Elements and Performance Criteria

This competency unit includes equipment applicable to forming glass in each of the specific areas of glass products manufacture -
flat glass
insulation, glass wool insulation, laminated blankets, roll and boards
fibreglass, glass filaments
packaging, bottles and jars.

This competency includes tools and equipment such as :
forming and associated equipment such as -
bushings
finshields
applicators
shoe and winder assemblies
spinners
lapping equipment
process water
lehr
furnace
bath
fiberisers
computers
measuring and recording equipment
communication equipment
hand tools
safety clothing and equipment.
The process includes setting up, monitoring and tuning equipment for optimum performance especially during start up, job change and equipment changes.

Typical problems include:
raw materials supply
equipment alignment
analysis of all plant data
control of temperature within specification
product quality
equipment speed
taking corrective action.

Plant data includes:
test results
instrument/control panel information
data from physical senses (sight, sound, hearing, etc)
temperatures, pressures, material flow and discharge rates and effects
variations to chemical reactions/material modifications.
All operations are performed in accordance with standard procedures and work instructions.

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.

Assessment context and methods
Assessment for this unit of competency will be on an operating plant. 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. Assessment will occur over a range of situations which will include disruptions to normal, smooth operation.
Simulation or case study/scenarios may be required to allow for timely assessment of parts of this competency unit (eg, element 5 referring to responding to routine and non-routine problems occurring during operation). Simulation should be based on the actual plant and will include 'walk-throughs' of the relevant competency components. Simulations may also include the use of case studies/scenarios and role plays.

Critical aspects
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 rather than on recovery from a disaster.

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

set up/tuning is completed to specifications
temperature and pressures are maintained within limits
adjustments made are completed in a timely manner in accordance with procedures/work instructions
quality is monitored to minimise wastage
start up and shut down 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 competency unit. These aspects may be best assessed using a range of scenarios/case studies/what ifs as the stimulus, with a walk-through forming part of the response. The assessment activities should include a range of problems which may have been generated from the past incident history of the plant, incidents on similar plants around the world, hazard analysis activities and similar sources.

Resource implications
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. A bank of scenarios/case studies/what ifs will be required as will a bank of questions which will be used to probe the reasoning behind the observable actions.

Other assessment advice
In all plants it may be appropriate to assess this unit concurrently with relevant teamwork and communication units.

Essential knowledge
Knowledge and understanding of the process sufficient to recognise process conditions that will lead to out of specification production.
Knowledge of the enterprise's standard procedures and work instructions and relevant regulatory requirements along with the ability to implement them in a manner relevant to the operation of the process.

Competence includes the ability to:


apply and/or explain:

composition and nature of the glass
set up and tuning of all equipment
start up and shut down processes
optimisation of process for yield maximisation
energy utilisation
importance of atmospheric conditions and effect on process
construction and limitations of the equipment
out of specification situations
quality problems

distinguish between causes of problems, such as:

raw material
mechanical
electrical/instrument
atmospheric
as is relevant to the set up and tuning of a process.

Communicating ideas and information
(2)

Collecting analysing and organising information
(2)

Planning and organising activities
(2)

Working with others and in teams
(2)

Using mathematical ideas and techniques
(1)

Solving problems
(2)

Using technology
(2)