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.
Elements and Performance Criteria
Elements | Performance Criteria |
1. Prepare for packing | 1.1 Check work order to determine number and type of cartons, and other packing consumables required 1.2 Select, fit correctly and use required personal protective equipment 1.3 Check machinery maintenance charts and rectify or report any items that require maintenance 1.4 Check and set machine format to meet the requirements of products and cartons specified in work order 1.5 Check all machine safety equipment is operational 1.6 Confirm quality inspection systems and equipment are correctly fitted and functional 1.7 Confirm serviceability of conveyors and reset all counters |
2. Operate and monitor the carton packing process | 2.1 Carry out test run and adjust as required to meet packing specifications 2.2 Ensure supply of consumables for packaging process 2.3 Carry out quality checks on sample cartons and complete records according to workplace requirements 2.4 Apply problem-solving principles and techniques to identify and rectify machine faults according to workplace procedures 2.5 Clean up spillages and breakages according to workplace procedures 2.6 Ensure quantity, process efficiency and quality specifications are met 2.7 Report major process problems and products that do not meet specifications 2.8 Handover carton packing process to another team member when required |
3. Change over packing run | 3.1 Prepare equipment and consumables for upcoming product change 3.2 Check and record product counters to ensure an accurate changeover 3.3 Coordinate team members to assist with changeover 3.4 Apply isolation measures according to workplace requirements 3.5 Empty machine of product and complete required changeover, and confirm parts, sensors, rails and stoppers have been adjusted and set 3.6 Complete end-of-run carton packing records and reports 3.7 Remove and store unused consumables and equipment parts not required after changeover 3.8 Conduct test run and make adjustments as required |
4. Shut down the carton packing process | 4.1 Empty machinery and equipment of packaged products 4.2 Shut down machinery according to workplace procedures 4.3 Remove and store unused packing materials 4.4 Complete carton packing records and reports 4.5 Clean and maintain packing machinery and equipment 4.6 Dispose of waste according to workplace and environmental procedures 4.7 Report issues requiring maintenance by technicians |
Evidence of Performance
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.
Evidence of Knowledge
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.
Assessment Conditions
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.
Foundation Skills
Skill | Description |
Reading | Interpret technical text and symbols in machinery operations manuals |
Writing | Complete quality reports using correct terminology |
Numeracy | Estimate and calculate quantity, weight and rate related to operating a packing line |
Oral communication | Use industry terminology to communicate with team members |
Sectors
Bottling and Packaging (BPG)