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

FDFGPS2009A Mapping and Delivery Guide
Operate a soap splitting process

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency FDFGPS2009A - Operate a soap splitting process
Description This unit of competency covers the skills and knowledge required to set up, operate, adjust and shut down a soap splitting process. This may also be referred to as an acid oil process. It covers the splitting of soap stock into an acid oil stream and an acid water stream.
Employability Skills This unit contains employability skills.
Learning Outcomes and Application This unit has application in an edible oils production environment. It typically targets the production worker responsible for applying basic operating principles to the operation and monitoring of a soap splitting process.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.
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: Prepare the equipment and soap splitting process for operation
  • Materials are confirmed and available to meet operating requirements
  • Machine components are adjusted to meet operating requirements
  • Processing/operating parameters are entered as required to meet safety and production requirements
  • Equipment performance is checked and adjusted as required
  • Pre-start checks are carried out as required by workplace requirements
       
Element: Operate and monitor the soap splitting process
  • The process is started and operated according to workplace procedures
  • Equipment is monitored to identify variation in operating conditions
  • Variation in equipment operation is identified and maintenance requirements are reported according to workplace reporting requirements
  • The process is monitored to confirm separation of acid oil and acid water streams
  • The work area is maintained according to housekeeping standards
  • Work is conducted in accordance with workplace environmental guidelines
  • Workplace records are maintained according to workplace recording requirements
       
Element: Shut down the soap splitting process
  • The appropriate shutdown procedure is identified
  • The process is shut down according to workplace procedures
  • Maintenance requirements are identified and reported according to workplace reporting requirements
       


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.

The Evidence Guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment

Assessment must be carried out in a manner that recognises the cultural and literacy requirements of the assessee and is appropriate to the work performed. Competence in this unit must be achieved in accordance with food safety standards and regulations.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Evidence of ability to:

conduct pre-start checks on machinery used for soap splitting

start, operate, monitor and adjust process equipment to achieve required quality outcomes

take corrective action in response to typical faults and inconsistencies

complete workplace records as required

apply safe work practices and identify OHS hazards and controls

safely shut down equipment

apply food safety procedures to work practices.

Context of and specific resources for assessment

Assessment must occur in a real or simulated workplace where the assessee has access to:

personal protective clothing and equipment

work procedures, including advice on safe work practices, food safety, quality and environmental requirements

information on equipment capacity and operating parameters

production schedule/batch instructions

specifications, control points and processing parameters

process and related equipment and services

materials to be processed

sampling schedules and test procedures and equipment as required

documentation and recording requirements and procedures

cleaning procedures, materials and equipment as required.

Method of assessment

This unit should be assessed together with core units and other units of competency relevant to the function or work role. Examples could be:

FDFOP2011A Conduct routine maintenance

FDFOP2013A Apply sampling procedures

FDFOP2030A Operate a process control interface

MSL973001A Perform basic tests.

Guidance information for assessment

To ensure consistency in one's performance, competency should be demonstrated on more than one occasion over a period of time in order to cover a variety of circumstances, cases and responsibilities, and where possible, over a number of assessment activities.

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.

Required skills

Ability to:

access workplace information to identify soap stock processing requirements

select, fit and use personal protective clothing and/or equipment

confirm supply of soap stock, acid and services

conduct pre-start checks, such as inspecting equipment condition to identify any signs of wear, selecting appropriate settings and/or related parameters, correctly configured for processing requirements, cancelling isolation or lock outs as required, positioning sensors and controls correctly, ensuring any scheduled maintenance has been carried out, and confirming that all safety guards are in place and operational

confirm service supply

start, operate, monitor and adjust process equipment to achieve required outcomes, including monitoring control points and conducting inspections as required to confirm process remains within specification, such as:

pH and temperature of reactors

pH and temperature of acid water

acid addition

tank levels

colour of acid oil

colour of acid water (minimum fatty matter in acid water stream)

