Elements and Performance Criteria

Context
This competency unit includes equipment applicable to any production process in the manufactured mineral product area including -
clay and ceramics
concrete
concrete products
ceramic crucibles
cement
fibre cement
plasterboard
ground minerals.
This competency includes tools and equipment such as -
changeover parts and equipment
computers
measuring and recording equipment
communication equipment
hand tools
safety clothing and equipment.
The process includes setting up and tuning equipment for start up, job change and equipment changes in preparation for production.
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
as is applicable to individual plant.
Typical problems include -
raw materials feed
equipment alignment
analysis of all plant data including test results, control instrument data and other observations
control of temperature within specification
product quality
equipment speed
taking corrective action.
It does not include setting up and tuning processes covered by -
PMCOPS340B Set up and optimise glass forming process
PMCOPS341B Set up and optimise flat glass forming process
PMCOPS342B Set up and optimise cutting and stacking process.
All operations are performed in accordance with standard procedures and work instructions.

Essential knowledge and enterprise requirements
Knowledge and understanding of the process sufficient to recognise process conditions and situations 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 within appropriate time constraints and in a manner relevant to the operation of the process.

Competence includes the ability to:


apply and/or explain:

nature of the product
set up and tuning of all equipment
start up and shut down processes
construction and limitations of the equipment
out of specification situations
quality problems

distinguish between following causes of problems:

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

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.

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

set up/tuning are completed to specifications and within timeframe
temperature and pressures are maintained within limits
quality is monitored to minimise wastage
start up and shut down occurs first time
signals and alarms are responded to immediately
process measurements are continually made or observed
adjustments made are completed in a timely manner in accordance with work instructions.
Competence must be demonstrated in the operation of all ancillary equipment to the level required for this competency unit.

Concurrent assessment and prerequisite competencies
This unit may be assessed concurrently with other relevant units.

Assessment method, context and resource implications
Competence in this unit may be assessed by observation over time on an operating plant. Where this is done, the timeframe must allow for adequate assessment of operation under all normal and a range of abnormal conditions. Where this is not practical, additional assessment techniques must be used.
Competence may also be assessed by use of a suitable simulation and/or a range of case studies/scenarios. A combination of these techniques should be used to ensure the competency is adequately assessed.
In all cases it is expected that the practical assessment will be supported by targeted questioning to assess the underpinning knowledge. Questioning will be undertaken in such a manner as is appropriate to the language and literacy levels of the operator and reflecting the requirements of the competency.
Resources required include suitable access to an operating plant or equipment which allows for appropriate and realistic simulation. A bank of case studies/scenarios will also be required where these form part of the assessment method. Questioning may take place either in the workplace, or in an adjacent, quiet facility such as an office or lunch room. No other special resources are required.

Communicating ideas and information
(2)

Collecting analysing and organising information
(2)

Planning and organising activities
(2)

Working with others and in teams
(1)

Using mathematical ideas and techniques
(1)

Solving problems
(2)

Using technology
(2)