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Evidence Guide: FBPBPG3008 - Operate an automated carton packing process

Student: __________________________________________________

Signature: _________________________________________________

Tips for gathering evidence to demonstrate your skills

The important thing to remember when gathering evidence is that the more evidence the better - that is, the more evidence you gather to demonstrate your skills, the more confident an assessor can be that you have learned the skills not just at one point in time, but are continuing to apply and develop those skills (as opposed to just learning for the test!). Furthermore, one piece of evidence that you collect will not usualy demonstrate all the required criteria for a unit of competency, whereas multiple overlapping pieces of evidence will usually do the trick!

From the Wiki University

 

FBPBPG3008 - Operate an automated carton packing process

What evidence can you provide to prove your understanding of each of the following citeria?

Operate and monitor the carton packing process

  1. Carry out test run and adjust as required to meet packing specifications
  2. Ensure supply of consumables for packaging process
  3. Carry out quality checks on sample cartons and complete records according to workplace requirements
  4. Apply problem-solving principles and techniques to identify and rectify machine faults according to workplace procedures
  5. Clean up spillages and breakages according to workplace procedures
  6. Ensure quantity, process efficiency and quality specifications are met
  7. Report major process problems and products that do not meet specifications
  8. Handover carton packing process to another team member when required
Carry out test run and adjust as required to meet packing specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure supply of consumables for packaging process

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Carry out quality checks on sample cartons and complete records according to workplace requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Apply problem-solving principles and techniques to identify and rectify machine faults according to workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Clean up spillages and breakages according to workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure quantity, process efficiency and quality specifications are met

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Report major process problems and products that do not meet specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Handover carton packing process to another team member when required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Change over packing run

  1. Prepare equipment and consumables for upcoming product change
  2. Check and record product counters to ensure an accurate changeover
  3. Coordinate team members to assist with changeover
  4. Apply isolation measures according to workplace requirements
  5. Empty machine of product and complete required changeover, and confirm parts, sensors, rails and stoppers have been adjusted and set
  6. Complete end-of-run carton packing records and reports
  7. Remove and store unused consumables and equipment parts not required after changeover
  8. Conduct test run and make adjustments as required
Prepare equipment and consumables for upcoming product change

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check and record product counters to ensure an accurate changeover

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Coordinate team members to assist with changeover

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Apply isolation measures according to workplace requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Empty machine of product and complete required changeover, and confirm parts, sensors, rails and stoppers have been adjusted and set

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete end-of-run carton packing records and reports

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Remove and store unused consumables and equipment parts not required after changeover

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Conduct test run and make adjustments as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down the carton packing process

  1. Empty machinery and equipment of packaged products
  2. Shut down machinery according to workplace procedures
  3. Remove and store unused packing materials
  4. Complete carton packing records and reports
  5. Clean and maintain packing machinery and equipment
  6. Dispose of waste according to workplace and environmental procedures
  7. Report issues requiring maintenance by technicians
Empty machinery and equipment of packaged products

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down machinery according to workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Remove and store unused packing materials

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete carton packing records and reports

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Clean and maintain packing machinery and equipment

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Dispose of waste according to workplace and environmental procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Report issues requiring maintenance by technicians

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Required Skills and Knowledge

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.

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.