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Evidence Guide: PMC553010 - Process raw meal into product

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

 

PMC553010 - Process raw meal into product

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

Prepare for processing

  1. Notify/keep informed all relevant people about the current status operations and any intention to make changes
  2. Perform all pre-start checks in accordance with standard operating procedures (SOPs)
  3. Set up and configure equipment start-up function complying with procedures
  4. Check plant/equipment settings against operating parameters as identified in SOPs
  5. Load raw materials in accordance with work instructions
  6. Start up plant/equipment in accordance with procedures
Notify/keep informed all relevant people about the current status operations and any intention to make changes

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Perform all pre-start checks in accordance with standard operating procedures (SOPs)

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set up and configure equipment start-up function complying with procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check plant/equipment settings against operating parameters as identified in SOPs

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Load raw materials in accordance with work instructions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Start up plant/equipment in accordance with procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Process raw meal

  1. Commence/continue process operations in accordance with specified operating procedures
  2. Monitor and check against target parameters instrument/control panels for variations, fluctuations or trends
  3. Maximise throughput of system while meeting quality target parameters
  4. Check and adjust ancillary equipment as required
Commence/continue process operations in accordance with specified operating procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor and check against target parameters instrument/control panels for variations, fluctuations or trends

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Maximise throughput of system while meeting quality target parameters

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check and adjust ancillary equipment as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Distribute product to storage

  1. Monitor and perform necessary adjustments to discharge rate and temperature as required
  2. Monitor the distribution transport system for efficiency and spillages and take appropriate action as required
  3. Monitor the distribution of product to the correct storage area and level of product in that area, and redirect as required
Monitor and perform necessary adjustments to discharge rate and temperature as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor the distribution transport system for efficiency and spillages and take appropriate action as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor the distribution of product to the correct storage area and level of product in that area, and redirect as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Respond to problems

  1. Identify possible routine and non-routine problems in the equipment or process
  2. Determine problems needing action
  3. Determine possible fault causes
  4. Rectify problem using appropriate solution within area of responsibility
  5. Follow through items initiated until final resolution has occurred
  6. Report problems outside area of responsibility to designated person
Identify possible routine and non-routine problems in the equipment or process

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine problems needing action

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine possible fault causes

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Rectify problem using appropriate solution within area of responsibility

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Follow through items initiated until final resolution has occurred

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Report problems outside area of responsibility to designated person

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down equipment

  1. Ensure line is clear of all product and left ready for shutdown
  2. Shut down equipment in accordance with procedures
  3. Complete appropriate records and logs
  4. Shut down equipment in an emergency situation
Ensure line is clear of all product and left ready for shutdown

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down equipment in accordance with procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete appropriate records and logs

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down equipment in an emergency situation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare equipment for maintenance

  1. Isolate equipment in accordance with procedures
  2. Remove any broken materials safely
  3. Ensure area is clear and safe for maintenance
Isolate equipment in accordance with procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Remove any broken materials safely

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure area is clear and safe for maintenance

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Control hazards

  1. Identify hazards in kiln work area
  2. Assess the risks arising from those hazards
  3. Implement measures to control those risks in line with procedures and duty of care
Identify hazards in kiln work area

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assess the risks arising from those hazards

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Implement measures to control those risks in line with procedures and duty of care

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

Elements describe the essential outcomes.

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

1

Prepare for processing

1.1

Notify/keep informed all relevant people about the current status operations and any intention to make changes

1.2

Perform all pre-start checks in accordance with standard operating procedures (SOPs)

1.3

Set up and configure equipment start-up function complying with procedures

1.4

Check plant/equipment settings against operating parameters as identified in SOPs

1.5

Load raw materials in accordance with work instructions

1.6

Start up plant/equipment in accordance with procedures

2

Process raw meal

2.1

Commence/continue process operations in accordance with specified operating procedures

2.2

Monitor and check against target parameters instrument/control panels for variations, fluctuations or trends

