Unit of Competency Mapping – Information for Teachers/Assessors – Information for Learners

FBPBPG3008 Mapping and Delivery Guide
Operate an automated carton packing process

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency FBPBPG3008 - Operate an automated carton packing process
Description
Employability Skills
Learning Outcomes and Application This unit of competency describes the skills and knowledge required to set up, operate and shut down an automated carton packing process using a range of complex equipment, including a case packing machine, divider inserter, case sealer, conveyers and other quality control equipment. The unit applies to individuals who work under broad direction in a packaging environment and are responsible for operating and monitoring a carton packing process, including safety compliance, production changeovers, consumables, cleaning and solving problems that arise with the process. Operators are responsible for solving problems that arise with machinery and reporting unresolved problems to technical specialists. All work must be carried out to comply with workplace procedures, according to state/territory health and safety and food safety regulations, legislation and standards that apply to the workplace.No licensing, legislative or certification requirements are known to apply to this unit at the time of publication.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.

Assessment of the skills in this unit of competency must take place under the following conditions:

physical conditions:

an industrial carton packaging plant

resources, equipment and materials:

the equipment stipulated in the performance evidence

packaging cartons and inserts

the containers to be packaged stipulated in the performance evidence

packaging consumables, including glue and ink

specifications:

two packing work orders stipulated in the performance evidence

workplace procedures for an automatic packing process and the machinery and equipment stipulated in the performance evidence

relationships:

supervisor and others stipulated in the performance evidence.

Assessors of this unit must satisfy the requirements for assessors in applicable vocational education and training legislation, frameworks and/or standards.
Prerequisites/co-requisites
Competency Field
Development and validation strategy and guide for assessors and learners Student Learning Resources Handouts
Activities 		Slides
PPT 		Assessment 1 Assessment 2 Assessment 3 Assessment 4
Elements of Competency Performance Criteria              
Element: Operate and monitor the carton packing process
  • Carry out test run and adjust as required to meet packing specifications
  • Ensure supply of consumables for packaging process
  • Carry out quality checks on sample cartons and complete records according to workplace requirements
  • Apply problem-solving principles and techniques to identify and rectify machine faults according to workplace procedures
  • Clean up spillages and breakages according to workplace procedures
  • Ensure quantity, process efficiency and quality specifications are met
  • Report major process problems and products that do not meet specifications
  • Handover carton packing process to another team member when required
       
Element: Change over packing run
  • Prepare equipment and consumables for upcoming product change
  • Check and record product counters to ensure an accurate changeover
  • Coordinate team members to assist with changeover
  • Apply isolation measures according to workplace requirements
  • Empty machine of product and complete required changeover, and confirm parts, sensors, rails and stoppers have been adjusted and set
  • Complete end-of-run carton packing records and reports
  • Remove and store unused consumables and equipment parts not required after changeover
  • Conduct test run and make adjustments as required
       
Element: Shut down the carton packing process
  • Empty machinery and equipment of packaged products
  • Shut down machinery according to workplace procedures
  • Remove and store unused packing materials
  • Complete carton packing records and reports
  • Clean and maintain packing machinery and equipment
  • Dispose of waste according to workplace and environmental procedures
  • Report issues requiring maintenance by technicians
       


Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

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 set up, operated, and shut down two automated packing processes for different work orders. Each process must use a conveyor fed automatic case packing machine packing at least 12,000 containers per hour, and include at least two of the following:

divider inserter

case sealer

check weigher or other quality inspection device

conveyer controls.

The processes must package at least two of the following carton types:

4-pack

6-pack

12-pack

18-pack

24-pack

30-pack.

For each process, the individual must have safely and efficiently performed the following:

identified, rectified and/or reported machinery faults, including:

defective tulip heads

carton divider problems

glue application system problems

reset machinery that is creating products that do not meet specifications

accurately and effectively handed over a packing process to another team member

communicated effectively with a supervisor and at least one of the following:

maintenance team member

laboratory or quality assurance team member

bottling and packaging team member

logistics team member

accurately completed workplace production records.

The individual must also complete a packing run changeover that requires a complete machine changeover, including the picking head and centring frame, according to workplace safety and 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:

product knowledge related to the containers to be packaged as stipulated in the performance evidence, including:

size, weight and volume

client or receiver requirements or specifications

operating principles of machinery and equipment, including:

conveyor fed automatic case packing machine capable of packing at least 12,000 containers per hour

divider inserter

case sealer

check weigher

conveyer controls

features and functions of machinery and equipment, including:

manufacturer and workplace instructions for safe operation

control panels and ancillary controls

operating capacities, efficiencies and applications

location and purpose of guards, rails and sensors

feedback instrumentation

services required, including compressed air, electricity and water

cleaning and maintenance requirements

machinery and equipment checks, including:

pre-start checks, including emergency stop checks

lock-out and tag-out procedures, including return to service after isolation

the interrelationships between the bottling, carton packing and palletising

product and process changeover procedures and responsibilities

quality control requirements, processes and actions, including:

packing order specifications

requirements of containers, variation in containers and the packing process

methods used to check quality

common causes of carton packing quality issues and corrective action required, including removal of out-of-specification containers and cartons

planned sampling and testing associated with process monitoring and control

responding to machinery alerts and notifications

recording of results

isolating samples for testing

product identification and traceability requirements, including:

client or receiver requirements or specifications

carton coding

health and safety hazards and controls, including awareness of the limitations of personal protective clothing and equipment relevant to the work process

procedures and responsibility for reporting production and performance information

environmental issues and controls relevant to the carton packing process, including:

rework and reuse of products

waste processing

manual handling procedures related to the packing process.

Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assignment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)

Assessment Tasks

Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.
Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.

Observation Checklist

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Carry out test run and adjust as required to meet packing specifications 
Ensure supply of consumables for packaging process 
Carry out quality checks on sample cartons and complete records according to workplace requirements 
Apply problem-solving principles and techniques to identify and rectify machine faults according to workplace procedures 
Clean up spillages and breakages according to workplace procedures 
Ensure quantity, process efficiency and quality specifications are met 
Report major process problems and products that do not meet specifications 
Handover carton packing process to another team member when required 
Prepare equipment and consumables for upcoming product change 
Check and record product counters to ensure an accurate changeover 
Coordinate team members to assist with changeover 
Apply isolation measures according to workplace requirements 
Empty machine of product and complete required changeover, and confirm parts, sensors, rails and stoppers have been adjusted and set 
Complete end-of-run carton packing records and reports 
Remove and store unused consumables and equipment parts not required after changeover 
Conduct test run and make adjustments as required 
Empty machinery and equipment of packaged products 
Shut down machinery according to workplace procedures 
Remove and store unused packing materials 
Complete carton packing records and reports 
Clean and maintain packing machinery and equipment 
Dispose of waste according to workplace and environmental procedures 
Report issues requiring maintenance by technicians 

Forms

Assessment Cover Sheet

FBPBPG3008 - Operate an automated carton packing process
Assessment task 1: [title]

Student name:

Student ID:

I declare that the assessment tasks submitted for this unit are my own work.

Student signature:

Result: Competent Not yet competent

Feedback to student

 

 

 

 

 

 

 

 

Assessor name:

Signature:

Date:

Assessment Record Sheet

FBPBPG3008 - Operate an automated carton packing process

Student name:

Student ID:

Assessment task 1: [title] Result: Competent Not yet competent

(add lines for each task)

Feedback to student:

 

 

 

 

 

 

 

 

Overall assessment result: Competent Not yet competent

Assessor name:

Signature:

Date:

Student signature:

Date: