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Evidence Guide: PMC553041C - 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

 

PMC553041C - 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's 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's 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's 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's 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 setup and configuration of equipment for startup 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 setup and configuration of equipment for startup 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

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 equipment 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. The emphasis should be on the ability to stay out of trouble than on recovery from a disaster.

Consistent performance should be demonstrated. In particular look to see that:

setup/tuning are completed to specifications

temperature and pressures are maintained within limits

quality is monitored to minimise wastage

startup and shutdown occur first time

early warning signs of equipment/processes needing attention or potential problems are recognised and dealt with in a timely manner

process measurements are continually made or observed

the range of possible causes can be identified and the most likely cause determined

appropriate action is taken to ensure a timely return to full performance

obvious problems to related plant areas are recognised and an appropriate contribution made to their solution.

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.

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 process conditions which will lead to out of specification production

implementing the enterprise's standard procedures and work instructions and relevant regulatory requirements 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:

composition and nature of the glass

setup/changeover of all equipment/tooling

startup and shutdown processes

optimisation of process for yield maximisation

construction and limitations of the equipment

out of specification situations

quality problems such as:

poor optics

excessive breakage

non-uniform break pattern

incorrect cross bend

excessive bow

scratches

poor glass shape

distinguish between causes of problems, such as:

raw material

mechanical

electrical/instrument

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

Application of equipment

This unit includes equipment applicable to formed glass manufacture, such as:

equipment/tooling which may include:

mould

lift jet array

quench ring

press ring

tile

other production equipment:

forming and conditioning equipment

computers

measuring recording equipment

communication equipment

hand tools

Types of changeovers

Types of changeovers may include:

deep bend to deep bend or deep bend to quick sag

quick sag to quick sag

advanced press bend to advanced or conventional press bend

conventional press bend to conventional press bend

It does NOT include processes involved with:

melting furnaces used in glass production (primary source)

scientific glass

Typical problems

Typical problems may include:

temperature and pressure problems

equipment problems

quality problems

Occupational health and safety (OHS)

All operations are subject to stringent OHS requirements and these must not be compromised at any time. Where there is an apparent conflict between performance criteria and OHS requirements, the OHS requirements take precedence