2.3

Maximise throughput of system while meeting quality target parameters

2.4

Check and adjust ancillary equipment as required

3

Distribute product to storage

3.1

Monitor and perform necessary adjustments to discharge rate and temperature as required

3.2

Monitor the distribution transport system for efficiency and spillages and take appropriate action as required

3.3

Monitor the distribution of product to the correct storage area and level of product in that area, and redirect as required

4

Respond to problems

4.1

Identify possible routine and non-routine problems in the equipment or process

4.2

Determine problems needing action

4.3

Determine possible fault causes

4.4

Rectify problem using appropriate solution within area of responsibility

4.5

Follow through items initiated until final resolution has occurred

4.6

Report problems outside area of responsibility to designated person

5

Shut down equipment

5.1

Ensure line is clear of all product and left ready for shutdown

5.2

Shut down equipment in accordance with procedures

5.3

Complete appropriate records and logs

5.4

Shut down equipment in an emergency situation

6

Prepare equipment for maintenance

6.1

Isolate equipment in accordance with procedures

6.2

Remove any broken materials safely

6.3

Ensure area is clear and safe for maintenance

7

Control hazards

7.1

Identify hazards in kiln work area

7.2

Assess the risks arising from those hazards

7.3

Implement measures to control those risks in line with procedures and duty of care

Required Skills and Knowledge

Elements describe the essential outcomes.

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

1

Prepare for processing

1.1

Notify/keep informed all relevant people about the current status operations and any intention to make changes

1.2

Perform all pre-start checks in accordance with standard operating procedures (SOPs)

1.3

Set up and configure equipment start-up function complying with procedures

1.4

Check plant/equipment settings against operating parameters as identified in SOPs

1.5

Load raw materials in accordance with work instructions

1.6

Start up plant/equipment in accordance with procedures

2

Process raw meal

2.1

Commence/continue process operations in accordance with specified operating procedures

2.2

Monitor and check against target parameters instrument/control panels for variations, fluctuations or trends

2.3

Maximise throughput of system while meeting quality target parameters

2.4

Check and adjust ancillary equipment as required

3

Distribute product to storage

3.1

Monitor and perform necessary adjustments to discharge rate and temperature as required

3.2

Monitor the distribution transport system for efficiency and spillages and take appropriate action as required

3.3

Monitor the distribution of product to the correct storage area and level of product in that area, and redirect as required

4

Respond to problems

4.1

Identify possible routine and non-routine problems in the equipment or process

4.2

Determine problems needing action

4.3

Determine possible fault causes

4.4

Rectify problem using appropriate solution within area of responsibility

4.5

Follow through items initiated until final resolution has occurred

4.6

Report problems outside area of responsibility to designated person

5

Shut down equipment

5.1

Ensure line is clear of all product and left ready for shutdown

5.2

Shut down equipment in accordance with procedures

5.3

Complete appropriate records and logs

5.4

Shut down equipment in an emergency situation

6

Prepare equipment for maintenance

6.1

Isolate equipment in accordance with procedures

6.2

Remove any broken materials safely

6.3

Ensure area is clear and safe for maintenance

7

Control hazards

7.1

Identify hazards in kiln work area

7.2

Assess the risks arising from those hazards

7.3

Implement measures to control those risks in line with procedures and duty of care

Evidence required to demonstrate competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria and demonstrate the ability to:

read and interpret procedures, job specifications, production schedules, test results, instruments/control panels, material labels and safety data sheets (SDS)

set up equipment to process specifications

perform pre-start checks, start-up/shutdown procedures and isolations

monitor key variables, including:

operating temperatures

material feed rate

discharge rate

material properties/chemical reactions

product integrity and general conformance to specification

use data and own senses to monitor plant and maximise performance

make adjustments to equipment settings, process conditions and/or raw materials to bring production into specification

identify hazards and apply relevant hazard controls

apply safety procedures

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

distinguish between causes of problems, including:

instrument failure/malfunction

electrical/mechanical failure/malfunction

raw material variations/contamination

kiln quality and optimisation practices

types of kiln fuels and reactions

process abnormalities

procedural errors

recognise and prioritise problems requiring action

resolve routine and non-routine problems

communicate effectively with team/work group and supervisors

complete workplace records

do basic arithmetical manipulations, including additions, subtractions, divisions, fractions and percentages.

