engineering employees (fabrication and mechanical trades

T r a n s f i e l d S e r v i c e s ( A u s t r a l i a ) P t y L t d

i n t h e M a c k a y S u g a r A l l i a n c e

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TRAINING AND RECLASSIFICATION AGREEMENT

ENGINEERING EMPLOYEES

(Fabrication and Mechanical Trades)

PRODUCTIVITY AND SKILLS BASED

TRAINING AND RECLASSIFICATION

Agreement

Issued: 31 October 2004

Transfield Services (Australia) Pty Ltd in the Mackay Sugar Alliance – Training Agreement

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Table of Contents

TRAINING AND RECLASSIFICATION AGREEMENT ..................................................... 1

Introduction. .............................................................................................................................. 1

Application. ................................................................................................................................ 1

Objectives. .................................................................................................................................. 1

Principles. .................................................................................................................................. 2

Training. .................................................................................................................................... 2

Available Work. ......................................................................................................................... 3

Requirements For Reclassification. .......................................................................................... 3

Guidelines for Reclassification. ................................................................................................ 4

Special Provisions and Limitations. ......................................................................................... 5

Applications for Reclassification. ............................................................................................. 7

Reclassification Planning for Individuals. ............................................................................... 8

Temporary Employees. .............................................................................................................. 8

Employee Relations. .................................................................................................................. 9

Disputes. ..................................................................................................................................... 9

Authorisation and Agreement. .................................................................................................. 9

AMENDMENTS:

1. Additional competencies added to Broad Job Category 1 skills list and Skills Audit document. (5.4, 5.19, 5.49, 10.1, 18.55)

2.



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INTRODUCTION.

1. This agreement between Transfield Services (Australia) Pty Ltd (Transfield Services) and the engineering employees at the Mackay Sugar Alliance (those employed generally as Fitters or Boilermakers), is intended to ensure safe, legal and logical application of skills in order to maximise productivity. Tradespeople typically referred to as ‘Building Trades’ (Plumbers and Carpenters) will be covered by this agreement in the future, with implementation to be effective on 28 Feb 05.

APPLICATION.

2. This agreement applies to all permanent and temporary engineering employees, employed by Transfield Services (Australia) Pty Ltd at the Mackay Sugar Site.

3. This agreement has specific application to TSL and its employees at the Mackay Sugar Alliance. It shall not be referred to by the parties in respect of any other employer.

4. This agreement will be applied in conjunction with relevant terms of the current Enterprise Agreement. For example, wage rates are those in the Mackay Sugar Alliance Enterprise Agreement.

5. This agreement supersedes all previous documents intended for the same purpose.

6. The following documents were referenced in the production of this agreement:

a. Mackay Sugar ENGINEERING EMPLOYEES (Fabrication and Mechanical Trades) PRODUCTIVITY AND SKILLS BASED TRAINING AND RECLASSIFICATION POLICY (01 Dec 1999);

b. Engineering Award State (2002);

c. TSL - Mackay Sugar Alliance Enterprise Agreement 2003-2006;

d. MSCA Enterprise Agreement 2003-2006: and

e. National Metals and Engineering Industry Competency Standards Implementation Guide, 4th Edition, (November 1999).

OBJECTIVES.

7. The intent of this Agreement is to provide a framework for job design and re-design, providing a methodology for skilling and reclassification of engineering employees. The specific objectives are to:

a. Improve workplace productivity and efficiency by developing a more skilled workforce through gaining the correct balance between specialisation and flexibility;

b. Stimulate the initiative, motivation and job satisfaction of employees;

c. Address skill needs and improvements in the way work is performed at the Mackay Sugar Alliance;


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d. Identify training which is of benefit to both employees and the Mackay Sugar Alliance; and

e. Provide appropriate recognition for competencies when achieved and when the appropriate skills, knowledge and attitudes acquired, are put to use in the workplace.

PRINCIPLES.

8. The following principles form an integral part of this agreement:

a. People will be free to perform any task if it can be completed safely, legally and logically, in accordance with the current job design and classification structure;

b. People will be expected to maintain their core, trade relevant skills, through relevant training, in order to remain as a specialist in their field;

c. People will be expected to utilise a broad range of skills (some from outside the traditional trade role) to support their specialist role;

d. Classification levels will be determined by reference to the employee's job model, to this training Agreement, and to the existing Engineering Competency Standards;

e. People will be consulted when it is required to alter their job design at the Mackay Sugar Alliance;

f. People will be encouraged to reach their maximum potential - in pay and productivity within the current job design;

g. Competence will be recognised no matter how or where the skill was acquired;

h. Competencies will be counted toward reclassification upon production of evidence from a Registered Training Organisation, or via an accredited Assessor, that competence has been achieved; and

i. The intent and the principles of this agreement receive primacy over all other parts of the agreement.

TRAINING.

9. Training Priorities. When training is undertaken, or planned to be undertaken by an employee at the Mackay Sugar Alliance, it shall prioritised in the following order:

a. Priority 1: Training to provide for legal compliance, or safety compliance to perform a particular task described within the employee's current job design;

b. Priority 2: Training to up-skill employees in order to meet a skill shortage within an employee's current job design; and

c. Priority 3: Training to meet a need which is outside an employee's current job design - i.e. preparation of an employee for movement to a different position - covered by another job design (eg. promotion to supervisor or other position).


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10. Competencies Available for Reclassification. Training undertaken as described above will be available for reclassification when it is in accordance with the principles of this Agreement.

11. Provision of Training. The responsibility for Priority 1 Training (as described above) will remain with the employer. Priority 2 and 3 training will remain the responsibility of the employee. However, where the employer sees fit to increase the skill level in a particular workplace to meet a clearly identified need, the employer will undertake to arrange and pay for the training.

AVAILABLE WORK.

12. The current job design has set the number of positions available at a particular level. This current job design will remain in place, and in the case where additional labour is required in a workplace, the advertisement for that labour is required to fit one of the existing positions and broad job categories. This will facilitate correct and efficient classification of new people.

13. Where the current job design model cannot adequately cover the additional labour required, a modified job design is to be agreed by the parties, and the position(s) advertised in line with the modified job design.

14. Some tasks will not be able to accessed by all people who have the relevant competency in their job model simply because there are not enough opportunities to utilise the skill or to access the equipment. (eg. Non-slewing Crane or Forklift) In this case, the competency will not be able to be counted toward reclassification. (In short, TSL does not need or want every tradesperson to hold a non-slew crane certificate.) The same principle applies to a number of skills – even trade specific skills. (eg. TSL does not need all tradespeople to hold advanced fluid power skills or advanced welding skills.)

15. There are a limited number of opportunities to use particular competencies for reclassification. These limits are based on the skills audit results which produced the current job design and are shown in the respective skills matrixes. These numbers can be increased or decreased in a job re-design process - which, if and when conducted, would include consultation with the relevant employee representatives.

16. In summary, the employer will only approve reclassification for an employee for acquisition of additional skills and/or qualifications, where the employee involved is required to exercise them in the course of their employment.

REQUIREMENTS FOR RECLASSIFICATION.

17. The job design process has identified five broad job categories in the Mackay Sugar Alliance covering all fitting and boilermaking activities. They are as follows:

a. Cane Supply Boilermaker;

b. Factories Boilermaker;

c. Machinist;

d. Locomotive Fitter; and

e. General Mill Fitter.


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18. The competency lists attached at appendix 1 set out the competencies relevant for training and reclassification in each broad job category. These lists contain the competencies deemed as 'base trade competencies', and the additional competencies which are relevant to each of the five broad job categories.

19. For persons to be considered for reclassification under this agreement, they must:

a. hold a relevant trade certificate;

b. be employed in one of the five broad job categories; and

c. hold and use skills in excess of the deemed base-trade competencies.

GUIDELINES FOR RECLASSIFICATION.

20. These guidelines form the general rules for reclassification and are in accordance with the National Metals and Engineering Industry Competency Standards Implementation Guide, 4th Edition, (November 1999).

Classification to C10:

21. For persons to be classified at C10 under this agreement they must meet the following criteria:

a. Hold a trade certificate relevant to one of the broad job categories; and

b. Be employed in one of the five broad Job Categories.

Reclassification from C10 to C9:

22. For persons to be reclassified from C10 to C9 they must meet the following criteria:

a. Meet the criteria for C10; and

b. Demonstrate the proficient use of a broad range of skills from the deemed base-trade; and

c. Demonstrate that they hold and use competencies with a total points value of 12, in addition to the deemed base-trade; and

d. Have applied for the reclassification on the relevant Skills Audit form (attached as appendix 2); and

e. Have had their immediate supervisor verify their claim for competent use of skills by countersigning the Skills Audit form or log-book; and

f. Hold a statement of attainment from a RTO verifying the competencies.




b. Demonstrate that they hold and use competencies with a total points value of 12, in addition to those used to gain C9; and


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c. Have applied for the reclassification on the relevant Skills Audit form (attached as appendix 2); and

d. Have had their immediate supervisor verify their claim for competent use of skills by countersigning the Skills Audit form or log-book; and

e. Hold a statement of attainment from a RTO verifying the competencies.




b. Demonstrate that they hold and use B Band or Dual Status competencies with a total points value of 12, in addition to those used to gain C8; and







b. Demonstrate that they hold and use B Band or applicable Dual Status competencies with a total points value of 12, in addition to those used to gain C7; and




SPECIAL PROVISIONS AND LIMITATIONS.

26. Specific rules to guide reclassification situations which fall outside the requirements of the implementation Guide are included in the following Paragraphs.

27. Welding Certificates. Currently, certified or coded welding is covered in the competency standards in ‘A Band’ competencies and by the rules in the Implementation Guide, these are not able to be utilised for reclassification above C8. However, in recognition that the previous agreements permitted certain combinations of welding certificates for reclassification, and given it is expected the relevant competencies will be upgraded to ‘Dual Status’ competencies in the next revision of the competency standards, Transfield Services (Australia) Pty Ltd is prepared to carry over recognition of these certificates.


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28. The following combinations of certificates will apply:

a. Welding Theory (Competency MEM5.26AA) must be held to be able to gain reclassification for any welding certificates;

b. Welding Certificate 4 (MMAW on Alloy Steel Pipe over 270mm) (MEM5.45AA covers Certificate 2 as well) must be held for promotion to C7;

c. Any of the following certificates may be used for promotion to C7 in combination with W4

(1) W1 – 1E (MMAW on Carbon Steel Plate and Pipe up to 270mm) and W3 – 3E (MMAW on Alloy Steel Plate and Pipe up to 270mm) (MEM5.46AA covers both certificates);

(2) W7 (Tungsten Inert Gas Arc Welding Process) (MEM5.44AA);

(3) W8F – (Flux Core Arc Welding Process) (MEM5.42AA); or

(4) W8G – (Gas Metal Arc Welding Process) (MEM5.43AA).

d. If W4 was used for reclassification to C8, then any two of the above certificates may be used for reclassification to C7.

29. Supervision Skills. Transfield Services (Australia) Pty Ltd agrees to include Certificate IV in Business (Frontline Management) for the purpose of training and reclassifying personnel employed as supervisors. These skills are able to be counted for reclassification to C7 but are intended for Supervisors who hold the responsibility for the full range of supervisory tasks, including:

a. Responsibility for WHS for their part of the workplace;

b. A broad range of people management issues including counselling and disciplinary interviews, performance management and maintaining effective workplace relationships;

c. Prioritising and delegating the work for a work team;

d. Collection and distribution of information utilising workplace infrmation systems;

e. Promoting change and encouraging the innovation of their work group; and

f. Providing a role model and delivering effective leadership for their work team.

30. Apprentice Masters will be able to access some parts of the Frontline Management competencies for reclassification to C7 as well. The specific competencies and values are yet to be determined.

31. Restricted Electrical Licence. The acquisition and use of a Restricted Electrical Licence is restricted to mechanical tradespeople with instrumentation skills and who are generally described as an ‘Instrument Fitter’ in the current job model. Where expanded use of the REL is required, the job model will be varied in accordance with the provisions of this agreement.

32. For the purposes of maintaining parity with the previous agreement, holding and using an REL will be recognised for promotion to C7.


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33. CERT IV in Workplace Assessment and Training. Positions such as Apprentice Master or Workshop Supervisor, where the incumbent is required to conduct formal training and assessment activities, shall be able to use units 17.1 and 17.2 for the purposes of reclassification.

34. Dogging and Overhead Lifting Equipment. The competencies relevant to dogging, crane chasing and overhead crane are over and above those skills which are typically permitted by the Workplace Health and Safety Act and Regulation. Transfield Services expects a base tradesperson to use an overhead crane or other mono-rail, jib crane etc., to lift loads which are incidental and peripheral to the trade work being performed and are estimated at less than 1000kg. Additionally, TSL would expect that each tradesperson would be able to perform the dogging and rigging associated with that level of lifting. (This is described in Workplace Health and Safety Regulation 1997, section 18.)

35. To access the competencies for ‘Undertake Dogging and Crane Chasing’ and ‘Operate Fixed or Moveable Load-shifting Equipment’ (MEM11.4 and MEM11.22 respectively), TSL requires the person to hold the relevant Certificate of Competency from the office of Workplace Health and Safety. Passing the assessment, holding the certificate and maintaining the employer’s authority to operate the in the respective roles is adequate evidence of competence for the purpose of this Agreement.

36. EPC152 – Introduction to Basic Rigging – or similar training will eventually be phased out of this agreement. It will be phased out in the next review of the agreement. People who have used EPC152 for reclassification are only able to use lifting and rigging skills as described above (WHS Regs, section 18). It is intended that all people who have been reclassified via EPC152 will be required to upgrade their skills to the Dogger Certificate of Competency in order to allow TSL to acess the full extent competency unit MEM11.4.

37. During the phase-out period, TSL agrees to recognise EPC152 for thos people who have used it for reclassification in the past.

APPLICATIONS FOR RECLASSIFICATION.

38. Applications for Reclassification are to be made through the immediate supervisor who will need to countersign the application in order for it to proceed. The applications will then need to be forwarded to the relevant Co-ordinator who will then seek to decide the application by consulataion with the Relavant Teamleaders, Manager and the Training Co-ordinator. The final decision of the reclassification application will come from the relevant Manager within 10 days of application.

39. Double Dipping. A competency shall not be paid for twice. For example, where a first-aid allowance is provided, people may not use the relevant competency for reclassification purposes. Likewise, if people receive a leading-hand allowance, they may not claim any management or supervisory competencies for reclassification.

40. Competencies included in a person's base-trade are not to be accessed for the purposes of reclassification.

41. A person may access more than one broad job category for additional skills for the purpose of reclassification. To do this, the employee must be freely transferrable between, and actively participating in the relevant broad job categories.

42. Where more than one broad job category is accessed for reclassification, the deemed base-trade for that person, is that for the principal job, for which the person is employed to perform. Eg. A Loco fitter is transferred to the machine shop for a period of peak load in that


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area. The fitter may claim any competencies from the Loco Fitters’ and the Machinists' additional competency list, but not those competencies included in the base-trade of a Loco Fitter (the principal occupation of the applicant).

RECLASSIFICATION PLANNING FOR INDIVIDUALS.

43. Transfield Services (Australia) Pty Ltd is responsible for arranging and co-ordinating mandatory training requirements to meet statutory and corporate governance requirements at the Mackay Sugar Alliance. Tradespeople are responsible for the maintenance of their own trade skills. Where Transfield Services identifies a skill shortage in its maintenance workforce, the company is likely decide to take action to rectify the shortage at its expense. However it may also choose not to rectify the need if it is safe, legal and logical to do so.

44. Having stated this, it is in the best interests of Transfield Services to encourage the up-skilling of tradespeople in the workforce at the Mackay Sugar Alliance. Accordingly, each tradesperson is to have an individual development plan which identifies Priority 1, 2 and 3 training discussed previously in this document. The completion of planning for Priority 1 training is mandatory. Tradespeople may decline to complete the remainder of the individual development plan.

45. The individual development plan need not contain formal off-the-job courses. It may cantain a mix of on and off-the-job training with an on-the-job assessment plan to determine competence at a pre-determined date. Some competencies, however, are only available off-the-job.

46. Tradespeople retain the freedom to develop themselves in any skill area they choose. If they want to target their own development at likely opportunities within Transfield Services, it is important for them to follow their individual development plan.

47. The plan is to be constructed between the team-leader and the tradesperson, and stored on the tradesperson's personnel file. The tradesperson must receive a copy of the form and should keep it safe for future reference if required. If the person is transferred to a new site or a new team leader, then the individual development plan should be reviewed.

48. A blank Individual Development Plan form is attached as appendix 3.

TEMPORARY EMPLOYEES.

49. The following provisions apply:

a. Transfield Services' interest is in developing the skills of its permanent workforce, and, in accordance with this principle, training opportunities and/or approval to attend recognised training programs under this policy will be given to permanent employees not temporary employees.

b. Temporary employees holding qualifications or having obtained competencies which form part of this policy are eligible to have these recognised in accordance with the Classification Guidelines of the Agreement.

c. However, if a person applies for a position as advertised a nominated level, the employee will only be entitled to be classified at that level. The advertised position must be in accordance with the current job design.

d. The person shall not subsequently be asked to perform tasks which are over and above those contained within the position advertised. If expanded access to the


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employee’s skills is required the terms of the employee’s employment contract are to be altered to reflect the intended expanded role and the employee is to be reclassified accordingly.

EMPLOYEE RELATIONS.

50. Transfield Services (Australia) Pty Ltd will ensure this Agreement is communicated widely, in particular, that it is communicated to the relevant consultative committees which exist from time to time.

51. Additionally, Team Leaders are to have access to the Agreement via the OSP and are to make it freely available to the relevant employees as part of their induction process.

DISPUTES.

52. Any grievance or dispute arising from the application of this Agreement shall be processed in accordance with the Disputes Avoidance Procedure contained in the Transfield Services - Mackay Sugar Alliance Enterprise Agreement.

Operation and Review.

53. This Agreement takes effect from 31 October, 2004 and shall apply until it is formally reviewed. During this period, training and reclassification matters for Transfield Services (Australia) Pty Ltd engineering employees at the Mackay Sugar Alliance shall only be determined with reference to this Agreement

54. The Agreement is to be reviewed periodically to maintain its alignment with:

a. Current work practices and job design at the Mackay Sugar Alliance; and

b. The current training package(s) containing the relevant competencies for classification and reclassification.

AUTHORISATION AND AGREEMENT.

55. This Agreement is authorised for operation from 31 October 2004 and has been developed and agreed with the engineering employees of the Mackay Sugar Alliance via their workplace representatives.

Bob Buckley Alliance Manager Transfield Services (Australia) Pty Ltd – Mackay Sugar Alliance Date: Darren Trask State Organiser AMWU Date:



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Appendix 1:

Competency Lists for Broad Job Categories.

1. During the job analysis phase of the implementation of Competency standards the following job models were determined. These represent the status quo at Mackay Sugar work sites and are used for determining the numbers of positions ant the skills available to those positions at the Mackay Sugar Alliance.

2. These job designs have been arranged pictorially in organisation charts to show the relationships with other parts of the organisation, and the broad job categories as applied to groups of ‘like’ positions. The broad Job Categories are as follows:



c. Machinist;


e. Factories Fitter.

3. These are shown overleaf for Fitters and for Boilermakers employed at the Mackay Sugar Alliance.

4. The broad job categories form the basis for determining base-trades and the additional competencies available for reclassification within each broad job category.

5. Competency lists as agreed on 31 Oct 04, showing the competencies for base-trade and those additional competencies for reclassification are included in this appendix.

End

J o b D e s i g n M o d e l T r a n s f i e l d S e r v i c e s ( A u s t r a l i a ) P t y L t d


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J o b D e s i g n M o d e l T r a n s f i e l d S e r v i c e s ( A u s t r a l i a ) P t y L t d


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Broad Job Category 1 – “Cane Supply Boilermaker” Unit code Ver Unit title P Base Cane

Supply Boilermaker

MEM1.1F A Undertake interactive workplace communication 0 BASE

MEM1.2F A Apply principles of Occupational Health and Safety in work environment

0 BASE

MEM1.3F A Apply quality procedures 0 BASE

MEM1.4F A Plan to undertake a routine task 0 BASE

MEM2.1C12 A Apply quality systems 2 BASE

MEM2.2C11 A Organise and analyse information 2 BASE

MEM2.3C11 B Operate in a work based team environment 2 BASE

MEM2.4C11 A Assist in the provision of on the job training 2 BASE

MEM2.5C11 A Measure with graduated devices 2 BASE

MEM2.6C10 A Plan a complete activity 4 BASE

MEM2.7C10 A Perform computations – basic 2 BASE

MEM2.8C10 A Perform computations 2 BASE

MEM2.9C10 A Perform computer operations 2 BASE

MEM4.4A B Perform routine oxy-acetylene gas welding 2

MEM5.5A A Carry out mechanical cutting 2 BASE

MEM5.6A A Perform brazing and/or silver soldering 2 BASE

MEM5.7A B Manual heating and thermal cutting 2 BASE

MEM5.9A B Automated thermal cutting 2 BASE

MEM5.10A A Undertake fabrication, forming, bending and shaping 8 BASE

MEM5.11A B Assemble fabricated components 8 BASE

MEM5.12A B Perform routine manual metal arc welding 2 BASE

MEM5.15A B Weld using manual metal arc welding process 4 BASE

MEM5.16A B Perform advanced welding using manual metal arc welding process

4 BASE

MEM5.17A B Weld using gas metal arc welding process 4 BASE

MEM5.18A B Perform advanced welding use gas metal arc welding process

4 BASE

MEM5.19A B Weld using GTAW process 4

MEM5.26A A Apply welding principles 4

MEM5.36A B Repair/replace/modify fabrications 4 BASE

MEM5.37A A Geometric development 6 BASE

MEM5.43A A Perform welds to code standards using gas metal arc welding process

6

MEM5.46A A Perform welds to code standards using manual metal arc welding process

6

MEM5.47A A Weld using flux core arc welding process 4 BASE

MEM5.48A A Perform advanced welding using flux core arc welding process

4 BASE

MEM5.49A B Perform routine gas tungsten arc welding 2

MEM5.50A A Perform routine gas metal arc welding 2 BASE

MEM8.11A A Undertake surface preparation using solvents and/or mechanical means

2 BASE


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Unit code Ver Unit title P Base Cane Supply

Boilermaker MEM9.1A A Draw and interpret sketch 2 BASE

MEM9.2A A Interpret technical drawing 4 BASE

MEM9.11A A Apply basic engineering design concepts 6

MEM10.1A A Erect Structures 4

MEM11.4A A Undertake dogging/crane chasing 4

MEM11.10A A Operate mobile load shifting equipment 4

MEM11.11A A Manual handling 2 BASE

MEM11.16A A Order materials 2

MEM11.22A A Operate fixed/moveable load shifting equipment 4

MEM12.7A B Mark off/out structural fabrications and shapes 4 BASE

MEM13.2A A Undertake Occupational Health & Safety activities in the workplace

3

MEM16.1B A Give formal presentations and take part in meetings 2

MEM16.2A Participate in formal interviews and negotiations 4

MEM17.1AB A *Assist in development and deliver training in the workplace

2

MEM17.2AB A *Conduct workplace assessment 2

MEM18.1A B Use hand tools 2 BASE

MEM18.2A A Use power tools/hand held operations 2 BASE

MEM18.11AB B **Shut down and isolate machines/equipment 2

MEM18.55A A Dismantle, replace and assemble engineering components

3

MEM24.1A A Perform basic penetrant testing 2 BASE

MEM24.8AB A *Perform ultrasonic testing 6

MEM24.12AB A *Apply metallurgy principles 4

Total available points 178


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Broad Job Category 2 – “Factories Boilermaker” Unit code V

er Unit title P Base

Factory Boilermaker



0 BASE












MEM2.13C5 A Perform mathematical computations 4

MEM5.4A B Perform routine oxy acetylene welding 2


MEM5.6A A Perform brazing and/or silver soldering 2 BASE


MEM5.9A B Automated thermal cutting 2 BASE

MEM5.10A A Undertake fabrication, forming, bending and shaping 8 BASE

MEM5.11A B Assemble fabricated components 8 BASE


MEM5.15A B Weld using manual metal arc welding process 4 BASE

MEM5.16A B Perform advanced welding using manual metal arc welding process

4 BASE

MEM5.17A B Weld using gas metal arc welding process 4 BASE

MEM5.18A B Perform advanced welding use gas metal arc welding process

4 BASE

MEM5.19A B Weld using gas tungsten arc welding process 4

MEM5.20A B Perform advanced welding using gas tungsten arc welding process

4

MEM5.24B A Perform welding supervision 12

MEM5.25B B Perform welding/fabrication inspection 12

MEM5.26A A Apply welding principles 4

MEM5.36A B Repair/replace/modify fabrications 4 BASE

MEM5.37A A Geometric development 6 BASE

MEM5.38A A Advanced geometric development – Cylindrical/Rectangular

2

MEM5.39A A Advanced geometric development – Conical 2

MEM5.40A A Advanced geometric development – Transitions 4

MEM5.41A A Weld using powder flame spraying 4


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Unit code Ver

Unit title P Base Factory Boilermaker

MEM5.43A A Perform welds to code standards using gas metal arc welding process

6

MEM5.44A A Perform welds to code standards using gas tungsten arc welding process

6

MEM5.45A A Perform pipe welds to code standards using manual metal arc welding process

6

MEM5.46A A Perform welds to code standards using manual metal arc welding process

6

MEM5.47A A Weld using flux core arc welding process 4 BASE

MEM5.48A A Perform advanced welding using flux core arc welding process

4

MEM5.49A B Perform routine gas tungsten arc welding 2 BASE


MEM7.1A A Operational maintenance of machines/equipment 2

MEM7.32A A Use workshop machines for basic operations 2


2 BASE

MEM9.1A A Draw and interpret sketch 2 BASE



MEM10.1A B Erect structures 4

MEM10.10A A Install pipework and pipework assemblies 4






MEM12.7A B Mark off/out structural fabrications and shapes 4 BASE


3




2






3


MEM24.3A A Perform basic magnetic particle testing 2 BASE

MEM24.7A A Perform ultrasonic thickness testing 2

MEM24.8AB A *Perform ultrasonic testing 6

MEM24.12AB A *Apply metallurgy principles 4

Total available points 246


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Broad Job Category 3 – “Machinist” Unit code Ver Unit title P Base

Machinist



0 BASE












MEM2.13C5 A Perform mathematical computations 4





MEM5.15A B Weld using manual metal arc welding process 4

MEM5.41A A Weld using powder flame spraying 4


MEM7.2A A Perform precision shaping/planing/slotting operations 4 BASE

MEM7.5A A Perform general machining 8 BASE

MEM7.6A A Perform lathe operations 4 BASE

MEM7.7A A Perform milling operations 4 BASE

MEM7.8A B Perform grinding operations 4 BASE

MEM7.11A A Complex milling operations 4

MEM7.13A A Perform machining operations using horizontal and/or vertical boring machine

4 BASE

MEM7.21A A Perform complex lathe operations 4

MEM7.29A A Perform routine sharpening/maintenance of production tools and cutters

4 BASE


2 BASE



MEM9.9B B Create 2D drawings using computer aided design system 8






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Unit code Ver Unit title P Base Machinist



MEM12.3A A **Precision mechanical measurement 2 BASE

MEM12.6A A Mark off/out (general engineering) 4 BASE


3

MEM13.3A A Work safely with industrial chemicals and materials 2 BASE

MEM13.5B A Manage Occupational Health & Safety for a workplace or section of a workplace

12




2




MEM18.3A B Use tools for precision work 4 BASE

MEM18.6A A Dismantle/repair/replace/assemble and fit engineering components

6 BASE


3 BASE


Total available points 172 97


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Broad Job Category 4 – “Locomotive Fitter” Unit code Ver Unit title P Loco Fitter

Base MEM1.1F A Undertake interactive workplace communication 0 BASE


0 BASE












MEM5.1A A Manual soldering/desoldering – electrical/electronic components

4



MEM5.6A A Perform brazing and/or silver soldering 2


MEM5.11A B Assemble fabricated components 8




MEM7.6A A Perform lathe operations 4


2 BASE




MEM10.10A A Install pipework and pipework assemblies 4 BASE








3





2


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Unit code Ver Unit title P Loco Fitter Base






6 BASE

MEM18.7A A Maintain and repair mechanical drives and mechanical transmission assemblies

4 BASE

MEM18.9A A Levelling and alignment of machines and engineering components

4 BASE

MEM18.12A A Mechanical seals – installation and removal 2 BASE

MEM18.24A A Maintain and repair engine cooling systems 2 BASE

MEM18.26A B Test compression ignition fuel systems 4

MEM18.28A B Maintain and repair engine lubrication systems 2 BASE

MEM18.30A A Diagnose and repair low voltage electrical systems 8

MEM18.33A A Perform engine bottom-end overhaul 4

MEM18.34A A Perform engine top-end overhaul 8

MEM18.35A A Diagnose and repair braking systems 6 BASE

MEM18.40A A Maintain and repair suspension systems 4 BASE

MEM18.47A A Diagnose and maintain electronic controlling systems on mobile plant

4

MEM18.52A A Maintain and repair fluid power systems for mobile plant 4


3 BASE

MEM18.86A A Test, evacuate and charge refrigeration systems 4




Page 12 of 4

Broad Job Category 5 – “General Mill Fitter” Unit code Ver Unit title P Base

General Mill Fitters



0 BASE












MEM5.1A A Manual soldering/desoldering – electrical/electronic components

4







MEM7.6A A Perform lathe operations 4

MEM7.7A A Perform milling operations 4

MEM7.24A A Operate and monitor machine/process 4

MEM7.33A A Operate and monitor basic boiler 6


2 BASE




MEM10.2A A Terminate and connect electrical wiring 3

MEM10.6A A Install machine/plant 4 BASE

MEM10.8B A Undertake commissioning procedures for plant and/or equipment

4

MEM10.10A A Install pipework and pipework assemblies 4 BASE

MEM11.1A B Erect/dismantle scaffolding and equipment 4






MEM12.2A A Electrical/electronic measurement 2


Page 13 of 4

Unit code Ver Unit title P Base General Mill Fitters

MEM12.3A A **Precision mechanical measurement 2



3


MEM13.5B A Manage Occupational Health & Safety for a workplace or section of a workplace

12

MEM13.7A A Maintain water cooling towers and treatment systems 2




2





MEM18.4A A Maintain and overhaul mechanical equipment 4 BASE

MEM18.5A A Bearings – fault diagnosis installation and removal 4 BASE


6 BASE

MEM18.7A A Maintain and repair mechanical drives and mechanical transmission assemblies

4 BASE

MEM18.9A A Levelling and alignment of machines and engineering components

4 BASE


MEM18.12A A Mechanical seals – installation and removal 2 BASE

MEM18.13A A Gland packing 2 BASE

MEM18.18A B Maintain pneumatic system components 4

MEM18.19AB A *Maintain and repair pneumatic systems 4

MEM18.20A B Maintain hydraulic system components 4

MEM18.21AB A *Maintain and repair hydraulic systems 4

MEM18.22AB A *Maintain/repair/replace fluid power controls 8

MEM18.46A A Fault find/repair electrical equipment/components which use up to 1000vAC/1500vDC

6

MEM18.49AB A **Disconnect/reconnect fixed wired equipment which use up to 1000vAC/1500vDC

3

MEM18.54AB A **Fault find, test, calibrate instrumentation systems, equipment

8


3 BASE

MEM18.62AB A **Install, maintain and calibrate instrumentation sensors, transmitters and final control elements

8

MEM18.64A A Maintain instrumentation system components 6


MEM24.3A A Perform basic magnetic particle testing 2

MEM24.7A A Perform ultrasonic thickness testing 2




Page 1 of

Appendix 2:

Skills Audits for Additional Skills for each of the Broad Job Categories.

1. Skills audit documents have been developed for each broad job category. They assume that the subject of the skills audit is competent in the base-trade skills appropriate to the person’s principal employment.

2. Accordingly the Skills Audit documents only seek confirmation of the skills which are additional to each broad job category. They are attached to this appendix in the following order:



c. Machinist;


e. Factories Fitter.

3. Each additional competency has an introductory paragraph accompanying it. This information provides a guide to the competency in question. For a full description of the competency, the latest competency standatd is to be accessed by clicking the appropriate link on the Transfield Services (Australia) Pty Ltd – Mackay Sugar Alliance OSP. The link for people on the Mackay Sugar Alliance network, is as follows:

4. The skills audits are assembled here in the same format as provided by MISTAS during the Skills Audit.



Page 1 of 4

Mackay Sugar - Skills Audit Plant: Cane Supply Boilermakers (#1) MISTAS – Manufacturing Industry Skills Training and Assessment Services – Melbourne/Sydney/Brisbane

Department: Cane Supply Employee's name:

Current job title: Boilermaker Qualifications held:

Current classification: Validation:

Endorsement:

Classification review: Base Identified In

AQF Level III Certificate in Engineering (Fabrication)

Employee comments: Employer comments: This Audit Document has been prepared by - MISTAS Signature:______________________________ Date:_______________________

NOTE: Only those units that you indicate are ‘held and used’ and are verified by Supervisors/managers are used for classification purposes provided all the Pre-Reqs are met.


Page 2 of 4

Unit No Unit Name and Descriptor Pre-

Reqs Hold Skill

Use Skill

Validation


MEM 5.4A B Perform routine oxy acetylene welding This unit covers the competencies required for routine OAW, including simple preparation, selection of equipment, settings and consumables, assembly and set up of equipment, and welding where welding is not required to meet Australian Standard 1554 General purpose or equivalent codes and/or licensing requirements.

N/A Pre-req for 5.41A only

MEM 5.19A B Weld using gas tungsten arc welding process This unit covers the competencies required for preparing materials, selecting and setting up the welding equipment, carrying out GTAW welding and inspecting for and correcting defects. Weld quality would typically conform to Australian Standard 1554 General Purpose, American Bureau of Shipping (ABS) or equivalent. Materials used would include low carbon and stainless steel.

5.49A A 18.1A B 18.2A A

MEM 5.26A A Apply welding principles This unit covers the competencies required by the statutory and regulatory requirements for welding procedures. It includes knowledge of welding terms, codes and symbols, the effects of heat treatment on metal in relation to welding, and the logical sequence for a welding process. It is to be assessed in combination with the assessment of one of the units satisfying the Australian Standard 1796 Certificates 1 to 9.

MEM 5.43A A Perform welds to code standards using gas metal arc welding process This unit covers the competencies required for the preparation and production of welds to code standards using GMAW. Butt and fillet welds in the flat, horizontal, vertical and overhead positions would be applied to meet Australian Standards 1210, AS 4140, ASME IX or equivalent. The unit may satisfy the requirements of AS 1796 Certificate 8

5.7A B 5.17A B 5.18A B 9.2A A 18.1A B 18.2A A

MEM 5.46A A Perform welds to code standards using manual metal arc welding process This unit covers the competencies required for the preparation and production of welds. Butt and fillet welds in the flat, horizontal, vertical and overhead positions would be applied to meet Australian Standards 1210, AS 4140, ASME IX or equivalent. The unit may satisfy the requirements of AS 1796 Certificates 1, 1E, 3 and 3E.

5.7A B 5.12A B 5.15A B 5.16A B 9.2A A 18.1A B 18.2A A

MEM 5.49A B Perform routine gas tungsten arc welding This unit covers the competencies required for identifying welding requirements from instructions, preparing the materials and carrying out routine GTAW . This unit applies in a maintenance or manufacturing environment where the welding is not required to meet the Australian Standard 1554 General Purpose. The materials used would typically be low carbon and mild steels.

Nil

MEM 9.11A A Apply basic engineering design concepts This unit is intended to cover in situ design skills by personnel who will then be responsible for the manufacture of the design outcome either individually or as part of a team.

9.1A A 9.2A A


Page 3 of 4

Unit No Unit Name and Descriptor Pre-Reqs

Hold Skill

Use Skill

Validation

MEM 10.1A B Erect structures This unit covers the competencies required to Inspect and prepare the erection site and erect structures. The structure would typically be of a substantial size where load bearing or building regulations may apply. Structures include metal frameworks, stairways, walkways, vessels, tanks, platforms, conveyors and moving lines.

Path: 4 5.7A B 5.12A B 5.15A B 9.1A A 9.2A A 12.7A A 18.1A B 18.2A A Path: 5 5.7A B 5.17A B 5.50A A 9.1A A 9.2A A 12.7A A 18.1A B 18.2A A

MEM 11.4A A Undertake dogging/crane chasing This unit covers the competencies required to attach slings to loads and move loads using appropriate communication and hand signals. The equipment range may include slings, ropes, shackles, eyebolts, spreader beams, chain blocks etc.

18.1A B

MEM 11.10A A Operate mobile load shifting equipment This unit covers the competencies required to conduct routine operation and safety checks of load shifting equipment, shift land place loads. Load shifting equipment includes front-end loaders/back hoes, ride on fork lifts and pallet trucks.

MEM 11.16A A Order materials This unit covers the competencies required to prepare a purchase /order list and place the order. The unit applies to purchasing activities undertaken by other than the purchasing officer.

MEM 11.22A A Operate fixed/moveable load shifting equipment This unit covers the competencies required to conduct routine operation and safety checks of load shifting equipment, pick up loads, shift and place loads. Moveable and fixed load shifting equipment may include pendant cranes, yard, workshop and travelling overhead cranes, monorail hoists and chain blocks, pivoting and slewing jibs rails etc.

MEM 13.2A A Undertake Occupational Health & Safety activities in the workplace This unit covers the competencies required to apply the principles of OHS in the workplace and undertake a safety audit for the employee’s area of responsibility. It apples to those who need OHS competencies beyond those inherent in their jobs.

MEM 16.1B A Give formal presentations and take part in meetings This unit covers the competencies required to participate in formal meetings and give formal presentations. The unit covers the communication skills required to make formal presentations or participate in formal meetings governed by formal rules and well established conventions.

MEM 16.2A B Participate in formal interviews and negotiations This unit covers the competencies required to plan and conduct interviews, participate in interviews and take part in negotiations. The unit covers the skills needed for effective communication in more formal onsite or small group situations where ideas are defined and specific outcomes are sought.

MEM 17.1A A Assist in development and deliver training in the workplace This unit covers the competencies required to plan for and deliver on the job training, and review the training program. Training, which may structured or informal, is delivered in a one to one or small group situation.

2.4C11A


Page 4 of 4


Hold Skill

Use Skill

Validation

MEM 17.2A A Conduct workplace assessment This unit covers the competencies required to identify, plan and carry out assessment, record the results and review the procedure. Methods of assessment may include observation, documentation, demonstration, projects, oral tests, computer based assessment, written tests, etc.

MEM 18.11A B Shut down and isolate machines/equipment This unit covers the competencies required to isolate and shut down machines and equipment. The machines and equipment range includes manual, semiautomatic and automatic machines of a stand alone, continuous production or process nature.

MEM 18.55A A Dismantle, replace and assemble engineering components This unit covers the competencies required to dismantle and identify faulty components, select replacements and assemble engineering components into assemblies or sub assemblies. Tasks are undertaken using engineering principles, designated procedures, appropriate tools, equipment and safe workshop practices.

Path: 1 2.5C11 A 9.2A A 18.1A B 18.2A A Path: 2 2.5C11 A 9.1A A 18.1A B 18.2A A

MEM 24.8A A Perform ultrasonic testing This unit provides the skills and knowledge required to operate ultrasonic testing equipment and the application of the testing procedure in a range of industrial applications. Knowledge of metallurgy, maths and physics associated with the level of application in this unit is required.

18.1A B 24.12A A

MEM 24.12A A Apply metallurgy principles This unit provides the knowledge of basic metallurgy principles as related to non destructive testing techniques.


Page 5 of 4

Supervisor Specific Competencies Unit No Unit Name and Descriptor (transferred fron Business Services training package – (Cert IV in Business (Frontline Management – BSB 41001)

Pre-Reqs

Hold Skill

Use Skill

Validation

BCMN 402A Develop Work Priorities. This unit covers the skills and knowledge required to plan own work schedules, monitor and obtain feedback on work performance and development.

BFLM402A Show Leadership in the workplace. Covers the development of leadership skills and reviews how leaders work with teams and individuals, their conduct and the initiative they take in influencing others.

BFLM403A Manage Effective Workplace Relationships Covers the development and maintenance of positive relationships in internal and external environments so that customers, suppliers and the organisation achieve planned outcomes.

BFLM405A Implement Operational Plans Covers planning, implementing, monitoring and recording of performance to achieve the business plans of the team/organisation.

BCMN411A Monitor a safe workplace. This unit is concerned with the OHS responsibilities of employees with supervisory responsibilities to implement and monitor the organisation’s OHS policies, procedures and programs in the relevant work area to meet legislative requirements.

BFLM406A Implement workplace information systems. Covers identification, acquisition, analysis and use of appropriate information to ensure effectiveness of the organisation’s performance.

BCMN412A Promote Innovation and Change This unit covers the skills and knowledge required to promote the use and implementation of innovative work practices to effect change.

BFLM404A Lead Work Teams Covers the skills and knowledge required to lead a team or workgroup in a business environment. It includes developing plans, providing leadership, and supervising the performance of a group.



Page 1 of 6

Mackay Sugar - Skills Audit Plant: Factory Boilermakers (#2) MISTAS – Manufacturing Industry Skills Training and Assessment Services – Melbourne/Sydney/Brisbane

Department: Factories Employee's name:

Current job title: Boilermaker Qualifications held:


Endorsement:






Page 2 of 6

Unit No Unit Name and Descriptor Pre-

Reqs Hold Skill

Use Skill

Validation


MEM 2.13C5 A Perform mathematical computations This unit covers the competencies required to perform mathematical computations using algebraic, trigonometric and geometric techniques.

2.7C10A 2.8C10A


N/A Pre-req for 5.41A only

MEM 5.19A B Weld using gas tungsten arc welding process This unit covers the competencies required for preparing materials, selecting and setting up the welding equipment, carrying out GTAW welding and inspecting for and correcting defects. Weld quality would typically conform to Australian Standard 1554 General Purpose, American Bureau of Shipping (ABS) or equivalent. Materials used would include low carbon and stainless steel.

5.49A A 18.1A B 18.2A A

MEM 5.20A B Perform advanced welding using gas tungsten arc welding process This unit covers the competencies required for preparing materials, selecting and setting up the welding equipment, carrying out advanced GTAW, inspecting for and correcting defects, and maintaining the weld records. Weld quality would typically conform to Australian Standard 1554 Structural Purpose, Bureau Det Norse Verticas or equivalent. Materials used would include low carbon, cast iron, stainless and low alloy steel. Welds would be fillet and butt in horizontal, vertical and overhead positions.

5.7A B 5.19A B 5.49A A 9.2A A 18.1A B 18.2A A

MEM 5.24B A Perform welding supervision Competencies in this unit are based on wide knowledge of welding science, processes, procedures and technical requirements. Individuals working in this field would hold at least one certificate satisfying the requirements of Australian Standard 1796 Certificate 1 to 9

5.26A A

MEM 5.25B B Perform welding/fabrication inspection

5.26A A

MEM 5.26A A Apply welding principles This unit covers the competencies required by the statutory and regulatory requirements for welding procedures. It includes knowledge of welding terms, codes and symbols, the effects of heat treatment on metal in relation to welding, and the logical sequence for a welding process. It is to be assessed in combination with the assessment of one of the units satisfying the Australian Standard 1796 Certificates 1 to 9.

MEM 5.38A A Advanced geometric development Cylindrical/Rectangular This unit applies to marking out of complex cylindrical/rectangular fabrications. Fabrications may include hoppers, chutes and involve compound bends and double offsets. This unit requires advanced skills in parallel line developments.

2.7C10A 2.8C10A 2.13C5 A 5.37A A 9.2A A


Page 3 of 6


Hold Skill

Use Skill

Validation

MEM 5.39A A Advanced geometric development Conical This unit applies to the marking out of complex conical fabrications using advanced geometric development. Fabrications may include hoppers with round/rectangular branch intersections. This unit requires advanced skills for the calculation of cutting, bending lines and developments.

2.7C10 A 2.8C10 A 2.13C5 A 5.37A A 9.2A A

MEM 5.40A A Advanced geometric development Transitions This unit applies to the marking out of complex fabrications using geometric development. Fabrications may include hoppers, chutes, elliptical shapes, curves, spirals etc. Patterns may include complex and irregular shapes. This unit requires advanced skills for the calculation of cutting, bending lines and developments.

2.7C10 A 2.8C10 A 2.13C5 A 5.37 A A 9.2A A

MEM 5.41A A Weld using powder flame spraying This unit covers powder spraying using hot and/or cold process, on a range of heavy or light materials. Powders are fed into the oxyacetylene flame and are deposited onto the surface to be built up or joined.

5.4A B 9.1A A

MEM 5.43A A Perform welds to code standards using gas metal arc welding process This unit covers the competencies required for the preparation and production of welds to code standards using GMAW. Butt and fillet welds in the flat, horizontal, vertical and overhead positions would be applied to meet Australian Standards 1210, AS 4140, ASME IX or equivalent. The unit may satisfy the requirements of AS 1796 Certificate 8

5.7A B 5.17A B 5.18A B 9.2A A 18.1A B 18.2A A

MEM 5.44A A Perform welds to code standards using gas tungsten arc welding process This unit covers the competencies required for the preparation and production of welds to code standards using GTAW. Butt and fillet welds in the flat, horizontal, vertical and overhead positions would be applied to meet Australian Standards 1210, AS 4140, ASME IX or equivalent. The unit may satisfy the requirements of AS 1796 Certificate 7

5.7A B 5.19A B 5.20A B 5.49A A 9.2A A 18.1A B 18.2A A

MEM 5.45A A Perform pipe welds to code standards using manual metal arc welding process This unit covers the competencies required for the preparation and production of welds. Butt welds in pipe with the axis horizontal, vertical and/or askew would be applied to meet Australian Standards 1210, AS 4140, ASME IX or equivalent. The unit may satisfy the requirements of AS 1796 Certificates 2 and 4.

5.7A B 5.12A B 5.15A B 5.16A B 9.2A A 18.1A B 18.2A A

MEM 5.46A A Perform welds to code standards using manual metal arc welding process This unit covers the competencies required for the preparation and production of welds. Butt and fillet welds in the flat, horizontal, vertical and overhead positions would be applied to meet Australian Standards 1210, AS 4140, ASME IX or equivalent. The unit may satisfy the requirements of AS 1796 Certificates 1, 1E, 3 and 3E.

5.7A B 5.12A B 5.15A B 5.16A B 9.2A A 18.1A B 18.2A A

MEM 5.48A A Perform advanced welding using flux core arc welding process This unit covers the competencies required for preparing materials, selecting and setting up the welding equipment, carrying out advanced FCAW, inspecting for and correcting defects, and maintaining the weld records. Weld quality would typically conform to Australian Standard 1554 Structural Purpose, Bureau Det Norse Verticas or equivalent. Materials used would include low carbon, cast iron, stainless and low alloy steel. Welds would be fillet and butt in horizontal, vertical and overhead positions.

5.7A B 5.47A A 5.50A A 9.2A A 18.1A B 18.2A A


Page 4 of 6


Hold Skill

Use Skill

Validation

MEM 7.1A A Operational maintenance of machines/equipment This unit covers the competencies required to carry out programmed safety and maintenance checks and undertake programmed maintenance on manual, semi automatic and automatic machines of a stand alone Continuous production or process nature.

18.1A B

MEM 7.32A A Use workshop machines for basic operations This unit covers the competencies required for the basic machining in a maintenance or jobbing environment. The machines may include but are not limited to lathe, radial arm drill, mills, etc., and cover the sharpening of tools as required.

18.1A B


9.1A A 9.2A A

MEM 10.1A B Erect structures This unit covers the competencies required to Inspect and prepare the erection site and erect structures. The structure would typically be of a substantial size where load bearing or building regulations may apply. Structures include metal frameworks, stairways, walkways, vessels, tanks, platforms, conveyors and moving lines.

Path: 4 5.7A B 5.12A B 5.15A B 9.1A A 9.2A A 12.7A A 18.1A B 18.2A A Path: 5 5.7A B 5.17A B 5.50A A 9.1A A 9.2A A 12.7A A 18.1A B 18.2A A

MEM 10.10A A Install pipework and pipework assemblies This unit covers the competencies required for planning, preparing and installing pipework and assemblies.

9.1A A 9.2A A 18.1A B 18.2A A


18.1A B





Page 5 of 6


Hold Skill

Use Skill

Validation





2.4C11A



MEM 18.55A A Dismantle, replace and assemble engineering components This unit covers the competencies required to dismantle and identify faulty components, select replacements and assemble engineering components into assemblies or sub assemblies. Tasks are undertaken using engineering principles, designated procedures, appropriate tools, equipment and safe workshop practices.

Path: 1 2.5C11 A 9.2A A 18.1A B 18.2A A Path: 2 2.5C11 A 9.1A A 18.1A B 18.2A A

MEM 24.7A A Perform ultrasonic thickness testing This unit provides the skills and knowledge required to perform ultrasonic thickness testing in a range of industrial applications. Knowledge of metallurgy associated with the level of application in this unit is required.

18.1A B


Page 6 of 6

Supervisor Specific Competencies Unit No Unit Name and Descriptor (transferred from Business Services training package – (Cert IV in Business (Frontline Management – BSB 41001)

Pre-Reqs

Hold Skill

Use Skill

Validation











Page 1 of 5

Mackay Sugar - Skills Audit Plant: Machinist (#3) MISTAS – Manufacturing Industry Skills Training and Assessment Services – Melbourne/Sydney/Brisbane


Current job title: Machinist Qualifications held:


Endorsement:


AQF Level III Certificate in Engineering (Mechanical)




Page 2 of 5

Unit No Unit Name and Descriptor Pre-Reqs Hold

Skill Use Skill

Validation


MEM 2.13C5 A Perform mathematical computations This unit covers the competencies required to perform mathematical computations using algebraic, trigonometric and geometric techniques.

2.7C10A 2.8C10A


MEM 5.15A B Weld using manual metal arc welding process This unit covers the competencies required for preparing materials, selecting and setting up the welding equipment, carrying out the welding and inspecting for and correcting defects. Weld quality would typically conform to Australian Standard 1554 General Purpose, American Bureau of Shipping (ABS) or equivalent. Materials used would include low carbon and stainless steel.

5.12A B 18.1A B 18.2A A

MEM 5.41A A Weld using powder flame spraying This unit covers powder spraying using hot and/or cold process, on a range of heavy or light materials. Powders are fed into the oxyacetylene flame and are deposited onto the surface to be built up or joined.

5.4A B 9.1A A

MEM 7.11A A Complex milling operations This unit covers the competencies required to set up work, identify inserts from International Standards Organisation standards, and perform complex milling. This unit applies to a range of milling operations including those requiring complex calculations and jobs requiring high precision or quality using a range of materials including non-standard metals and alloys.

2.5C11 A 2.7C10 A 2.8C10 A 2.13C5 A 7.5A A 7.7A A 9.2A A 12.3A A 18.1A B

MEM 7.21A A Perform complex lathe operations This unit covers the competencies required to set up work, identify inserts from International Standards Organisation standards, perform complex turning. This unit may be applied to more unusual, difficult or non standard turning operations requiring high precision or quality using a range of materials including non standard metals and alloys.

2.5C11 A 2.7C10 A 2.8C10 A 2.13C5 A 7.5A A 7.6A A 9.2A A 12.3A A 18.1A B

MEM 9.9B B Create 2D drawings using computer aided design system This unit covers the competencies required to prepare the CAD environment, create 2D drawings, and produce output including linked bills of materials. The unit applies to the fields of mechanical, electrical/electronic, fabrication and fluid power.

