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Evidence Guide: FBPBPG3009 - Operate an automated palletising 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

 

FBPBPG3009 - Operate an automated palletising process

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

Prepare for palletising

  1. Check work order to determine the pallet type, layer format and any other required information
  2. Select, fit correctly and use required personal protective equipment
  3. Check machinery maintenance charts and rectify or report any items that require maintenance
  4. Check and set machine format to meet the palletising requirements specified in work order
  5. Check all machine safety equipment is operational
  6. Confirm pallet reference applicator is operational
  7. Confirm serviceability of conveyors, and reset all product counters and glue application device
  8. Confirm pallets and other packaging consumables required for the run
  9. Carry out test run and adjust as required to meet palletising specifications, including carton orientation, stacking and stretch wrap tension
  10. Ensure supply of consumables for palletising process
  11. Carry out quality checks on sample pallets and complete records according to workplace requirements
  12. Apply problem-solving principles and techniques to identify and rectify machine faults according to workplace procedures
  13. Restack pallets and clean up spillages according to safety procedures
  14. Monitor palletising process to ensure process efficiency and quality specifications are met, including correct pallet identification labels
  15. Report major process problems and products that do not meet specifications
  16. Handover palletising process to another team member when required
Check work order to determine the pallet type, layer format and any other required information

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Select, fit correctly and use required personal protective equipment

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check machinery maintenance charts and rectify or report any items that require maintenance

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check and set machine format to meet the palletising requirements specified in work order

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check all machine safety equipment is operational

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Confirm pallet reference applicator is operational

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Confirm serviceability of conveyors, and reset all product counters and glue application device

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Confirm pallets and other packaging consumables required for the run

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Carry out test run and adjust as required to meet palletising specifications, including carton orientation, stacking and stretch wrap tension

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure supply of consumables for palletising process

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Carry out quality checks on sample pallets 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:

 

 

 

 

 

 

 

Restack pallets and clean up spillages according to safety procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor palletising process to ensure process efficiency and quality specifications are met, including correct pallet identification labels

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Report major process problems and products that do not meet specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Handover palletising process to another team member when required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Change over palletising run

  1. Prepare equipment and consumables for upcoming changeover
  2. Check and record product counters to ensure an accurate changeover
  3. Apply isolation measures according to workplace requirements
  4. Empty machine of product and complete required changeover, and confirm parts, sensors, rails and stoppers have been adjusted and set
  5. Remove and store unused consumables and equipment parts not required after changeover
  6. Conduct test run and make adjustments as required
Prepare equipment and consumables for upcoming changeover

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check and record product counters to ensure an accurate 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:

 

 

 

 

 

 

 

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 palletising process

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down machinery and equipment according to workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Remove and store unused materials

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete carton palletising records and reports

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Clean and maintain palletising 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 complete palletising processes for different work orders, using automatic palletising machines, including a pallet wrapper. One process must palletise 12-pack cartons and the other 6-pack cartons, that are configured differently.

Each process must complete at least 20pallets per hour during a three-hour shift. Each pallet must have at least three carton layers, and be correctly configured, stacked and stretch wrapped using an automated pallet wrapper.

For each of the palletising work orders, the individual must have safely and efficiently performed the following:

confirmed the product and palletising requirements and set up all the equipment and machinery, including individual pallet configuration requirements

operated, monitored and shut down the palletising process, equipment and machinery

correctly labelled each pallet for end users to track the date and location of production

used sample checks to identify quality issues

identified, rectified and/or reported machinery faults, including:

blockages caused by damaged pallets

cartons not correctly orientated

pallets not stopping in the correct position

carriage or pusher not making the end position

excessive stretch wrap and slip sheet breakage causing sensor faults

machinery settings resulting in incorrect palletising

accurately and effectively handed over a palletising process to another team member

accurately completed workplace production records

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.

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 palletised as stipulated in the performance evidence, including:

size, weight and volume

client or receiver requirements or specifications

regulatory requirements

operating principles of machinery and equipment, including:

conveyor fed automatic palletising machine

automated stretch wrapper

pallet tag applicators

carton orientation devices

features and functions of machinery and equipment, including:

manufacturer and workplace instructions for safe operation

control panel and ancillary devices

operating capacities, efficiencies and applications

location and purpose of guards, rails and sensors

feedback instrumentation

services required and action to take if services are not available

cleaning 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

consumables including slip sheets, interlayers, hot melt glue and stretch film

the interrelationships between bottling, carton packing, palletising and end of line dispatch processes

product and process changeover procedures and responsibilities

quality control requirements, processes and actions, including:

palletising order specifications

pallets for domestic and export use

methods used to check quality

common causes of palletising quality and corrective action required, including removal of out-of-specification pallets

planned sampling and testing associated with palletising process monitoring and control

responding to machinery alerts and notifications

recording of results

isolating non-conforming pallets

product identification and traceability requirements, including:

workplace requirements

client or receiver requirements or specifications

pallet identification/tagging requirements

health and safety hazards and controls, including awareness of the limitations of 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 palletising process, including:

rework and reuse of products

waste processing

materials and manual handling procedures related to the palletising process.