Must provide evidence that demonstrates knowledge relevant to their job sufficient to operate independently and to solve routine and non-routine problems, including knowledge of:

functions, limitations and principles of operation of the kiln and ancillary/supporting equipment

impact of variations in equipment settings, process conditions and raw materials on product quality and production output

factors which may affect product quality or production output and appropriate remedies

physics and chemistry relevant to the equipment/process/materials

characteristics of materials being processed and their behaviour in relation to process conditions and stages of production

quality requirements at each stage of production

common adjustments in process variables and their impact on product quality and production output

start-up and shutdown processes

routine and non-routine problems that may arise, the range of possible causes and appropriate actions

organisation procedures relevant to the work environment/job role

hierarchy of control

hazards that may arise in the job/work environment and:

their possible causes

potential consequences

appropriate risk controls.

Range Statement

This field allows for 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.

Regulatory framework

The latest version of all legislation, regulations, industry codes of practice and Australian/international standards, or the version specified by the local regulatory authority, must be used.

Applicable legislation, regulations, standards and codes of practice include:

health, safety and environmental (HSE) legislation, regulations and codes of practice relevant to the workplace, equipment and production processes and hazardous materials

Australian/international standards relevant to the materials being used and products being made

any relevant licence and certification requirements.

All operations to which this unit applies are subject to stringent HSE requirements, which may be imposed through state/territory or federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between performance criteria and such requirements the legislative requirements take precedence.

Procedures

All operations must be performed in accordance with relevant procedures.

Procedures are written, verbal, visual, computer-based or in some other form, and include one or any combination of:

manufacturer's technical information

job cards

drawings

emergency procedures

work instructions

SOPs

safe work method statements (SWMS)

formulas/recipes

batch sheets

temporary instructions

any similar instructions provided for the smooth running of the plant.

Hazards

Hazards must be identified and controlled. Identifying hazards requires consideration of:

heat, smoke, dust, vapours or other atmospheric hazards

weight, shape, volume of materials to be handled

hazardous products and materials

sharp edges, protrusions or obstructions

slippery surfaces, spills or leaks

electricity

gas

gases and liquids under pressure

noise

rotational equipment or vibration

plant services (steam, condensate, cooling water, etc)

structural hazards

equipment failures

machinery, equipment and product mass

limited head spaces or overhangs

working at heights

working in restricted or confined spaces

other hazards that might arise.

Problems

Routine and non-routine problems must be resolved.

Routine problems are predictable and have known solutions and include one or more of:

equipment malfunctions

temperature fluctuations

quality of product

material/feed variations

spillages and leakages

inaccuracies in blending and proportioning of raw materials

out-of-specification moisture content of raw materials/slurry

variations in temperature, time and cooling rates

variations in feed rates or quantities

vibration.

Non-routine problems are unexpected problems or variations of previous problems.

Non-routine problems must be resolved by applying operational knowledge to develop new solutions, either individually or in collaboration with relevant experts, to:

determine problems needing action

determine possible fault causes

develop solutions to problems which do not have a known solution

follow through items initiated until final resolution has occurred

report problems outside area of responsibility to designated person.

Operational knowledge includes one or more of:

procedures

training

technical information, such as journals and engineering specifications

remembered experience

relevant knowledge obtained from appropriate people.

Tools and equipment

Tools and equipment include:

kiln

instrument panels (local)

measuring and recording equipment

ancillary equipment that is integral to the process

support equipment (e.g. grinding mills, pumps, dust collectors, mixing and blending silos, vibrating screens and rotary kilns).

Additional equipment will be selected as required from:

communication equipment

hand tools

emergency stop buttons and lanyards

safety clothing and equipment.