Modification History
Not applicable.
Unit Descriptor
Unit descriptor
This competency covers the ability to optimise the process performance of a complete plant area. It includes ensuring that production systems comply with Health, Safety and Environment (HSE) requirements, that process, plant and equipment utilisation is planned and carried out, and that problems are solved to fully meet operational needs and ensure that production of finished goods meets customer requirements.
Application of the Unit
Application of this unit
This competency requires the application of detailed operational and process knowledge, including the principles of operation of equipment, and the chemistry and/or physics and/or biology/biochemistry of changes to materials occurring during processing. It embodies a significant breadth and depth of technical knowledge and process understanding.
Assessment of this competency should ensure that the applicant can apply this knowledge to a process, and should typically rely on the applicant undertaking, or leading, a significant process improvement project.
This competency is typically performed by a senior operator, team leader or frontline manager.
Licensing/Regulatory Information
Not applicable.
Pre-Requisites
Prerequisites
This unit has prerequisites of
- MSAPMSUP390A Use structured problem solving tools
Employability Skills Information
Employability Skills
This unit contains employability skills.
Elements and Performance Criteria Pre-Content
|
ELEMENT Elements describe the essential outcomes of a unit of competency |
PERFORMANCE CRITERIA Performance criteria describe the required performance needed to demonstrate achievement of the element. Assessment of performance is to be consistent with the evidence guide. |
Elements and Performance Criteria
|
ELEMENT ELEMENT |
PERFORMANCE CRITERIA Performance criteria describe the required performance needed to demonstrate achievement of the element. Assessment of performance is to be consistent with the evidence guide. |
|
1. Analyse and evaluate current plant, equipment and processes. |
1.1 Compare actual process, plant and equipment performance with requirements and/or historical data/records and/or design performance. 1.2 Identify abnormal or sub-optimal process, plant and equipment performance. 1.3 Identify hazards associated with the plant and equipment. 1.4 Collect and evaluate product, materials and/or process records to determine possible causes for sub-optimal performance. 1.5 Use appropriate techniques to rank possible causes from most to least probable cause. |
|
2. Develop plan for corrective and/or optimisation action. |
2.1 Analyse cause(s) to determine appropriate corrective action. 2.2 Predict the impact of a change in one unit/area on other related plant units/areas. 2.3 Predict the impact of a change on health, safety and environmental performance 2.4 Develop measurable objectives and evaluate alternatives. 2.5 Identify requirements to implement change. 2.6 Consult with stakeholders regarding planned changes and impacts. 2.7 Develop optimisation plan taking account of hazards identified and HSE implications and communicate to appropriate personnel. 2.8 Evaluate optimisation action to determine measures of effectiveness. |
|
3. Coordinate corrective and/ or optimisation action plan |
3.1 Coordinate all appropriate unit areas and operations in order to rectify problem causes in process, plant and equipment performance. 3.2 Initiate and/or implement all required corrective/ optimisation actions. 3.3 Communicate corrective/optimisation outcomes to all relevant personnel. 3.4 Implement procedures/systems to eliminate possible future causes. 3.5 Record and maintain log of all relevant information. |
|
4. Develop continuous improvement strategies. |
4.1 Review sources of information to identify possible factors causing sub-optimal performance. 4.2 Identify options for removing or controlling the risk of sub-optimal performance. 4.3 Assess the adequacy of existing control and quality methods and systems. 4.4 Identify opportunities to continuously improve performance. 4.5 Develop recommendations for continual improvement of process, plant and equipment effectiveness. 4.6 Consult with appropriate personnel and implement continuous improvement strategies. 4.7 Document implementation of continuous improvement strategies. |
Required Skills and Knowledge
This describes the essential skills and knowledge and their level required for this unit.
Knowledge and understanding of the:
- equipment,
- processes
- systems
sufficient to
- identify hazards associated with the process
- recognise opportunities to improve and/or enhance the quality of performance of the plant.
This knowledge needs to include:
- the relevant technical theory of the plant area
- an in depth understanding across the entire plant area
- the organisation standard procedures and work instructions
- relevant regulatory requirements, including those related to OHS risk control as appropriate to process/plant area optimisation.
Competence includes the ability to:
- apply analytical skills which enable corrective or optimal conditions to prevail
- identify and control hazards by applying the hierarchy of control as part of the optimisation process
- interpret information and make appropriate process control decisions.
Competence includes the ability to distinguish between:
- optimum and marginal performance of the plant
- effective and marginal performance corrections and actions.
as is relevant to the practical operation of all major equipment/process/systems within the area.
Optimising process systems requires application of detailed operational and process knowledge to address issues such as:
- starting material quality
- yield maximisation
- throughput maximisation
- energy efficiency
- use of utilities
- labour utilisation
- overall cost
- efficient use of equipment
- reducing downtime
- minimisation of waste and rework
- improved workplace layout and workflow.
Language , literacy and numeracy requirements
This unit requires the ability to communicate at all levels about what may be complex technical matters. It also requires the ability to evaluate complex information and sort often conflicting information into useful and distracting and to rank/prioritise information.
Writing is required to the level of reading and interpreting technical information, developing and modifying plans and procedures and interpreting relevant regulatory requirements.
