Elements and Performance Criteria

This competency unit includes annealing/conditioning/reheating equipment applicable to each specific area of glass products manufacture:
packaging, bottles and jars
automotive glass
flat glass.

This competency includes tools and equipment such as :
reheating equipment and associated equipment
toughening equipment
mirror and laminating equipment
annealing and associated equipment
gas stations
computers
measuring and recording equipment
communication equipment
hand tools
safety clothing and equipment.
This competency includes the operation of all ancillary equipment and the operation of plant using PLCs where appropriate.

It does NOT include processes involved with :
melting furnaces used in glass production
forming of glass products directly from a melting furnace.

Typical problems include :
temperature and pressure problems
equipment problems
quality problems.
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 studies/scenarios may be required to allow for timely assessment of parts of this competency unit (eg, element 4 referring to the identification of a range of faults 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 reheating equipment be understood and that the importance of critical material properties, settings, parameters 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:

temperatures and stress parameters are maintained within limits
equipment set up is completed in accordance with work instructions including identification of isolation points, correct isolation of equipment and correct entering of new parameters
start up and shut down occurs first time
signals and alarms are responded to immediately
process measurements are continually made, observed and interpreted
quality is maintained to customer specifications.
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 responding to a range of problems.

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.

It may be appropriate to assess this unit concurrently with:

PMCSUP292A Sample and test materials and product.

Essential knowledge
Knowledge and understanding of the reheating process sufficient to recognise process conditions which will lead to out of specification production and to take appropriate action.
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 reheating equipment.

Competence includes the ability to:


apply and/or explain:

composition and nature of the glass
start up and shut down processes
construction and limitations of reheating equipment and conditions
out of specification situations
annealing/toughening/conditioning/mirror/laminating/reheating process set up, including identification of isolation points and entering new parameters into PLC
temperature and temporary and permanent stress
annealing and post-annealing processes
toughening and post-toughening processes
quality problems such as poor optics, excessive breakage, non-uniform break pattern, incorrect cross bend, excessive bow, scratches and poor glass shape
distinguish between causes of faults such as -
raw material
mechanical
electrical/instrument
as is relevant to the practical operation of the melting process.

Communicating ideas and information
(1)

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
(1)

Using technology
(2)