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

MSFGG4006 Mapping and Delivery Guide
Operate complex glass processing plant control systems

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency MSFGG4006 - Operate complex glass processing plant control systems
Description
Employability Skills
Learning Outcomes and Application This unit of competency covers operating a complex glass processing plant control panel utilising control loops and a broad range of control algorithms to control plant areas and multiple products/process streams. It will typically be located in a control room and require managing multiple complex tasks.The technician/central control room operator takes overall responsibility for the operation of all equipment and processes within the plant area and may include optimisation of the area using the control system. No licensing, legislative or certification requirements 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.

Assessors must:

hold training and assessment competencies as determined by the National Skills Standards Council (NSSC) or its successors

have vocational competency in the furnishing industry at least to the level being assessed with broad industry knowledge and experience, usually combined with a relevant industry qualification

be familiar with the current skills and knowledge used and have relevant, current experience in the furnishing industry.

Assessment methods must confirm consistency of performance over time rather than a single assessment event and in a range of workplace relevant contexts.

Assessment must be by observation of relevant tasks with questioning on underpinning knowledge and, where applicable, multimedia evidence, supervisor’s reports, projects and work samples.

Assessment is to be conducted on single units of competency or in conjunction with other related units of competency. Foundation skills are integral to competent performance in the unit and should not be assessed separately.

Assessment must occur on the job or in a workplace simulated facility with relevant process, equipment, materials, work instructions and deadlines.

Access is required to control systems for glass processing plant and equipment, workplace documentation, procedures and job requirements.
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: Use operator interface
  • Keyboards, track ball and monitor and/or stand-alone controllers are used to access control system/panel
  • Glass processing task is monitored using the operator interfaces selecting appropriate controller modes
  • Historical data and information are accessed as required
  • Messages and alarms are monitored and acknowledged with appropriate action taken
  • Advanced control features are accessed and managed as appropriate
       
Element: Access control information
  • Relevant data and information are accessed from the control system by applying systems knowledge
  • Status of individual pieces of equipment is determine from the control panel readings and the information used to identify potential faults
  • Fluctuations and variations in process through the interpretation of existing trends and control schematics are minimised
  • Overall operating effectiveness of the plant area is determine and related to the required targets for the area
  • Process variations/irregularities to procedures are recoded as necessary
       
Element: Control process variations and monitor operations
  • Historical data on plant operations are used to assist the identification of problems and all available information processed to identify potential faults
  • Required set point/output changes are undertaken to meet plant area and process requirements
  • Production is adjusted in response to test results and control panel information
  • Key process and environmental variables are monitored and appropriate action taken
  • Controller settings are adjusted in accordance with procedures with advanced control features utilised as appropriate
  • Plant area is optimised in accordance with guidelines
  • Calibration operations are made as appropriate
  • Coordination with stakeholders external to the plant area is undertaken as required
  • Adjustments and variations to specifications/schedules are recorded and communicated to appropriate personnel
       
Element: Facilitate planned and unplanned process start-ups and shutdowns
  • Procedures to planned startup and shutdown processes are selected and applied
  • Procedures to unplanned shutdown processes are selected and applied where required
  • Required emergency responses are implemented
  • Necessary information is communicated to all personnel affected by events
  • Required information is logged regularly
       
Element: Respond to alarms or out of specification conditions and control hazards
  • System(s) affected by the alarm or condition are identified, prioritised and appropriate action taken
  • Alarm or incidents are responded to promptly by following procedures
  • Any out of specification material is dealt with in accordance with procedures and the problem/solution communicated to appropriate personnel
  • Incident information is recorded as required and details of the alarm and action taken communicated to the next shift at change over
  • Incidents are followed up to confirm that appropriate action has been taken
  • Hazards in the production/processing work area are identified and the risks arising from those hazards assessed
  • Measures to control risks are implemented in line with procedures and duty of care
       
Element: Resolve other problems within scope of responsibility
  • Possible problems in equipment, control systems or process are identified to determine problems needing action
  • Possible fault causes are established and problems rectified using appropriate solution within area of responsibility
  • Initiated control actions are followed through until final resolution has occurred with problems outside area of responsibility reported to designated person
       


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.

