Elements and Performance Criteria

Range description
Work is carried out according to company procedures, regulatory and licensing requirements, legislative requirements, and industrial awards and agreements
Legislative requirements are typically reflected in procedures and specifications. Legislation relevant to this industry includes the Food Standards Code including labelling, weights and measures legislation; and legislation covering food safety, environmental management, occupational health and safety, anti-discrimination and equal opportunity. When applied to the pharmaceutical industry, relevant GMP codes apply in place of the Food Standards Code and reference to food safety is replaced by GMP
Workplace information may include Standard Operating Procedures (SOPs), specifications, production schedules and instructions, performance records and reports
A system typically involves a series of inter-related processes that must be co-ordinated and concurrently operated to produce the required outcome
System operation may involve co-ordination of operators of system components
Handovers may be done in person or via recording/communication systems according to workplace arrangements
Operation and monitoring of equipment and system processes typically requires the use of control panels and systems
Shutdown procedures may include cleaning. In some cases cleaning may be carried out by a dedicated cleaning crew
Confirming cleaning requirements and status may involve accessing cleaning records

Ability to:
Access production schedule and related information to identify system output and operating requirements. This may involve planning daily production schedules and/or modifying plans to respond to operating conditions and customer requirements
Liaise with relevant work areas to confirm and/or secure necessary materials, services, equipment and labour to meet production requirements
Confirm supply of necessary equipment and related attachments, materials and services
Select, fit and use personal protective clothing and/or equipment
Set and/or adjust equipment to meet process output requirements. This includes inspecting equipment condition to identify any signs of wear; confirming selection of appropriate settings and/or related parameters; ensuring that isolation or lockouts are cancelled as required; confirming that equipment is clean and correctly configured for processing requirements; sensors and controls are correctly positioned; any scheduled maintenance has been carried out, and that all safety guards are in place and operational. Checks may be done by the system operator or involve observing/supporting others setting and adjusting equipment and conducting pre-start checks
Load and/or position materials, ingredients and/or product as required
Operate and monitor the production system. This may involve use of a process control system and/or observing/supporting others to follow correct operating procedures
Monitor materials flow and work-in-progress through the system
Confirm that the system operates within specified parameters and inspection/ control points are monitored
Determine responses to out-of-specification results or non-conformance within level of responsibility
Monitor operating efficiencies of the system and investigate, resolve and/or report problems
Plan scheduled events to minimise disruption to production
Conduct/co-ordinate product or batch changeovers
Conduct/co-ordinate shift handovers
Review and maintain procedures to support system improvements
Maintain work area to meet housekeeping standards

Knowledge of:
Purpose and basic principles of the production system. This includes an understanding of the system process flow, the inter-relationships of each process to identify the impact of variation on related processes, and optimisation options
Basic operating principles of equipment and related accessories used by the system. This includes a knowledge of equipment adjustment points, status and purpose of guards, and range and location/alignment requirements of sensors and related feedback instruments
Operating capacities of equipment used in the system. This may include an awareness of different types of equipment and/or components as required by processing/packaging operations
Understanding of related systems and responsibilities for interaction. These typically include related production systems, services supply, packaging/ warehousing, maintenance, laboratory/quality assurance and planning and scheduling
Technical knowledge of product characteristics and common types of variation in materials and/or ingredients used. This includes an understanding of the effect of variation on each stage of the system and scope to adjust or correct
Typical equipment faults and related causes. This includes recognition of signs and symptoms of faulty equipment and early warning signs of potential problems
Relevant procedures, specifications and operating parameters for the system and the individual processes
Isolation, lock out and tag out procedures and responsibilities
Hazards, risks, controls and methods for monitoring processes within the system. This includes health and safety, food safety, quality and environmental hazards and risks
Workplace system and approach to equipment maintenance
Process improvement procedures and related consultative arrangements
Troubleshooting procedures and problem solving techniques
Communication responsibilities to inform related work areas/support functions and other shifts of operational status and production issues
Procedures and responsibility for reporting production and performance information

Relationship with other standards
Pre-requisite units
At least two specialist units at AQF 2 relevant to the system operated are pre-requisites for this unit, except where this unit is applied to a Plant Baking or Retail Baking qualification where no pre-requisite units from AQF 2 apply.
Co-assessment of related units

This unit should be assessed together with core units and other units of competence relevant to the function or work role. In addition, the following optional or ancillary units may be relevant:

FDFZPRCI2A Operate a process control interface
FDFOPTSM3A Support and mentor individuals and groups

Resources required for assessment

Assessment must occur in a real or simulated workplace where the assessee has access to:

Personal protective clothing and equipment
Production schedule and related advice on system requirements
Information on equipment capacity and operating parameters
Production system equipment and related accessories and services
Materials/consumables required by the process
Communication and recording systems and procedures

Assessment requirements
For information on how to assess this competency standard and who can assess, refer to the Assessment Guidelines for this Training Package.