An individual demonstrating competency must satisfy all of the elements and performance criteria in this unit.
There must be evidence that the individual has independently coordinated the safe and efficient set-up, operation, handover and shutdown of two packaging runs for two different products over two separate shifts. Each shift is to be at least three hours, have its own work order, and include:
at least four of the following processes and related equipment:
de-palletising
filling
carton erecting
carton packing
palletising
labelling
coding.
For each shift, the individual must have:
ensured sufficient supply of consumables to complete the packaging run
ensured finished product meets required specifications
coordinated at least four packaging operations workers, including scheduling start and finish times, meal and rest breaks
communicated with filling and packaging team members, and at least two of the following:
maintenance team member
laboratory or quality assurance team member
logistics team member
supervisor
addressed quality issues and anomalies caused by equipment failure and operator error
addressed team members’ health and safety requirements, including:
correct fit and use of personal protective equipment
correct use of machinery guards, including lock-out and isolation
compliance with vehicle and pedestrian traffic control
monitored timely and accurate completion of workplace records, including:
packaging notes
productivity reports
machinery and equipment logs
workplace safety reports
effectively coordinated the changeover of two packaging runs according to workplace time requirements.
An individual must be able to demonstrate the knowledge required to perform the tasks outlined in the elements and performance criteria of this unit. This includes knowledge of:
packaging work orders and production schedules
operating principles of machinery and equipment, including:
de-palletiser
bottle or other container fillers
carton erecter
carton packer
palletiser
delivery tanks
labeller
coder
inert gas related equipment, including bulk and small cylinders, regulators, valves and pipes
features and functions of machinery and equipment, including:
manufacturer and workplace instructions for safe operation
control panels and ancillary controls, including manual operations mode
operating capacities, efficiencies and applications
congestion points and other limiting factors
location and purpose of guards, rails and sensors
knowledge of maintenance required and action to take if maintenance services are not available
cleaning requirements
routine and non-routine machine and equipment faults, and process for rectification
services, including electricity, water, compressed air and inert gases
vessel cooling and heating systems and equipment
machinery and equipment checks, including:
pre-start checks, including emergency stop checks
lock-out and tag-out
return to service after isolation
consumables, including:
bottles
bottle closures
pallet dividers
cartons
carton dividers
glue
labels
pallets
water
inert gases, including nitrogen and carbon dioxide
cleaning products
typical problems related to consumables, including label glue bleed, label roll tension, packaging colour variations, carton folds and die cuts, damaged bottles and dirty bottles
staff welfare, including:
working conditions, including temperature, vibration, noise and dust
rostering, breaks, rest and fatigue management
product and process quality indicators, including:
alcohol
temperature
oxidation
packaging quality control requirements, processes and actions, including:
product specifications
methods used to check quality
common causes of packaging process quality issues and corrective action required
planned sampling and testing associated with process monitoring and control
responding to machinery alerts and notifications
recording of results
records and reporting requirements, including:
quality
productivity
handover
health and safety
process information, including wine tracking
product knowledge related to the product being packaged, including:
wine variety
volume
client or receiver requirements or specifications
food safety regulatory requirements
the interrelationships between packaging processes and cellar operations processes
product/process changeover procedures and responsibilities
product identification and traceability requirements, including:
workplace requirements
client or receiver requirements or specifications
work health and safety hazards and controls, including:
awareness of the limitations of controls
personal protective equipment
hazardous substances, including cleaning products and gases
procedures and responsibility for reporting production and performance information
environmental issues and controls relevant to the process, including:
rework and reuse of products
water use and recycling
waste processing
materials and manual handling procedures related to packaging processes.