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

MEM04001 Mapping and Delivery Guide
Operate melting furnaces

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency MEM04001 - Operate melting furnaces
Description
Employability Skills
Learning Outcomes and Application This unit of competency defines the skills and knowledge required to operate melting furnaces.It applies to the operation and operational maintenance of furnaces primarily used for continuous or staged bulk melting/smelting of a range of metals, holding of hot liquids, or the melting of metals for production processes, such as casting, moulding and galvanising.Where the interpretation of technical drawings is required unit MEM09002 Interpret technical drawing should also be selected.Where the selection and use of engineering measuring equipment is required unit MEM12023 Perform engineering measurements should also be selected.Where the selection and use of tools is required unit MEM18001 Use hand tools and unit MEM18002 Use power tools/hand held operations, should also be selected as appropriate.No licensing, legislative or certification requirements apply to this unit at the time of publication.Band: AUnit Weight: 4
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.
Prerequisites/co-requisites
Competency Field Casting and moulding
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: Select materials
  • Complete requisitions as required according to SOPs
  • Undertake charge analysis and convert the charge analysis to furnace charge weight and weigh charge in accordance with SOPs
  • Enter routine and familiar information onto proformas and standard workplace forms
       
Element: Start up furnace
  • Inspect furnace for any defects or damage
  • Identify faults and areas for routine repair of the furnace
  • Undertake routine operational maintenance of furnace
  • Start up furnace according to procedures
  • Report all start-up faults in accordance with procedures
       
Element: Charge furnace
  • Identify and follow emergency/safety procedures
  • Pre-heat materials if required
  • Charge materials into furnace
  • Identify and keep available suitable areas for emergency unloading of molten metal
       
Element: Monitor furnace
  • Maintain furnace at optimum operating condition
  • Take sample for chemical analysis and apply remedial action as required
  • Dross and/or degas furnace
  • Check temperature of metal and adjust if necessary
       
Element: Shut down furnace
  • Complete shutdown of furnace
  • Undertake routine operational maintenance of furnace in accordance with procedures
       
Element: Determine job requirements
  • Follow standard operating procedures (SOPs)
       
Element: Comply with work health and safety (WHS) requirements at all times
       
Element: Use appropriate personal protective equipment (PPE) in accordance with SOPs
       
Element: Identify job requirements from specifications, job sheets or work instructions
  • Complete requisitions as required according to SOPs
       
Element: Undertake charge analysis and convert the charge analysis to furnace charge weight and weigh charge in accordance with SOPs
       
Element: Enter routine and familiar information onto proformas and standard workplace forms
  • Inspect furnace for any defects or damage
       
Element: Identify faults and areas for routine repair of the furnace
       
Element: Undertake routine operational maintenance of furnace
       
Element: Start up furnace according to procedures
       
Element: Report all start-up faults in accordance with procedures
  • Identify and follow emergency/safety procedures
       
Element: Pre-heat materials if required
       
Element: Charge materials into furnace
       
Element: Identify and keep available suitable areas for emergency unloading of molten metal
  • Maintain furnace at optimum operating condition
       
Element: Take sample for chemical analysis and apply remedial action as required
       
Element: Dross and/or degas furnace
       
Element: Check temperature of metal and adjust if necessary
       
Element: Tap or unload the furnace
  • Identify the quantity of the required metal
       
Element: Undertake tapping or unloading safely according to procedures
  • Complete shutdown of furnace
       
Element: Undertake routine operational maintenance of furnace in accordance with procedures
       

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.

This field allows for different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.

Furnaces include one (1) or more of the following:

singular or multi

coke

oil

gas fired

electric induction

arc

resistance

Operational maintenance includes one (1) or more of the following:

routine lubrication

cleaning

routine repair/repointing of refractory

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
Complete requisitions as required according to SOPs 
Undertake charge analysis and convert the charge analysis to furnace charge weight and weigh charge in accordance with SOPs 
Enter routine and familiar information onto proformas and standard workplace forms 
Inspect furnace for any defects or damage 
Identify faults and areas for routine repair of the furnace 
Undertake routine operational maintenance of furnace 
Start up furnace according to procedures 
Report all start-up faults in accordance with procedures 
Identify and follow emergency/safety procedures 
Pre-heat materials if required 
Charge materials into furnace 
Identify and keep available suitable areas for emergency unloading of molten metal 
Maintain furnace at optimum operating condition 
Take sample for chemical analysis and apply remedial action as required 
Dross and/or degas furnace 
Check temperature of metal and adjust if necessary 
Complete shutdown of furnace 
Undertake routine operational maintenance of furnace in accordance with procedures 
Follow standard operating procedures (SOPs) 
 
 
Complete requisitions as required according to SOPs 
 
Inspect furnace for any defects or damage 
 
 
 
Identify and follow emergency/safety procedures 
 
 
Maintain furnace at optimum operating condition 
 
 
 
Identify the quantity of the required metal 
Complete shutdown of furnace 
 

Forms

Assessment Cover Sheet

MEM04001 - Operate melting furnaces
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

MEM04001 - Operate melting furnaces

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: