Unit of competency details

Unit descriptor 

This unit describes the outcomes required to monitor and control coated paper processes in the pulp and paper industry

General legislation, regulatory, licensing and certification requirements applicable to this unit are detailed in the range statement

Specific high risk licensing requirements for this unit may be applicable and are to be met separately and prior to the achievement of this unit

Application of the unit 

This unit applies to operators who monitor and control 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:

• monitor and maintain process
• monitor and maintain product, and
• record and report product and process performance data

to meet safety, quality and productivity requirements

It does not include starting up, shutting down or troubleshooting and rectifying coated paper processes

Employability skills 

This unit contains employability skills

Elements describe the essential outcomes of a unit of competency.

Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold italicised text is used, further information is detailed in the required skills and knowledge section and the range statement. Assessment of performance is to be consistent with the evidence guide.

ELEMENT 

PERFORMANCE CRITERIA 

1. Monitor and maintain process

1.1. Process is monitored and maintained within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements

1.2. Production requirements are checked at start of shift to plan the day's activities as required

1.3. Operational status is confirmed by inspection, observation and other information

1.4. Process supplies are maintained to production requirements

1.5. Process is monitored to ensure coating system operations are within specification

1.6. Process levels are monitored and maintained

1.7. Operator level preventative maintenance schedules are carried out as required

1.8. Routine process and system variations from specification are identified, rectified and/or reported

2. Monitor and maintain product

2.1. Product is monitored and maintained within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements

2.2. Product is monitored and maintained to quality requirements

2.3. Routine visual observations and assessments are conducted on product and systems operations

2.4. Test samples are taken and results interpreted and recorded as required

2.5. Systems operations adjustments are made to rectify out-of-specification product

3. Record and report product and process performance data

3.1. Product and process performance data is recorded and reported within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements

3.2. Production data is interpreted and entered into recording system

3.3. Problems or variations with the process or product are communicated to relevant personnel

REQUIRED SKILLS AND KNOWLEDGE 

This describes the skills and knowledge required for this unit.

Required skills 

• Uses required forms of communication in monitoring and controlling coated paper processes
• Reads and interprets required documentation, procedures and reports
• Accesses, navigates and enters computer-based information
• Monitors, analyses and interprets data
• Interprets instruments, gauges and data recording equipment
• Identifies and actions problems within level of responsibility
• Identifies and monitors process control points
• Maintains situational awareness in the work area
• Takes samples, conducts tests and interprets and records results if required
• Uses measuring equipment as required
• Maintains a clear and hazard free plant work area
• Operates high risk load shifting equipment as required
• Maintains quality specifications
• Inspects and maintains equipment and systems to specifications
• Analyses and uses sensory information to adjust process to maintain 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
• Safe handling of materials and chemicals
• Quality requirements
• Relevant forms of communication
• Basic problem-solving techniques consistent with level of responsibility
• Working knowledge of coated paper processes, system layout and associated services including operating parameters, variation and associated adjustments within level of responsibility
• Sampling and testing process for plant and system operations, and process monitoring - purpose, standards and procedures as per site agreements
• Effect of process adjustments during monitoring and operation
• 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 GUIDE 

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 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 monitoring and controlling 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
• 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
• obstructions
• 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