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Elements and Performance Criteria

  1. Prepare the melting equipment
  2. Test furnace back-up equipment
  3. Melt raw materials
  4. Monitor and interpret data and adjust operation
  5. Rectify problems
  6. Control hazards

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.


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:

job cards

emergency procedures

work instructions


safe work method statements (SWMS)


batch sheets

temporary instructions

any similar instructions provided for the smooth running of the plant.

Tools and equipment

Tools and equipment include:


measuring and recording equipment

ancillary equipment that is integral to the process.


Routine problems must be resolved by applying known solutions.

Routine problems are predictable and include one or more of:

raw materials feed

change of fuel source

variations in furnace temperature

variations in melt quality.

Known solutions are drawn from one or more of:



remembered experience.

Non-routine problems must be reported according to according to relevant procedures.


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

high temperatures

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



gases and liquids under pressure


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.

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.

Performance Evidence

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, job sheets, procedures, instruments/control panels, test results, material labels and safety information

perform pre-start procedures

conduct back-up equipment test procedures to schedule

analyse test results and control instrument data to identify fluctuations, variations and trends in process variables

monitor key variables, including:


material flow and discharge rates

fuel source

melt quality

product integrity and general conformance to specification

operate and adjust the equipment to meet product quality and production output specifications

identify hazards and apply relevant hazard controls

apply safety procedures

apply housekeeping procedures

recognise out-of-specification products, process problems and materials faults

recognise routine and non-routine problems

identify when the operator is able to rectify problems, when assistance is required and who is the appropriate source for assistance

take action to resolve problems or report them to appropriate personnel

distinguish between possible causes of routine problems, including:

raw material variations

equipment malfunctions

electrical/instrument malfunctions

process abnormalities

communicate effectively with team/work group and supervisors

complete workplace records

do basic arithmetical manipulations, including additions, subtractions, divisions, fractions and percentages.

Knowledge Evidence

Must provide evidence that demonstrates knowledge relevant to their job sufficient to operate under routine only supervision and to solve routine problems, including knowledge of:

principles of glass melting process

control philosophy of process

functions, limitations and principles of operation of melting equipment

composition and nature of the glass

critical material properties, settings and readings

combustion fundamentals

test procedures and schedule

basic physics, and where appropriate chemistry, relevant to the equipment/process/materials

the potential effects of variations in raw materials and equipment operation in relation to quality of product

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

start-up and shutdown processes

routine problems, their probable causes and relevant corrective 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.