monitor supply and flow of materials to and from the process

take corrective action in response to out-of-specification results

prepare acid oil for loading and delivery

respond to and/or report equipment failure within level of responsibility

locate emergency stop functions on equipment; pH rises and temperature drops

follow isolation and lock out/tag out procedures as required to take process and related equipment off-line in preparation for cleaning and/or maintenance within level of responsibility

complete workplace records as required

maintain work area to meet housekeeping standards

use process control systems according to enterprise procedures

conduct routine maintenance according to enterprise procedures

clean equipment according to enterprise procedures

use oral communication skills/language competence to fulfil the job role as specified by the organisation, including questioning, active listening, asking for clarification and seeking advice from supervisor

work cooperatively within a culturally diverse workforce

Required knowledge

Knowledge of:

purpose and basic principles of soap splitting, including an understanding of the process used to split soap stock and the end uses of each stream

basic operating principles of equipment, such as main equipment components, status and purpose of guards, equipment operating capacities and applications, and the purpose and location of sensors and related feedback instrumentation

services required and action to take if services are not available

the flow of this process and the effect of outputs on downstream processes, including the impact of acid water pH on the performance of the effluent plant and impact of allowing 'fatty' acid water to flow downstream

requirements of acid oil and acid water streams to be achieved

the effect of variation in soap stock on the soap splitting process

operating requirements and parameters and corrective action required where operation is outside specified operating parameters

typical equipment faults and related causes, including signs and symptoms of faulty equipment and early warning signs of potential problems

methods used to monitor the production process, including the purpose and methods used to conduct relevant tests (tests typically include pH, moisture and FFA)

contamination risks associated with the process and related control measures

common causes of variation and corrective action required

occupational health and safety (OHS) hazards and controls, including hazards associated with handling hazardous substances

requirements of different shutdowns as appropriate to the process and workplace production requirements, including emergency and routine shutdowns and procedures to follow in the event of a power outage

isolation, lock out and tag out procedures and responsibilities

procedures and responsibility for reporting production and performance information

environmental issues and controls relevant to the process, including waste/rework collection and handling procedures related to the process

basic operating principles of process control, where relevant, including the relationship between control panels and systems and the physical equipment

routine maintenance procedures where relevant

cleaning and sanitation procedures where relevant

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Policies and procedures

Work is carried out according to company policies and procedures, regulatory and licensing requirements, legislative requirements, and industrial awards and agreements

Workplace information

Workplace information may include:

standard operating procedures (SOPs)

specifications

production schedules and instructions

manufacturers' advice

standard forms and reports

Soap splitting/acidification equipment

Soap splitting/acidification equipment typically includes:

pumps

reactors

acid and steam addition systems

settling tanks

Operation of equipment and processes

Operation of equipment and processes may require:

the use of process control panels and systems

Services

Services may need to be confirmed. These depend on the nature of the process. Typical examples include:

power

steam

water

compressed and instrumentation air

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
Materials are confirmed and available to meet operating requirements 
Machine components are adjusted to meet operating requirements 
Processing/operating parameters are entered as required to meet safety and production requirements 
Equipment performance is checked and adjusted as required 
Pre-start checks are carried out as required by workplace requirements 
The process is started and operated according to workplace procedures 
Equipment is monitored to identify variation in operating conditions 
Variation in equipment operation is identified and maintenance requirements are reported according to workplace reporting requirements 
The process is monitored to confirm separation of acid oil and acid water streams 
The work area is maintained according to housekeeping standards 
Work is conducted in accordance with workplace environmental guidelines 
Workplace records are maintained according to workplace recording requirements 
The appropriate shutdown procedure is identified 
The process is shut down according to workplace procedures 
Maintenance requirements are identified and reported according to workplace reporting requirements 

Forms

Assessment Cover Sheet

FDFGPS2009A - Operate a soap splitting 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

FDFGPS2009A - Operate a soap splitting 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: