Application
This unit applies to operators who troubleshoot and rectify coated paper processes in the pulp and paper industry. This work typically involves complex integrated equipment and continuous operations This unit generally applies to those who: identify and diagnose causes of process variation, plant or equipment faults rectify process variation, plant and equipment faults identify and rectify product quality faults, and record and report troubleshooting activities to meet safety, quality and productivity requirements It does not include monitoring and controlling, starting up or shutting down coated paper processes |
Prerequisites
Not Applicable
Elements and Performance Criteria
ELEMENT | PERFORMANCE CRITERIA |
1. Identify and diagnose causes of process variation, plant or equipment faults | 1.1. Causes of process variation, plant or equipment faults are identified and diagnosed within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements 1.2. Visual assessments and machine alarm systems are interpreted to determine fault type and location 1.3. Routine physical inspections of plant and processes are made to identify faults 1.4. Cause and source of process variation, plant or equipment faults is identified and located using appropriate techniques 1.5. Relevant historical data is accessed and analysed to confirm diagnosis as required 1.6. Problems are communicated to relevant personnel |
2. Rectify process variation, plant and equipment faults | 2.1. Process variation, plant and equipment faults are rectified within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 2.2. Emergency stop or shutdown, isolation and lockout procedures are initiated prior to fault rectification 2.3. Faulty equipment or instrumentation is isolated and repaired or replaced 2.4. Corrective operational adjustments and maintenance requirements are implemented 2.5. Restoration to normal operation is achieved and communicated to relevant personnel |
3. Identify and rectify product quality faults | 3.1. Product quality faults are identified and rectified within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 3.2. Product faults or variations are identified by observation, systematic sampling and testing 3.3. Out-of-specification product is managed 3.4. Sampling for a range of tests is undertaken 3.5. Required tests are conducted 3.6. Test results are interpreted and operations are adjusted to correct variations |
4. Record and report troubleshooting activities | 4.1. Troubleshooting activities are recorded and reported within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 4.2. Variations from specification and machine operation faults are documented 4.3. Assessment and evaluation of causes of deviation, and corrective action undertaken is recorded as required 4.4. Relevant information is communicated to appropriate personnel |
Required Skills
This describes the skills and knowledge required for this unit. |
Required skills |
Identifies, accesses and interprets relevant historical and operational data and information Uses required forms of communication in troubleshooting and rectifying coated paper processes Reads and interprets required documentation, procedures and reports Prepares written information for a range of audiences Makes recommendations for further action Accesses, navigates and enters computer-based information Monitors, analyses and interprets data Interprets instruments, gauges and data recording equipment Communicates effectively with personnel to assist with analysis and resolution of operational problems Assists others to identify and resolve operational problems in the workplace Identifies and actions systems, quality and equipment faults within level of responsibility Identifies causes and effects of faults and corrective action on associated processes Selects and uses appropriate troubleshooting methods Takes timely corrective action to maximise safety, quality and productivity Undertakes necessary calculations to aid troubleshooting, as required Identifies and monitors process control points Maintains situational awareness in the work area Responds to emergencies or unplanned shutdowns in accordance with SOP Implements isolations and lockouts according to SOP Identifies and implements operational procedures Maintains plant operation and production with minimal interruptions Maintains grade specification and quality or initiates appropriate action to rectify Identifies and implements test requirements Takes samples, conducts tests and interprets and records results if required Uses measuring equipment as required Operates high risk load shifting equipment as required Uses technology to assist work performance Analyses and uses sensory information to adjust process to maximise safety, quality and productivity Uses electronic and other control systems to control equipment and processes as required |
Required knowledge |
Procedures, regulations and legislative requirements relevant to coated paper processes including OHS, environmental including relevant sustainability requirements/practices, SOP, isolation procedures, safe working requirements, risks and hazard identification and housekeeping Relevant forms of communication Detailed knowledge of coated paper processes and associated services sufficient to troubleshoot including: plant layout theory of operation causes and effects of adjustments made to coated paper plant and processes relationships between coated paper processes and associated services An appropriate range of troubleshooting methods Impact of inappropriate responses Sampling and testing process for plant and system operations, and process monitoring - purpose, standards and procedures as per site agreements Cause and effect of test results and actions Product grade and process adjustment procedures Application of high risk load shifting equipment as required Sensory information that indicates a deviation from standard operating parameters Sufficient knowledge of electronic and other control systems, operation and application to make appropriate adjustments that control coated paper processes, within level of responsibility |
Evidence Required
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 | |
Critical aspects for assessment and evidence required to demonstrate competency in this unit | Evidence should be relevant to the work. It should satisfy the requirements of the elements and performance criteria and include consideration of: the required knowledge and skills tailored to the needs of the specific workplace applicable OHS regulations, environmental and safe working requirements/practices, SOP and housekeeping requirements applicable aspects of the range statement practical workplace demonstration of skills in troubleshooting and rectifying coated paper processes |
Context of and specific resources for assessment | A workplace assessment must be used to assess: the application of required knowledge on the job the application of skills on the job, over time and under a range of typical conditions that may be experienced in coated paper processes Access to the full range of equipment involved in integrated continuous manufacturing of coated paper processes in a pulp or paper mill is required |
Method of assessment | A combination of assessment methods should be used. The following examples are appropriate for this unit: observation of applied skills and knowledge on the job workplace demonstrations via a mock-up or simulation that replicate part/s of the job answers to written or verbal questions about specific skills and knowledge third-party reports from relevant and skilled personnel written evidence e.g. log sheet entries, checklist entries, test results Assessment processes and techniques must be culturally appropriate and in keeping with the language and literacy capacity of the learner and the work being performed. This includes conducting an assessment in a manner that allows thoughts to be conveyed verbally so that the learner can both understand and be understood by the assessor (e.g. use plain English and terminology used on the job) A holistic assessment with other units relevant to the pulp and paper industry, mill and job role is recommended Additional information on approaches to assessment for the pulp and paper industry is provided in the Assessment Guidelines for this Training Package |
Range Statement
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. | |
Productivity requirements may include: | energy efficiency waste minimisation evaporation minimisation, including landfill and waste water reduction environmentally safe waste disposal consideration of resource utilisation, including fibre efficiency minimising delays chemical recovery maximisation meeting key performance indicators line speed handovers quality checks meeting output targets i.e. net tonnes per employee per annum machine/process time availability i.e. time the machine or process is making product machine/process production rate |
Coated paper processes may include: | tail feed systems chemical and material batching laminating and coating splicing clay plant operation calender pre-reeler operations super calendering monitoring systems rewindering drying systems internal unloading combine rollers testing |
Materials and supplies may include: | chemicals and polymers power water additives steam labels felts equipment gas accessories (parts) air base paper |
Equipment may include: | coater splicer pre-reelers crimpers calender super-calender parent rolls and reels cranes pigment coating makedown plant starch cooker slitter computer systems electronic screens and alarms process control systems analogue and digital instrumentation fully automated, semi-automated, manually operated plant and equipment appropriate to the coated paper process |
Electronic control systems may include: | Digital Control System (DCS) touch screens robotics |
Legislation, regulatory, licensing and certification requirements may include: | OHS and environmental requirements (local, state and commonwealth) activity or task specific high risk licensing requirements |
Documentation, procedures and reports may include: | SOP quality procedures environmental sustainability requirements/practices plant manufacturing operating manuals enterprise policies and procedures Material Safety Data Sheets (MSDS) oil or chemical spills and disposal guidelines plant isolation documentation safe work documentation e.g. plant clearance, job safety analysis, permit systems product specifications and schedules maintenance logs job sheets site agreements safety instructions process and instrument diagrams machine manuals troubleshooting guides incidents reports |
Maintenance may include: | operator level maintenance as per site agreements operator maintenance schedules maintenance systems maintenance suppliers proactive maintenance strategies e.g. Total Productive Maintenance (TPM), Reliability Centred Maintenance (RCM) |
Actions may include: | process adjustments reporting to authorised person rectifying problem within level of responsibility |
Communications may include | interaction with: internal/external customers and suppliers team members production/service co-ordinators maintenance services operator support personnel operational management statutory authorities |
Situational awareness may include | awareness of: traffic pedestrians location of equipment product hazards obstruction unexpected movement |
Forms of communication may include: | written e.g. log books, emails, incident and other reports, run sheets, data entry reading and interpreting documentation e.g. SOP, manuals, checklists, drawings verbal e.g. radio skills, telephone, face to face, handover non-verbal e.g. hand signals, alarms, observations signage e.g. safety, access |
Sensory information may include: | visual sound feel touch smell vibration temperature |
Sectors
Not Applicable
Employability Skills
This unit contains employability skills |
Licensing Information
Refer to Unit Descriptor