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Use operator interface

1.1

Keyboards, track ball and monitor and/or stand-alone controllers are used to access control system/panel

1.2

Glass processing task is monitored using the operator interfaces selecting appropriate controller modes

1.3

Historical data and information are accessed as required

1.4

Messages and alarms are monitored and acknowledged with appropriate action taken

1.5

Advanced control features are accessed and managed as appropriate

2

Access control information

2.1

Relevant data and information are accessed from the control system by applying systems knowledge

2.2

Status of individual pieces of equipment is determine from the control panel readings and the information used to identify potential faults

2.3

Fluctuations and variations in process through the interpretation of existing trends and control schematics are minimised

2.4

Overall operating effectiveness of the plant area is determine and related to the required targets for the area

2.5

Process variations/irregularities to procedures are recoded as necessary

3

Control process variations and monitor operations

3.1

Historical data on plant operations are used to assist the identification of problems and all available information processed to identify potential faults

3.2

Required set point/output changes are undertaken to meet plant area and process requirements

3.3

Production is adjusted in response to test results and control panel information

3.4

Key process and environmental variables are monitored and appropriate action taken

3.5

Controller settings are adjusted in accordance with procedures with advanced control features utilised as appropriate

3.6

Plant area is optimised in accordance with guidelines

3.7

Calibration operations are made as appropriate

3.8

Coordination with stakeholders external to the plant area is undertaken as required

3.9

Adjustments and variations to specifications/schedules are recorded and communicated to appropriate personnel

4

Facilitate planned and unplanned process start-ups and shutdowns

4.1

Procedures to planned startup and shutdown processes are selected and applied

4.2

Procedures to unplanned shutdown processes are selected and applied where required

4.3

Required emergency responses are implemented

4.4

Necessary information is communicated to all personnel affected by events

4.5

Required information is logged regularly

5

Respond to alarms or out of specification conditions and control hazards

5.1

System(s) affected by the alarm or condition are identified, prioritised and appropriate action taken

5.2

Alarm or incidents are responded to promptly by following procedures

5.3

Any out of specification material is dealt with in accordance with procedures and the problem/solution communicated to appropriate personnel

5.4

Incident information is recorded as required and details of the alarm and action taken communicated to the next shift at change over

5.5

Incidents are followed up to confirm that appropriate action has been taken

5.6

Hazards in the production/processing work area are identified and the risks arising from those hazards assessed

5.7

Measures to control risks are implemented in line with procedures and duty of care

6

Resolve other problems within scope of responsibility

6.1

Possible problems in equipment, control systems or process are identified to determine problems needing action

6.2

Possible fault causes are established and problems rectified using appropriate solution within area of responsibility

6.3

Initiated control actions are followed through until final resolution has occurred with problems outside area of responsibility reported to designated person

Consistently:

recognise early warning signs of equipment/processes needing attention or with potential problems

determine and analyse the range of possible plant problem causes and the most likely cause

take appropriate action to ensure a timely return to full performance

recognise obvious problems in related plant areas and make an appropriate contribution to their solution

Distinguish between causes of problems/alarms/fault indications, such as:

instrument failure/malfunction

electrical failure/malfunction

mechanical failure/malfunction

equipment design deficiencies

product parameters (temperature, flows, pressure and levels)

process control system malfunction

power/utility failures

software problems

Communicate ideas and information to enable confirmation of work requirements and specifications and the reporting of work outcomes and problems

Avoid backtracking, work flow interruptions or wastage

Work with others and in a team by recognising dependencies and using cooperative approaches to optimise work flow and productivity

