SKILL  KNOWLEDGE  SAFETY

MSAPMOPS200A - Operate equipment

Description

 This competency covers the operation of equipment and the resolving of routine problems to procedure in the production process. This competency is for organisation specific equipment items which are not otherwise covered in this Training Package

Pre Requisites

 Nil

Application

 This competency applies to operators who are required to undertake the routine operation of equipment in the production process. The key factors are the making of products to meet quality standards and workplace requirements. This competency is typically performed by operators working either independently or as part of a work team.  It includes:
  •     checking job sheets for work requirements
  •     following approved hazard minimisation procedures for any hazards connected with materials and process, using work instructions, labels and materials safety data sheets, and in accordance with OHS legislative responsibilities
  •     monitoring equipment operation and reporting process variations checking product for quality and conformity to specifications discarding non-conforming products ensuring discarded materials are reused where possible and waste and scrap is disposed of in accordance with workplace instructions
  •     identifying and taking action on routine process problems
  •     completing logs and reports

Performance Criteria

 1. Check work requirements.    
1.1 Identify work requirements from work plan or request.
1.2 Check product, materials and equipment meet requirements for job(s).
1.3 Recognise requirements which may not be in accordance with usual practice.
1.4 Ask questions of appropriate person to confirm unusual practice.
1.5 Ensure housekeeping is to requirements.
1.6 Identify hazards associated with the job and take appropriate action.
1.7 Perform other pre-operational checks in accordance with procedures.

2 Start up item of equipment as required.    
2.1 Conduct prestart checks.
2.2 Start up item of equipment

3. Operate equipment to procedures.    
3.1 Check equipment is operating within required limits.
3.2 Check product meets specifications and quality standards.
3.3 Ensure product is consistently ready for next duty/ operation as appropriate.
3.4 Maintain supply of material(s) as required.
3.5 Complete logs and records as required.
3.6 Collect and segregate scrap, trim and other materials as required.
3.7 Keep equipment and work area clean.
3.8 Pause equipment and perform emergency stop, as required.

4. Respond to routine problems to procedures.    
4.1 Recognise known faults that occur during the operation.
4.2 Identify and take action on causes of routine faults.
4.3 Log problems as required.
4.4 Identify non-routine process and quality problems and take appropriate action.

Required Skills & Knowledge

 This describes the essential skills and knowledge and their level required for this unit.
Application of knowledge of the materials, equipment and process sufficient to recognise out of specification products, process problems and materials faults.
Knowledge of the organisation's procedures and relevant regulatory requirements along with the ability to implement them within appropriate time constraints and work standards.

Knowledge of and skills in the operation of the item of equipment and main components sufficient to consistently meet required specifications and standards including:
  •     operation of process equipment and components
  •     production workflow sequences and materials demand
  •     reasons for checking process control panels and reporting readings which do not conform to the work instructions
  •     approved hazard control and safety procedures and the use of PPE in relation to handling materials and using equipment
  •     equipment operation and cleanup; potential effects of variations in raw materials and equipment operation in relation to quality of product
  •     waste management and importance of reusing non-conforming products wherever possible
  •     correct selection and use of equipment, materials, processes and procedures
  •     monitor equipment operation and product quality
  •     identify factors which may affect product quality or production output and appropriate remedies
  •     distinguish between possible causes of routine faults such as:
  •     incorrect quantity of materials
  •     contaminated materials/additives
  •     equipment faults/damage
  •     wrong raw materials/additives
  •     machine failure.

Competence also includes the ability to:
  •     plan own work, including predicting consequences and identifying improvements
  •     identify when the operator is able to rectify faults, when assistance is required and who is the appropriate source for assistance
  •     identify and describe own role and role of others involved directly in the process.

Language, literacy and numeracy requirements
This unit requires the ability to read and interpret typical product specifications, job sheets, procedures, material labels and safety information as provided to operators.
Writing is required to the level of completing workplace forms.
Basic numeracy is required, eg to determine that two 25 kg bags are needed to make up a requirement for 50 kg.

Range Statement

 Context
This competency applies to operators working either independently or as part of a work team.

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.

Tools and equipment
This competency includes use of equipment and tools such as:
  •     process equipment and its major components
  •     hand tools used in the this process
  •     material loading equipment used for loading of raw materials
  •     relevant personal protective equipment.

Hazards
Typical hazards include:
  •     spills
  •     dusts/vapours
  •     slips trips and falls
  •     temperature
  •     hazardous substances
  •     moving equipment
  •     manual handling hazards.

Problems
'Respond to routine problems' means 'apply known solutions to a limited range of predictable problems'.  Typical process and product problems may include:
  •     equipment malfunction
  •     variations in process conditions
  •     variations in materials or contamination of materials
  •     equipment, tool, die or mould damage
  •     routine product faults
  •     machine malfunction
  •     mould/tooling problems
  •     variations in materials and/or contamination of materials.

Variables
Key variables to be monitored include:
  •     atmospheric conditions
  •     temperature (hot/cold) variations in equipment or product
  •     die/product tolerances
  •     system/operating pressure
  •     programming variables
  •     operator variability
  •     timing or product cycles.

Evidence Guide

 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.
Assessment will occur on an industrial example of the equipment and will be undertaken in a work-like environment.

Critical aspects for assessment and evidence required to demonstrate competency in this unit
It is essential that competence is demonstrated in the knowledge and skills defined in this unit. These may include the ability to:
  •     recognise the importance of material properties and qualities
  •     apply approved procedures
  •     take appropriate action to resolve faults or report faults to appropriate personnel
  •     explain and implement emergency shutdown procedures.

Consistent performance should be demonstrated. For example, look to see that:
  •     production standards are met consistently
  •     upstream and downstream communication is timely and effective operating procedures and work instructions are read and interpreted correctly
  •     problems are identified and appropriate action is taken (ie the problem is fixed or reported)
  •     all safety procedures are followed.

Assessment method and context
Competence in this unit may be assessed:
  •     in an appropriate, industrial item of equipment requiring demonstration of operation start and stop procedures
  •     in a situation allowing the generation of evidence of the ability to respond to problems
  •     by using a suitable simulation and/or a range of case studies/scenarios
  •     through a combination of these techniques.

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.

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