Numeracy is required to the level of analysing product/process performance data, interpreting process condition information and deriving useful information from technical brochures, papers and similar. Calculation will be required to assist this and to determine priorities for optimisation plans (ie benefit/cost or other quantitative criteria)
Evidence Guide
The Evidence Guide provides advice on assessment and must be read in conjunction with the Performance Criteria, Required Skills and Knowledge, the Range Statement and the Assessment Guidelines for this Training Package.
Overview of assessment
A holistic approach should be taken to the assessment.
Assessors must be satisfied that the person can consistently perform the unit as a whole, as defined by the Elements, Performance Criteria and skills and knowledge.
Competence must be demonstrated in the ability to analyse and evaluate current production performance, and develop and implement plans to optimise process systems.
While the technician is expected to take a lead technical role, and to demonstrate competence as defined above, optimisation is rarely undertaken by an individual alone and liaison with all relevant stakeholders is an expected part of this competency.
Where the assessee does not currently possess evidence of competency in MSASUP390A Use structured problem solving tools , it may be coassessed with this unit.
Criticalaspects for assessment and evidence required to demonstrate competency in this unit
It is essential that the equipment/process/system be understood in depth and that the importance of critical material properties/settings/readings is known. Competence must be demonstrated in the ability to recognise and analyse potential situations requiring action and then in implementing appropriate corrective action.
Consistent performance should be demonstrated. For example, look to see that:
- non-routine problems are recognised and defined
- hazards are identified and controlled by applying the hierarchy of control
- possible causes of complex problems are identified based on experience and the use of analytical techniques in solving the problem, including identifying variations and cause, separating single problems from multiple problems and the recognition of recurring problems
- fundamental cause of process or equipment faults is determined
- corrective/preventative actions are developed to avoid recurrence of the problem and optimise the condition of the process, plant and equipment
- product quality and uniformity are maintained.
Competence must be demonstrated in the operation of all ancillary equipment to the level required for this competency unit.
Competence also includes the ability to implement improvements within appropriate time constraints and in a manner relevant to the operation of the equipment, processes and systems.
Context of assessment
Competence in this unit may be assessed by:
- observation over time in a processing plant allowing for adequate assessment of operation under all normal and a range of abnormal conditions. Where this is not practical, additional assessment techniques must be used.
- using a suitable simulation and/or a range of case studies/scenarios
- undertaking a specific project based in the plant
- a combination of these techniques.
Method of assessment
In all cases it is expected that practical assessment will be combined with targeted questioning to assess the underpinning knowledge and theoretical assessment will be combined with appropriate practical/simulation or similar assessment. Assessors need to be aware of any cultural issues that may affect responses to questions.
Assessment processes and techniques must be culturally appropriate and appropriate to the oracy, language and literacy capacity of the assessee and the work being performed.
Specific resources for assessment
This section should be read in conjunction with the Range Statement for this unit of competency. Resources required include suitable access to an operating plant or equipment that allows for appropriate and realistic simulation. A bank of case studies/scenarios and questions will also be required to the extent that they form part of the assessment method. Questioning may take place either in the workplace, or in an adjacent, quiet facility such as an office or lunchroom. No other special resources are required.
Access must be provided to appropriate learning and/or assessment support when required. Where applicable, physical resources should include equipment modified for people with disabilities.
Range Statement
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. Add any 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.
Where reference is made to industry codes of practice, and/or Australian/international standards, the latest version must be used.
Context
This unit describes the work conducted by senior operators, team leaders or front line managers who optimise process systems as part of their work function. It includes all items of equipment and unit operations which form part of the production process of a complete area.
Typical problems will require the application of detailed operational and process knowledge over the entire production/manufacturing area, including the principles of operation of the equipment and the chemistry, physics, biology and/or biochemistry of the changes to materials occurring within that area.
All operations are performed in accordance with organisation procedures, licensing requirements, legislative requirements and industrial awards and agreements.
Procedures
All operations are performed in accordance with procedures. Procedures means all relevant workplace procedures, work instructions, temporary instructions and relevant industry and government codes and standards. These may include or have been prepared from/to comply with:
- industry codes of practice
- materials safety data sheets
- equipment manuals
- equipment start up, operation and shut down procedures
- calibration and maintenance schedules
- quality manuals and procedures
- organisation recording and reporting procedures
- production and laboratory schedules
- material, production and product specifications.
Data /records
Historical data/records may include:
- hazard logs
- incident reports
- maintenance records
- product non-conformance reports
- production records.
Implementing change
Requirements to implement change may include:
- changes to procedures
- training of operators
- equipment modifications
- ensuring all HSE requirements are addressed.
Relevant /appropriate personnel
Relevant/appropriate personnel may include:
- managers
- OHS representatives and OHS committee.
Relevant information
Relevant information logged to include:
- modifications to plant or equipment
- modifications to procedures or practices.
Sources of information
Sources of information may include:
- hazard logs
- incident reports
- maintenance records
- work practices
- procedures
- industry journals
- equipment supplier information
- industry best practice information.
Health , Safety and Environment (HSE )
All operations to which this unit applies are subject to stringent health, safety and environment requirements, which may be imposed through State or Federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between Performance Criteria and HSE requirements, the HSE requirements take precedence.
Unit Sector(s)
Not applicable.