Interactions between control loops

Interactions between plant units within the entire plant

The architecture and location of the glass process/production equipment

Specific glass plant process operations

Interactions between glass plant items/processes

Glass product specifications and tolerances

Systems operating parameters

System integrity limits

Process control philosophies and strategies

Emergency shutdown procedures

Basic science of upstream and downstream glass processes

Impact of external factors (e.g. variations in weather and feed)

Complex process drawings (e.g. piping and instrumentation diagrams (P&ID), probability of failure on demand (PFD) and cause and effect)

Basis of control for glass processing plant/s

Instrumentation and control systems, including feed forward, feedback and open control

Instrumentation and control system components (e.g. relevant primary sensing devices, final control elements, and transducers/transmitters)

Control loops, including P&ID control, set points, controlled variable and indicated variable

Interaction between multiple control loops, including cascade control

Impacts of changing controller settings and the limits within which changes can be made

Effective communication techniques

Organisational 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.

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Use operator interface

1.1

Keyboards, track ball and monitor and/or stand-alone controllers are used to access control system/panel

1.2

Glass processing task is monitored using the operator interfaces selecting appropriate controller modes

1.3

Historical data and information are accessed as required

1.4

Messages and alarms are monitored and acknowledged with appropriate action taken

1.5

Advanced control features are accessed and managed as appropriate

2

Access control information

2.1

Relevant data and information are accessed from the control system by applying systems knowledge

2.2

Status of individual pieces of equipment is determine from the control panel readings and the information used to identify potential faults

2.3

Fluctuations and variations in process through the interpretation of existing trends and control schematics are minimised

2.4

Overall operating effectiveness of the plant area is determine and related to the required targets for the area

2.5

Process variations/irregularities to procedures are recoded as necessary

3

Control process variations and monitor operations

3.1

Historical data on plant operations are used to assist the identification of problems and all available information processed to identify potential faults

3.2

Required set point/output changes are undertaken to meet plant area and process requirements

3.3

Production is adjusted in response to test results and control panel information

3.4

Key process and environmental variables are monitored and appropriate action taken

3.5

Controller settings are adjusted in accordance with procedures with advanced control features utilised as appropriate

3.6

Plant area is optimised in accordance with guidelines

3.7

Calibration operations are made as appropriate

3.8

Coordination with stakeholders external to the plant area is undertaken as required

3.9

Adjustments and variations to specifications/schedules are recorded and communicated to appropriate personnel

4

Facilitate planned and unplanned process start-ups and shutdowns

4.1

Procedures to planned startup and shutdown processes are selected and applied

4.2

Procedures to unplanned shutdown processes are selected and applied where required

4.3

Required emergency responses are implemented

4.4

Necessary information is communicated to all personnel affected by events

4.5

Required information is logged regularly

5

Respond to alarms or out of specification conditions and control hazards

5.1

System(s) affected by the alarm or condition are identified, prioritised and appropriate action taken

5.2

Alarm or incidents are responded to promptly by following procedures

5.3

Any out of specification material is dealt with in accordance with procedures and the problem/solution communicated to appropriate personnel

5.4

Incident information is recorded as required and details of the alarm and action taken communicated to the next shift at change over

5.5

Incidents are followed up to confirm that appropriate action has been taken

5.6

Hazards in the production/processing work area are identified and the risks arising from those hazards assessed

5.7

Measures to control risks are implemented in line with procedures and duty of care

6

Resolve other problems within scope of responsibility

6.1

Possible problems in equipment, control systems or process are identified to determine problems needing action

6.2

Possible fault causes are established and problems rectified using appropriate solution within area of responsibility

6.3

Initiated control actions are followed through until final resolution has occurred with problems outside area of responsibility reported to designated person

Specifies 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. Range is restricted to essential operating conditions and any other variables essential to the work environment.

