equipment/tooling and take appropriate action
  3. Install and set up appropriate equipment/tooling for new production process in accordance with work instructions
  4. Ensure alignment of all equipment and perform checks according to product specifications and work instructions
  5. Ensure set-up and configuration of equipment for start-up complies with work instructions
  6. Perform checks and tests to product and equipment in accordance with work instructions
Perform 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 equipment/tooling for new production process in accordance with work instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure alignment of all equipment and perform checks according to product specifications and work instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure set-up and configuration of equipment for start-up complies with work instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Perform checks and tests to product and equipment in accordance with work instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor, interpret data and adjust operation

  1. Ensure forming equipment start-up function complies with work instructions
  2. Ensure glass forming equipment is operated in accordance with work instructions
  3. Monitor instruments and control panels, and interpret test results for fluctuations, variations and trends
  4. Monitor plant and process and deduce conditions of materials in process and products being made
  5. Determine appropriate action to improve process operation
  6. Adjust furnace controls to ensure glass parameters are maintained to job specifications
  7. Check that process operation has improved
  8. Continue analysing data and making adjustments until desired level of process operation is achieved and product is within specifications in accordance with work instructions
Ensure forming equipment start-up function complies with work instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure glass forming equipment is operated in accordance with work instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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 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:

 

 

 

 

 

 

 

Sample, test and record product data

  1. Carry out sampling procedures appropriate to the product and the test 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 in hard or electronic form as required by standard procedures and work instructions
Carry out sampling procedures appropriate to the product and the test 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 in hard or electronic form as required by standard procedures and work instructions

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 log books 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 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:

 

 

 

 

 

 

 

Shut down equipment

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure 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

Remove current equipment and/or tooling

1.1

Identify all safety and emergency procedures

1.2

Shut down furnace and ancillary equipment in accordance with work instructions and manufacturer specifications

1.3

Conduct tests and checks on equipment/tooling prior to removal in accordance with work instructions

1.4

Remove current equipment/tooling in accordance with work instructions and manufacturer specifications

1.5

Complete records and logs for removal

2

Install and set up new equipment and/or tooling

2.1

Perform checks and tests prior to installation

2.2

Identify any faults in equipment/tooling and take appropriate action

2.3

Install and set up appropriate equipment/tooling for new production process in accordance with work instructions

2.4

Ensure alignment of all equipment and perform checks according to product specifications and work instructions

2.5

Ensure set-up and configuration of equipment for start-up complies with work instructions

2.6

Perform checks and tests to product and equipment in accordance with work instructions

3

Monitor, interpret data and adjust operation

3.1

Ensure forming equipment start-up function complies with work instructions

3.2

Ensure glass forming equipment is operated in accordance with work instructions

3.3

Monitor instruments and control panels, and interpret test results for fluctuations, variations and trends

3.4

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

3.5

Determine appropriate action to improve process operation

3.6

Adjust furnace controls to ensure glass parameters are maintained to job specifications

3.7

Check that process operation has improved

3.8

Continue analysing data and making adjustments until desired level of process operation is achieved and product is within specifications in accordance with work instructions

4

Sample, test and record product data

4.1

Carry out sampling procedures appropriate to the product and the test in line with enterprise requirements

4.2

Complete appropriate test to enterprise and client requirements

4.3

Identify variations from process parameters and take appropriate action

4.4

Measure/graph and record operating parameters according to enterprise requirements

4.5

Record test results in hard or electronic form as required by standard procedures and work instructions

5

Rectify equipment and quality problems

5.1

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

5.2

Diagnose possible causes of equipment and quality faults

5.3

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

5.4

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

5.5

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

5.6

Identify non-routine problems and report to designated person

6

Shut down equipment

6.1

Shut down equipment in accordance with work instructions

6.2

Complete appropriate records and logs

6.3

Shut down equipment in an emergency situation

7

Prepare equipment for maintenance

7.1

Isolate equipment in accordance with work instructions

7.2

Ensure area is clear and safe for maintenance

7.3

Complete all records and logs

8

Control hazards

8.1

Identify hazards from the job to be done

8.2

Identify other hazards in the work area

8.3

Assess the risks arising from those hazards

8.4

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

Remove current equipment and/or tooling

1.1

Identify all safety and emergency procedures

1.2

Shut down furnace and ancillary equipment in accordance with work instructions and manufacturer specifications

1.3

Conduct tests and checks on equipment/tooling prior to removal in accordance with work instructions

1.4

Remove current equipment/tooling in accordance with work instructions and manufacturer specifications

1.5

Complete records and logs for removal

2

Install and set up new equipment and/or tooling

2.1

Perform checks and tests prior to installation

2.2

Identify any faults in equipment/tooling and take appropriate action

2.3

Install and set up appropriate equipment/tooling for new production process in accordance with work instructions

2.4

Ensure alignment of all equipment and perform checks according to product specifications and work instructions

2.5

Ensure set-up and configuration of equipment for start-up complies with work instructions

2.6

Perform checks and tests to product and equipment in accordance with work instructions

3

Monitor, interpret data and adjust operation

3.1

Ensure forming equipment start-up function complies with work instructions

3.2

Ensure glass forming equipment is operated in accordance with work instructions

3.3

Monitor instruments and control panels, and interpret test results for fluctuations, variations and trends

3.4

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

3.5

Determine appropriate action to improve process operation

3.6

Adjust furnace controls to ensure glass parameters are maintained to job specifications

3.7

Check that process operation has improved

3.8

Continue analysing data and making adjustments until desired level of process operation is achieved and product is within specifications in accordance with work instructions

4

Sample, test and record product data

4.1

Carry out sampling procedures appropriate to the product and the test in line with enterprise requirements

4.2

Complete appropriate test to enterprise and client requirements

4.3

Identify variations from process parameters and take appropriate action

4.4

Measure/graph and record operating parameters according to enterprise requirements

4.5

Record test results in hard or electronic form as required by standard procedures and work instructions

5

Rectify equipment and quality problems

5.1

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

5.2

Diagnose possible causes of equipment and quality faults

5.3

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

5.4

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

5.5

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

5.6

Identify non-routine problems and report to designated person

6

Shut down equipment

6.1

Shut down equipment in accordance with work instructions

6.2

Complete appropriate records and logs

6.3

Shut down equipment in an emergency situation

7

Prepare equipment for maintenance

7.1

Isolate equipment in accordance with work instructions

7.2

Ensure area is clear and safe for maintenance

7.3

Complete all records and logs

8

Control hazards

8.1

Identify hazards from the job to be done

8.2

Identify other hazards in the work area

8.3

Assess the risks arising from those hazards

8.4

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 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:

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

raw material variations/contamination

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 glass making furnaces

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

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:

temperature and pressure problems

equipment problems

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 making furnace

ancillary equipment that is integral to the process

programmable logic controllers (PLC), if fitted

measuring and recording equipment.