2.9C10 A 9.2A A


9.1A A 9.2A A


18.1A B


Page 3 of 5

Unit No Unit Name and Descriptor Pre-Reqs Hold Skill

Use Skill

Validation






2.4C11A



Page 4 of 5


Pre-Reqs

Hold Skill

Use Skill

Validation











Page 1 of 5

Mackay Sugar - Skills Audit Plant: Locomotive Fitter (#4) MISTAS – Manufacturing Industry Skills Training and Assessment Services – Melbourne/Sydney/Brisbane

Department: Cane Supply - Locomotives Employee's name:

Current job title: Locomotive Fitter Qualifications held:


Endorsement:






Page 2 of 5


Skill Use Skill

Validation


MEM 5.1A A Manual soldering/desoldering electrical/electronic components This unit covers manual soldering/desoldering for the installation and fabrication of electrical/electronic components. Advanced specification and high reliability soldering associated with the installation of electrical/electronic components, in areas where reliability of connections is critical, is covered by Unit 5.2A (High reliability soldering and desoldering).


MEM 5.6A A Perform brazing and/or silver soldering This unit covers the standards of work quality & safety required to perform appropriate assembly of heating Equipment

MEM 5.11A B Assemble fabricated components This unit covers the use of general fabricated components in either plate, pipe and section or sheet. Typical applications are transitions, pipeworks and structural fabrication, ductwork, general jobbing work, fired and unfired pressure vessels. This unit does not cover the skills required for the assembly of fabricated engineering components, these skills are covered by the Unit 18.6A

5.5 A A 5.7B 5.12A B 5.15A B 9.2A A 18.1A B 18.2A A


5.12A B 18.1A B 18.2A A

MEM 7.6A A Perform lathe operations This unit covers the competencies required to determine the job requirements, mount the job, perform the turning operations and check the components for conformance to specifications. The unit applies to a range of lathes and accessories, precision measuring equipment, cutting tools and standard engineering materials.

2.5C11 A 7.5A A 9.2A A 18.1A B


9.1A A 9.2A A


18.1A B


Page 3 of 5


Use Skill

Validation


Use Skill

Points








2.4C11A



Page 4 of 5


Use Skill

Validation

MEM 18.26A B Test compression ignition fuel systems This unit covers the competencies required to assess the fuel system operation. Fuel system components include diesel injectors, fuel pumps, governing apparatus and replacement would require the person to time the high pressure pump or injectors to the engine.

2.5C11 A 9.1A A 18.1A B

MEM 18.30A A Diagnose and repair low voltage electrical systems This unit covers the competencies required to use test instruments, test the battery, and assess and repair wiring faults. The unit applies to testing and repair activities associated with 12, 24 and 36 volt wiring systems on vehicles, plant and stationary equipment.

Path: 1 2.5C11A 9.1A A 18.1AB 18.2AA 18.55AA Path: 2 2.5C11A 9.2A A 18.1AB 18.2AA 18.55A A

MEM 18.33A A Perform engine bottom end overhaul This unit covers the competencies required to dismantle, clean and assess parts, record and interpret measurements and recondition components. The unit encompasses cylinder honing, replacement of bearing, piston rings and similar activities, but not major machining such as crankshaft cylinder boring and tunnel boring.

Path: 1 2.5C11 A 9.1A A 18.1A B 18.2A A 18.55A A Path: 2 2.5C11 A 9.2A A 18.1A B 18.2A A 18.55A A

MEM 18.34A A Perform engine top end overhaul This unit covers the competencies required to dismantle, clean and assess parts, record and interpret measurements and recondition the cylinder head. The unit covers work associated with the reconditioning of cylinder heads including determining the causes of failure, and replacement of inserts, guides and injector sleeves, grinding of valves and seats, crack/twist/bend testing, etc.

2.5C11 A 9.1A A 9.2A A 18.1A B 18.2A A 18.3A B 18.6A A 18.55A A

MEM 18.47A A Diagnose and maintain electronic controlling systems on mobile plant This unit covers the skills and knowledge required to diagnose and repair electronic control systems

Path: 1 2.5C11 A 9.1A A 18.1A B 18.2A A 18.30A A 18.55A A Path: 2 2.5C11 A 9.2A A 18.1A B 18.2A A 18.30A A 18.55A A

MEM 18.52A A Maintain and repair fluid power systems for mobile plant This unit covers the skills and knowledge required to diagnose, fault find and repair basic fluid power systems used in the earthmoving, agricultural and transport industries.

Path: 1 2.5C11 A 9.1A A 18.1A B 18.2A A 18.55A A Path: 2 2.5C11 A 9.2A A 18.1A B 18.2A A 18.55A A


Page 5 of 5


Use Skill

Validation

MEM 18.86A A Test, evacuate and charge refrigeration systems This unit covers the competencies required for the refrigerant and system assessment, evacuation and charge.

2.5C11 A 9.2A A 18.1A B 18.2A A 18.55A A


Page 6 of 5


Pre-Reqs

Hold Skill

Use Skill

Validation











Page 1 of 8

Mackay Sugar - Skills Audit Plant: General Mill Fitter (#5) MISTAS – Manufacturing Industry Skills Training and Assessment Services – Melbourne/Sydney/Brisbane


Current job title: General Mill Fitter Qualifications held:


Endorsement:






Page 2 of 8


Skill Use Skill

Validation


MEM 5.6A A Perform brazing and/or silver soldering This unit covers the standards of work quality & safety required to perform appropriate assembly of heating Equipment


5.12A B 18.1A B 18.2A A

MEM 7.6A A Perform lathe operations This unit covers the competencies required to determine the job requirements, mount the job, perform the turning operations and check the components for conformance to specifications. The unit applies to a range of lathes and accessories, precision measuring equipment, cutting tools and standard engineering materials.

2.5C11 A 7.5A A 9.2A A 18.1A B

MEM 7.7A A Perform milling operations This unit covers the competencies required to determine the job requirements, perform the milling operations and check the components for conformance to specifications. The unit applies to a range of milling machines including vertical, horizontal and universal types and using precision measuring equipment, cutting tools and standard engineering materials.

2.5C11 A 7.5A A 9.2A A 18.1A B


9.1A A 9.2A A

MEM 7.24A A Operate and monitor machine/process This unit covers the competencies required to obtain the job instruction, conduct the pre start checks, and operate and monitor the machine or process. This unit applies to a range of production operations or processes, such as pressing, punching, plastic moulding, extruding, bending, joining, rolling, forming, drawing, metal removal, pickling, cylinder filling, printing painting, etc.

MEM 7.33A A Operate and monitor basic boiler This unit covers the competencies required for the start up, take over/hand over and shut down of a basic boiler, including inspection procedures as specified in the manufacturer’s recommendations and workplace procedures, identification of maintenance requirements and hazard control measures. The boilers covered by this unit would have the following features: single fixed combustion air supply, non modulating single heat source, and fixed firing rate. This unit covers boilers used for all purposes, including the generation of steam.

Path: 2 2.2C11 A 2.5C11 A 9.1ª A 18.1ª B 18.2ª A 18.55ª A

MEM 10.8B A Undertake commissioning procedures for plant and/or equipment This unit covers the competencies required to plan the commissioning procedure, assess system performance, adjust plant report on performance. Machine/plant includes rotating equipment and machinery, production equipment and plant and machinery, process equipment and machine tools, etc.

Path: 1 2.5C11 A 9.1ª A 9.2ª A 10.6ª A 18.1ª B 18.2ª A 18.3ª B 18.6ª A 18.9A A 18.55A A


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Use Skill

Validation

MEM 11.1A B Erect/dismantle scaffolding and equipment This unit covers the competencies required to erect and dismantle scaffolding/equipment. The range of equipment covered includes prefabricated tower scaffolds, tube and fitting scaffolds to six-metre height, fall protection devices, catch platforms and bracket scaffolds.

18.1A B


18.1A B




MEM 12.3A A Precision mechanical measurement This unit covers the competencies required for using precision measuring equipment, setting comparison measuring devices and maintaining precision equipment. The unit applies to precision and/or complex use of strip gauges, engineering squares, angle deckers, sine bars, angle gauges, polygons, dividing heads, rotary tables, precision levels, micrometers, height gauges, hardness testers, and texture measuring equipment etc.


MEM 13.5B A Manage Occupational Health & Safety for a workplace or section of a workplace This unit covers the competencies required to assist in the development of OHS policy, understand and implement OHS principles for prevention of injury and disease through progressive use of the hierarchy of control, perform safety audits of the workplace, and maintain accident/incident records and statistics.

13.2A A

MEM 13.7A A Maintain water cooling towers and treatment systems This unit covers the competencies required to apply the principles of Australian Standard 3666 or equivalent, assess reticulation systems, measure water properties, and maintain reticulation/treatment systems. The unit applies to the maintenance activities associated with large water reticulation systems.

18.1A B


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Use Skill

Validation




2.4C11A


MEM 18.10A A Equipment condition monitoring and recording This unit covers the competencies required to undertake condition monitoring. This unit applies to specialist monitoring activities undertaken as a part of a preventative maintenance plan of program.

2.5C11 A 9.1ª A 9.2ª A 18.1ª B 18.2ª A 18.3ª B 18.6ª A 6 18.55A A


MEM 18.18A B Maintain pneumatic system components This unit covers the competencies required to check pneumatic system components and identify and repair or replace faulty components. Pneumatic system components are identified, inspected and assessed using fluid power principles to predetermined specifications interpreted from data sheets and circuits diagrams.

2.5C11 A 9.1ª A 9.2ª A 18.1ª B 18.2ª A 18.3ª B 18.6ª A 18.55A A

MEM 18.19A A Maintain and repair pneumatic systems This unit covers the competencies required to undertake preventive maintenance checks/adjustments on pneumatic systems, and fault find, repair or overhaul, and recommission pneumatic systems. The unit relates to the use of pneumatic test equipment including leak testers, escape rate gauges, hand held pressure testers and other appropriate equipment.

2.5C11 A 9.1ª A 9.2ª A 18.1ª B 18.2ª A 18.3ª B 18.6A A 18.18A B 18.55A A


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Use Skill

Validation

MEM 18.20A B Maintain hydraulic system components This unit covers the competencies required to check hydraulic system components and identify and repair or replace faulty components. Hydraulic system components are identified, inspected and assessed using fluid power principles to predetermined specifications interpreted from data sheets and circuits diagrams.

2.5C11 A 9.1ª A 9.2ª A 18.1ª B 18.2ª A 18.3ª B 18.6ª A 18.55A A

MEM 18.21A A Maintain and repair hydraulic systems This unit covers the competencies required to undertake preventive maintenance checks/adjustments on hydraulic systems, and fault find, repair or overhaul, and recommission hydraulic systems. The unit relates to the use of hydraulic test equipment including leak testers, escape rate gauges, hand held pressure testers and other appropriate equipment.

2.5C11 A 9.1ª A 9.2ª A 18.1ª B 18.2ª A 18.3ª B 18.6A A 18.20A B 18.55A A

MEM 18.22A A Maintain/repair/replace fluid power controls This unit covers the competencies required to install and replace fluid power controls, adjust fluid power system control sequence and operation. It also covers fault finding of fluid power systems control circuits, maintaining and repairing or replacing system control components and checking and adjusting the sequence of fluid power system controls. System circuit/components are identified, traced, inspected and operational function assessed and verified using fluid power principles to predetermined specifications interpreted from data sheets and circuit diagrams.

Path: 1 2.5C11 A 9.1ª A 9.2ª A 18.1ª B 18.2ª A 18.3ª B 18.6ª A 18.18ª B 18.19ª A 18.55ª A Path: 2 2.5C11 A 9.1ª A 9.2ª A 18.1ª B 18.2ª A 18.3ª B 18.6ª A 18.20A B 18.21A A 18.55A A

MEM 24.3A A Perform basic magnetic particle testing This unit provides the skills and knowledge required to perform basic magnetic particle testing procedures in a range of industrial applications. It covers the principles of magnetism and the associated application of basic magnetic particle testing techniques in the field of non destructive testing. Knowledge of metallurgy associated with the level of application in this unit is required.

18.1A B

MEM 24.7A A Perform ultrasonic thickness testing This unit provides the skills and knowledge required to perform ultrasonic thickness testing in a range of industrial applications. Knowledge of metallurgy associated with the level of application in this unit is required.

18.1A B


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Restricted Electrical Licence Competencies Unit No Unit Name and Descriptor Pre-Reqs Hold

Skill Use Skill

Validation

MEM 10.2A A Terminate and connect electrical wiring This unit covers soldering/desoldering in the context of termination, disconnection or reconnection of electrical wiring and circuits. Soldering/desoldering of electrical/electronic components may also require the selection of Unit 5.1A (Manual soldering/desoldering electrical/electronic components) or Unit 5.2A (High reliability soldering and desoldering) as applicable

9.2A A 12.2A A 18.1A B

MEM 12.2A A Electrical/electronic measurement This unit covers the competencies required for using basic electromeasuring devices to check variables and the ability to maintain the devices. The unit extends to the use of analog or digital multimeters, tong testers, potentiometers etc.

MEM 18.46A A Fault find/repair electrical equipment/components which use up to 1000vAC/1500vDC This unit covers the competencies required to locate and rectify the faults. Finding techniques may include testing for circuit continuity, insulation resistance, polarity, earth continuity etc. Equipment and components may include single and multi phase motor drive and heating appliances, relays, coils, transformers, thermostats, gauges, illuminating devices, switches, relays, coils circuit fusses and breakers, gauges, etc using up to 650 volts power supplies on non interconnected circuits

9.1A A 9.2A A 10.2A A 12.2A A 18.1A B 18.2A A

MEM 18.49A A Disconnect/reconnect fixed wired equipment (which use up to 1000vAC/1500vDC) This unit covers the competencies required to connect and disconnect equipment. Work is performed in situ and it may include the original connection of fixed wire equipment. Disconnection of equipment may include electric motors, modular sensing devices, limit switches, etc.

9.2A A 10.2A A 12.2A A 18.1A B


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Instrument Fitter – Specific Competencies Unit No Unit Name and Descriptor Pre-Reqs Hold

Skill Use Skill

Validation

MEM 5.1A A Manual soldering/desoldering electrical/electronic components This unit covers manual soldering/desoldering for the installation and fabrication of electrical/electronic components. Advanced specification and high reliability soldering associated with the installation of electrical/electronic components, in areas where reliability of connections is critical, is covered by Unit 5.2A (High reliability soldering and desoldering).

MEM 18.54A A Fault find, test, calibrate instrumentation systems, equipment This unit covers the competencies required to test instrumentation systems and equipment, apply data collection techniques and localise fault conditions, analyse and report test results and calibrate instrumentation systems and components. The unit applies to undertaking test procedures to determine correct operational function of electrical, electronic mechanical, fluid power systems, equipment, components and associated items.

Path: 2 2.5C11 A 9.1A A 9.2A A 12.2A A 18.1A B 18.2A A 18.55A A 18.64A A

MEM 18.62A A Install, maintain and calibrate instrumentation sensors, transmitters and final control elements This unit covers the competencies required to select and install appropriate sensors and signal transmitters, maintain and diagnose sensors and signal transmitters, complete fault documentation. It covers the ability to plan corrective action, repair, replace and overhaul sensors and signal transmitters calibrate, test, reinstall and recommission instrumentation sensors and signal transmitters. Tasks relate to the use of mechanical, electrical, electronic (analog and digital) and associated sensing indications and signal transmitting instrumentation, representing measurement of pressure, temperature, level, flow rate, weight, density and other process variables.

Path: 2 2.5C11 A 9.1A A 9.2A A 12.2A A 18.1A B 18.2A A 18.54A A 18.55A A 18.64A A

MEM 18.64A A Maintain instrumentation system components This unit provide the skills and knowledge to maintain instrument system components of a primarily mechanical nature. An understanding of instrumentation principles is required.

2.5C11 A 9.1A A 12.2A A 18.1A B 18.2A A 18.55A A Path: 2 2.5C11 A 9.2A A 12.2A A 18.1A B 18.2A A 18.55A A


Page 8 of 8

Supervisor Specific Competencies Unit No Unit Name and Descriptor (transferred from Business Services training package – (Cert IV in Business (Frontline Management – BSB 41001)

Pre-Reqs

Hold Skill

Use Skill

Validation











Page 1 of 2

Appendix 3:

Individual Development Plan for Tradespeople.

TRANSFIELD SERVICES MACKAY SUGAR ALLIANCE INDIVIDUAL DEVELOPMENT PLAN

Form No: TMF-xxxx-xx-xxxx Date: November 2004 Revision No: x Page: 2 of 57

NAME:

LOCATION:

BROAD JOB CATEGORY: CURRENT CLASSIFICATION: SUPERVISOR:

Current Competencies:

Unit Code Unit Title Points Unit Code Unit Title Points

Development Plan: For Reclassification from C10 to C9

Unit Title Pri Points Value Action Timeline Responsibility

For Reclassification from C9 to C8


Transfield Services (Australia) Pty Ltd – Mackay Sugar Alliance Training Agreement

Page 3 of 3

Form No: TMF-xxxx-xx-xxxx Date: November 2004 Revision No: x Page: 3 of 57





EMPLOYEE SIGNATURE:

DATE: SUPERVISOR’S SIGNATURE: Date:

Comments: Approval:

Approved Yes / No If No, Please state Reason(s): SUPERVISOR’S SIGNATURE:

Date:

TRAINING CO-ORDINATOR’S SIGNATURE:

Date:

MANAGER’S SIGNATURE:

DATE:

engineering employees (fabrication and mechanical trades

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