Unit scope includes:

equipment and unit operations which form part of the glass processing control system, such as:

process control systems (e.g. distributed control systems)

use of multiple control systems

personal computers

printers

fire and gas detection/protection systems

emergency shutdown systems

communication systems

Typical problems for glass processing plant include:

operating without advanced control features

loss of power/utilities

analysing failure modes

variation/loss of feed

unstable control of pressure, temperature level and flows

control equipment failure

process plant trips

change in atmospheric conditions (rain, temperature, wind and lightning)

emergency situations

Work health and safety (WHS) requirements include:

Commonwealth, state or territory legislation and regulations

organisational safety policies and procedures

the use of personal protective equipment and clothing

firefighting equipment

first aid equipment

hazard and risk control and elimination of hazardous materials and substances

manual handling, including lifting and carrying

Alarms or abnormal conditions include:

emergencies, including emergency shutdown

partial or complete controller failure

Appropriate action includes:

determining problems needing action

determining possible fault causes

rectifying problem using appropriate solution within area of responsibility

following through items initiated until final resolution has occurred

reporting problems outside area of responsibility to designated person

Procedures include:

work instructions

standard operating procedures

processing data and requirements

batch sheets

temporary instructions

any instructions provided for the smooth running of the plant

verbal, written or computer-based procedures

Organisational requirements include:

legal, organisational and site guidelines, policies and procedures relating to own role and responsibility

quality assurance

procedural manuals

quality and continuous improvement processes and standards

WHS procedures

emergency and evacuation

ethical standards

recording and reporting

access and equity principles and practices

equipment use, maintenance and storage

environmental management (waste disposal, recycling and re-use guidelines)

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
Keyboards, track ball and monitor and/or stand-alone controllers are used to access control system/panel 
Glass processing task is monitored using the operator interfaces selecting appropriate controller modes 
Historical data and information are accessed as required 
Messages and alarms are monitored and acknowledged with appropriate action taken 
Advanced control features are accessed and managed as appropriate 
Relevant data and information are accessed from the control system by applying systems knowledge 
Status of individual pieces of equipment is determine from the control panel readings and the information used to identify potential faults 
Fluctuations and variations in process through the interpretation of existing trends and control schematics are minimised 
Overall operating effectiveness of the plant area is determine and related to the required targets for the area 
Process variations/irregularities to procedures are recoded as necessary 
Historical data on plant operations are used to assist the identification of problems and all available information processed to identify potential faults 
Required set point/output changes are undertaken to meet plant area and process requirements 
Production is adjusted in response to test results and control panel information 
Key process and environmental variables are monitored and appropriate action taken 
Controller settings are adjusted in accordance with procedures with advanced control features utilised as appropriate 
Plant area is optimised in accordance with guidelines 
Calibration operations are made as appropriate 
Coordination with stakeholders external to the plant area is undertaken as required 
Adjustments and variations to specifications/schedules are recorded and communicated to appropriate personnel 
Procedures to planned startup and shutdown processes are selected and applied 
Procedures to unplanned shutdown processes are selected and applied where required 
Required emergency responses are implemented 
Necessary information is communicated to all personnel affected by events 
Required information is logged regularly 
System(s) affected by the alarm or condition are identified, prioritised and appropriate action taken 
Alarm or incidents are responded to promptly by following procedures 
Any out of specification material is dealt with in accordance with procedures and the problem/solution communicated to appropriate personnel 
Incident information is recorded as required and details of the alarm and action taken communicated to the next shift at change over 
Incidents are followed up to confirm that appropriate action has been taken 
Hazards in the production/processing work area are identified and the risks arising from those hazards assessed 
Measures to control risks are implemented in line with procedures and duty of care 
Possible problems in equipment, control systems or process are identified to determine problems needing action 
Possible fault causes are established and problems rectified using appropriate solution within area of responsibility 
Initiated control actions are followed through until final resolution has occurred with problems outside area of responsibility reported to designated person 

Forms

Assessment Cover Sheet

MSFGG4006 - Operate complex glass processing plant control systems
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

MSFGG4006 - Operate complex glass processing plant control systems

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: