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Pulp and Paper Manufacturing Industry

Training Package

Companion Volume Implementation Guide

Release 1.0

Contents

Overview information ....................................................................................................... 1

Version control and modification history .............................................................................. 1

Qualifications ......................................................................................................................... 2

Units of competency .............................................................................................................. 2

Qualification mapping information ....................................................................................... 7

Unit of competency mapping information ............................................................................ 8

Key work and training requirements the industry .............................................................. 12

Regulation and licencing implications for implementation ................................................. 15

Implementation information ........................................................................................... 16

What is a training package? ................................................................................................. 16

Compliance with the Australian Qualifications Framework (AQF) ...................................... 16

AQF Qualifications Pathways Policy ..................................................................................... 16

Pathways chart ..................................................................................................................... 17

Industry sectors and occupational outcomes of qualification ............................................ 18

Endorsed and non-endorsed components .......................................................................... 20

Explanation of any mandatory entry requirements for qualifications ................................ 20

Credit arrangements ............................................................................................................ 20

Access and equity considerations ........................................................................................ 21

Foundation skills .................................................................................................................. 22

Advice on any workplace health and safety implications in the industry ........................... 22

Resource and equipment list ............................................................................................... 23

Legal considerations for learners in the workplace/on placements ................................... 24

Links to other relevant documents .................................................................................. 24


Pulp and Paper Manufacturing Training Package Page 1 of 27

Overview information

This Companion Volume Implementation Guide has been developed to assist trainers, assessors,

Registered Training Organisations (RTOs) and industry representatives to deliver the PPM Pulp and

Paper Manufacturing Industry Training Package. It provides advice about the structure and

content of the training package, as well as an overview of its components, including: qualifications,

units of competency and assessment requirements.

Release 1.0 of the Pulp and Paper Manufacturing (PPM) Training Package is the first release

formatted according to the new training package standards. It consists of eighty (80) units of

competency.

Version control and modification history

Release Release Date Comments

1.0 TBC Primary release of PPM Pulp and Paper Manufacturing Industry Training Package. PPM replaces FPP10 Pulp and Paper Manufacturing Industry Training Package Release 1.3

Units of Competency have been rewritten in line with a new format determined by the Australian Government.

Qualifications have been repackaged to reflect a closer alignment with job roles.



Qualifications Qualification code Qualification title

PPM20116 Certificate II in Pulping Operations

PPM20216 Certificate II in Papermaking Operations

PPM30116 Certificate III in Pulping Operations

PPM30216 Certificate III in Papermaking Operations

PPM40116 Certificate IV in Pulping Operations

PPM40216 Certificate IV in Papermaking Operations

PPM50116 Diploma of Pulp and Paper Process Management

Units of competency Unit code Unit title

PPMCPP210 Monitor and control coated paper processes

PPMCPP320 Prepare and start up coated paper processes

PPMCPP330 Co-ordinate the shutdown of coated paper processes

PPMCPP440 Troubleshoot and rectify coated paper processes

PPMCPR210 Prepare chemical products

PPMCSK310 Operate process control equipment

PPMDEO210 Monitor and control dry end operations

PPMDEO320 Prepare and start up dry end operations

PPMDEO330 Co-ordinate and implement dry end shutdown

PPMDEO440 Troubleshoot and rectify dry end systems

PPMENV210 Identify and monitor environmental discharges/emissions

PPMENV320 Monitor and control environmental hazards

PPMEPG210 Monitor and control power generation system

PPMEPG320 Manage a power generation system startup

PPMEPG330 Co-ordinate power generation system shutdown

PPMEPG440 Troubleshoot and rectify power generation system

PPMFCO210 Monitor, control and shut down finishing and converting operations

PPMFCO320 Prepare and start up finishing and converting operations

PPMFCO340 Troubleshoot and rectify finishing and converting systems

PPMHWP250 Store and dispatch waste paper

PPMHWP260 Receive waste paper

PPMHWP270 Unload waste paper

PPMMHV210 Operate overhead crane

PPMNUM210 Estimate and calculate basic data

PPMNUM320 Measure and calculate routine workplace data

PPMNUM430 Calculate and analyse production and financial performance

PPMWHS210 Participate in WHS processes

PPMWHS310 Contribute to WHS processes

PPMWHS320 Maintain WHS processes

PPMWHS410 Identify, assess and control WHS risk in own work

PPMWHS420 Manage WHS processes

PPMPLN210 Plan and undertake a routine task

PPMPLN420 Plan a complex activity

PPMPRM210 Undertake operator level preventative maintenance

PPMPRM220 Perform lubrication

PPMPRS210 Identify and rectify problems in the workplace



PPMPRS320 Solve systemic problems in the workplace

PPMPRV210 Operate ancillary equipment

PPMPRV320 Co-ordinate and direct clothing changes

PPMPUL210 Monitor and control pulping operations

PPMPUL250 Store and distribute pulped product

PPMPUL320 Prepare and start up pulping system operations

PPMPUL330 Co-ordinate and implement pulping plant shutdowns

PPMPUL440 Troubleshoot and rectify pulping processes

PPMQAS210 Apply basic quality practices

PPMQAS420 Co-ordinate in-process quality assurance

PPMQAS430 Oversee quality assurance process

PPMREC210 Monitor and control chemical recovery operations

PPMREC320 Prepare and start up chemical recovery operations

PPMREC330 Co-ordinate and implement chemical recovery shutdowns

PPMREC440 Troubleshoot and rectify chemical recovery operations

PPMREL210 Contribute to effective working relationships

PPMRES210 Prepare and operate the woodchip production system

PPMRES250 Distribute woodchips

PPMRES260 Receive materials

PPMRES270 Unload materials

PPMRES340 Troubleshoot and rectify primary resource operations

PPMSPR210 Monitor and control stock preparation systems

PPMSPR320 Prepare and start up stock preparation system for production

PPMSPR330 Co-ordinate and implement stock preparation system shutdown

PPMSPR440 Troubleshoot and rectify stock preparation systems

PPMSTM210 Monitor and control boiler operation

PPMSTM320 Manage steam boiler startup

PPMSTM330 Shut down and bank steam boiler

PPMSTM440 Troubleshoot and rectify boiler plant systems

PPMSUS210 Apply sustainable work practices/policies

PPMSUS510 Develop workplace policy and procedures for sustainability

PPMWAR250 Store product

PPMWAR255 Prepare and dispatch product

PPMWAR280 Warehouse product packaging

PPMWAS210 Operate water systems

PPMWAS340 Troubleshoot and rectify water systems

PPMWEO210 Monitor and control wet end operations

PPMWEO320 Prepare and start up wet end operations

PPMWEO330 Co-ordinate and implement wet end shutdown

PPMWEO440 Troubleshoot and rectify wet end systems

PPMWPO210 Monitor and control waste paper operations

PPMWPO320 Prepare and start up waste paper operations

PPMWPO330 Co-ordinate and implement waste paper shutdown

PPMWPO440 Troubleshoot and rectify waste paper operations

*PPM units of competency within the Pulp and Paper Manufacturing Training Package have no prerequisite units.



Imported units of competency Units of competency have been imported into the Pulp and Paper Manufacturing Training Package

to provide greater flexibility, choice and transferability of skills within the industry. These include

FWP units which provide skills for mobility across the forest, wood, paper and timber products

industry.

Unit Code Unit Title

BSBADM405 Organise meetings

BSBADM502 Manage meetings

BSBAUD501 Initiate a quality audit

BSBCMM101 Apply basic communication skills

BSBCMM201 Communicate in the workplace

BSBCMM401 Make a presentation

BSBFIM501 Manage budgets and financial plans

BSBFLM305 Support operational plan

BSBFLM309 Support continuous improvement systems and processes

BSBFLM311 Support a workplace learning environment

BSBFLM312 Contribute to team effectiveness

BSBLED501 Develop a workplace learning environment

BSBMGT502 Manage people performance

BSBMGT517 Manage operational plan

BSBMGT608 Manage innovation and continuous improvement

BSBWHS405 Contribute to implementing and maintaining WHS management systems

BSBWHS404 Contribute to WHS hazard identification risk assessment and risk control

BSBOHS404B Contribute to the implementation of strategies to control OHS risk

BSBPMG522 Undertake project work

BSBREL401 Establish networks

BSBRES401 Analyse and present research information

BSBRSK401 Identify risk and apply risk management processes

BSBWHS401 Implement and monitor WHS policies procedures and programs to meet legislative requirements

BSBWHS402 Assist with compliance with WHS laws

BSBWHS403 Contribute to implementing and maintaining WHS consultation and participation processes

BSBWHS409 Assist with workplace monitoring processes

BSBWHS510 Contribute to implementing emergency procedures

BSBLDR402 Lead effective workplace relationships

BSBLDR403 Promote team effectiveness

BSBWOR501 Manage personal work priorities and professional development

BSBWOR502 Ensure team effectiveness

BSBWRK402A Empower workers

BSBWRK403A Communicate with workers

BSBWRK404A Promote equality of opportunity and fair treatment for all workers

BSBWRK406A Participate in the bargaining process

BSBWRK407A Provide advice to union members

BSBWRK408A Undertake negotiations

BSBWRK409 Prepare for and participate in dispute resolution



BSBWRK506A Coordinate research and analysis

CPPSEC2011B Control access to and exit from premises

CPPSEC2015A Patrol premises

CPPSEC3007A Maintain security of environment

FWPCOR6201 Manage sustainability in the workplace

FWPCOT5207 Implement sustainability in the workplace

FWPCOT5208 Build and maintain community relationships

FWPCOT6201 Manage community engagement

FWPCOT6205 Prepare an enterprise carbon management report

FWPCOT6208 Manage innovative thinking and practice in the forest and wood products industry

FWPCOT6209 Manage forest and wood products industry research

FWPCOT8101 Lead forest and wood products industry innovative thinking and practice

FWPCOT8102 Initiate and lead a forest and wood products industry innovation

HLTAID003 Provide first aid

MEM09002B Interpret technical drawing

MEM11016B Order materials

MEM12023A Perform engineering measurements

MEM12024A Perform computations

MEM14005A Plan a complete activity

MEM18001C Use hand tools

MEM18002B Use power tools/hand held operations

MEM18011C Shut down and isolate machines/equipment

*MEM18055B Dismantle replace and assemble engineering components Prerequisites MEM09002B Interpret technical drawing

MEM12023A Perform engineering measurements

MEM18001C Use hand tools

MEM18002B Use power tools/hand held operations

MEM30020A Develop and manage a plan for a simple manufacturing related project

MSS403002A Ensure process improvements are sustained

MSACMT270A Use sustainable energy practices

MSACMT271A Use sustainable environmental practices

MSACMT671A Develop and manage sustainable environmental practices

MSAENV472B Implement and monitor environmentally sustainable work practices

MSAPMOHS110A Follow emergency response procedures

MSAPMOHS220A Provide initial first aid response

MSAPMOPS212A Use organisation computers or data systems

MSAPMSUP101A Clean workplace or equipment

MSAPMSUP382A Provide coaching/mentoring in the workplace

MSAPMSUP400A Develop and monitor quality systems

MSL904001 Perform standard calibrations

MSL973001 Perform basic tests

MSS014003A Optimise sustainability of a process or plant area

MSS402020 Apply quick changeover procedures

MSS402030 Apply cost factors to work practices

MSS402040 Apply 5S procedures

MSS402050 Monitor process capability

MSS402051 Apply quality standards



MSS402081 Contribute to the application of a proactive maintenance strategy

MSS403001A Implement competitive systems and practices

MSS403002 Ensure process improvements are sustained

MSS403011A Facilitate implementation of competitive systems and practices

MSS403032A Analyse manual handling processes

MSS403040A Facilitate and improve implementation of 5S

MSS403051A Mistake proof an operational process

MSS404052A Apply statistics to operational processes

PMAOHS211B Prepare equipment for emergency response

PSPPM402B Manage simple projects

TAEASS301 Contribute to assessment

TAEASS401 Plan assessment activities and processes

TAEASS402 Assess competence

TAEASS403 Participate in assessment validation

TAEASS502B Design and develop assessment tools

TAEASS505A Lead and coordinate assessment systems and services

TAEDEL301 Provide work skill instruction

TAEDEL401A Plan organise and deliver group based learning

TAEDEL402A Plan organise and facilitate learning in the workplace

TAEDEL404 Mentor in the workplace

TAEDES401A Design and develop learning programs

TAEDES402A Use training packages and accredited courses to meet client needs

TAEDES502A Design and develop learning resources

TAETAS501B Undertake organisational training needs analysis

TLIA2012 Pick and process orders

TLIA2022 Participate in stocktakes

TLIA3016 Use inventory systems to organise stock control

TLID1001 Shift materials safely using manual handling methods

TLID1002 Shift a load using manually operated equipment

TLID2003 Handle dangerous goods/hazardous substances

TLID2004 Load and unload goods/cargo

TLID2010 Operate a forklift

TLID2013 Move materials mechanically using automated equipment

TLID2047 Prepare cargo for transfer with slings

TLID3011 Conduct specialised forklift operations

TLID3024 Use specialised liquid bulk transfer equipment (gravity/pressurised)

TLID3031 Rig load

TLID3035 Operate a boom type elevating work platform

TLIE4006A Collect analyse and present workplace data and information

UEPOPS341A Shut down a steam turbine

UEPOPS411B Run up a steam turbine

* Imported units of competency within the Pulp and Paper Manufacturing Training Package

marked with an asterisk * contain prerequisite units. Prerequisite units do not count towards any

PPM qualification and must be completed prior to the applicable imported unit of competency.



Qualification mapping information

Mapping of qualifications to the previous training package

PPM Relationship to FPP10 Release 1.3

Relation to the previous iteration of the training package

Equivalent/ Not-equivalent

PPM20116 Certificate II in Pulping Operations

FPP20110 Certificate II in Pulping Operations

Core units repackaged

Elective unit packaging simplified

Imported units have been updated to the most current at time of publication

Equivalent

PPM20216 Certificate II in Papermaking Operations

FPP 20210 Certificate II in Papermaking Operations




Equivalent

PPM30116 Certificate III in Pulping Operations

FPP 30110 Certificate III in Pulping Operations




Equivalent

PPM30216 Certificate III in Papermaking Operations

FPP 30210 Certificate III in Papermaking Operations




Equivalent

PPM40116 Certificate IV in Pulping Operations

FPP 40110 Certificate IV in Pulping Operations




Equivalent

PPM40216 Certificate IV in Papermaking Operations

FPP 40210 Certificate IV in Papermaking Operations




Equivalent


FPP 50110 Diploma of Pulp and Paper Process Management


Equivalent



Unit of competency mapping information

Mapping of units to the previous training package

Unit code and title PPM Unit code and title FPP10 (Release 1.3) Relationship

PPMCPP210 Monitor and control coated paper processes

FPPCPP210A Monitor and control coated paper processes

Equivalent

PPMCPP320 Prepare and start up coated paper processes

FPPCPP320A Prepare and start up coated paper processes

Equivalent

PPMCPP330 Co-ordinate the shutdown of coated paper processes

FPPCPP330A Co-ordinate the shutdown of coated paper processes

Equivalent

PPMCPP440 Troubleshoot and rectify coated paper processes

FPPCPP440A Troubleshoot and rectify coated paper processes

Equivalent

PPMCPR210 Prepare chemical products FPPCPR210A Prepare chemical products Equivalent

PPMCSK310 Operate process control equipment

FPPCSK310A Operate process control equipment

Equivalent

PPMDEO210 Monitor and control dry end operations

FPPDEO210A Monitor and control dry end operations

Equivalent

PPMDEO320 Prepare and start up dry end operations

FPPDEO320A Prepare and start up dry end operations

Equivalent

PPMDEO330 Co-ordinate and implement dry end shutdown

FPPDEO330A Co-ordinate and implement dry end shutdown

Equivalent

PPMDEO440 Troubleshoot and rectify dry end systems

FPPDEO440A Troubleshoot and rectify dry end systems

Equivalent

PPMENV210 Identify and monitor environmental discharges/emissions

FPPENV210A Identify and monitor environmental discharges/emissions

Equivalent

PPMENV320 Monitor and control environmental hazards

FPPENV320A Monitor and control environmental hazards

Equivalent

PPMEPG210 Monitor and control power generation system

FPPEPG210A Monitor and control power generation system

Equivalent

PPMEPG320 Manage a power generation system startup

FPPEPG320A Manage a power generation system startup

Equivalent

PPMEPG330 Co-ordinate power generation system shutdown

FPPEPG330A Co-ordinate power generation system shutdown

Equivalent

PPMEPG440 Troubleshoot and rectify power generation system

FPPEPG440A Troubleshoot and rectify power generation system

Equivalent

PPMFCO210 Monitor, control and shutdown finishing and converting operations

FPPFCO210A Monitor, control and shutdown finishing and converting operations

Equivalent

PPMFCO320 Prepare and start up finishing and converting operations

FPPFCO320A Prepare and start up finishing and converting operations

Equivalent

PPMFCO340 Troubleshoot and rectify finishing and converting systems

FPPFCO340A Troubleshoot and rectify finishing and converting systems

Equivalent

PPMHWP250 Store and dispatch waste paper

FPPHWP250A Store and dispatch waste paper

Equivalent

PPMHWP260 Receive waste paper FPPHWP260A Receive waste paper Equivalent

PPMHWP270 Unload waste paper FPPHWP270A Unload waste paper Equivalent

PPMMHV210 Operate overhead crane FPPMHV210A Operate overhead crane Equivalent



PPMNUM210 Estimate and calculate basic data

FPPNUM210A Estimate and calculate basic data

Equivalent

PPMNUM320 Measure and calculate routine workplace data

FPPNUM320A Measure and calculate routine workplace data

Equivalent

PPMNUM430 Calculate and analyse production and financial performance

FPPNUM430A Calculate and analyse production and financial performance

Equivalent

PPMWHS210 Participate in WHS processes FPPOHS210A Participate in OHS processes Equivalent

PPMWHS310 Contribute to WHS processes FPPOHS310A Contribute to OHS processes Equivalent

PPMWHS320 Maintain WHS processes FPPOHS320A Maintain OHS processes Equivalent

PPMWHS410 Identify, assess and control WHS risk in own work

FPPOHS410A Identify, assess and control OHS risk in own work

Equivalent

PPMWHS420 Manage WHS processes FPPOHS420A Manage OHS processes Equivalent

PPMPLN210 Plan and undertake a routine task

FPPPLN210A Plan and undertake a routine task

Equivalent

PPMPLN420 Plan a complex activity FPPPLN420A Plan a complex activity Equivalent

PPMPRM210 Undertake operator level preventative maintenance

FPPPRM210A Undertake operator level preventative maintenance

Equivalent

PPMPRM220 Perform lubrication FPPPRM220A Perform lubrication Equivalent

PPMPRS210 Identify and rectify problems in the workplace

FPPPRS210A Identify and rectify problems in the workplace

Equivalent

PPMPRS320 Solve systemic problems in the workplace

FPPPRS320A Solve systemic problems in the workplace

Equivalent

PPMPRV210 Operate ancillary equipment FPPPRV210A Operate ancillary equipment Equivalent

PPMPRV320 Co-ordinate and direct clothing changes

FPPPRV320A Co-ordinate and direct clothing changes

Equivalent

PPMPUL210 Monitor and control pulping operations

FPPPUL210A Monitor and control pulping operations

Equivalent

PPMPUL250 Store and distribute pulped product

FPPPUL250A Store and distribute pulped product

Equivalent

PPMPUL320 Prepare and start up pulping system operations

FPPPUL320A Prepare and start up pulping system operations

Equivalent

PPMPUL330 Co-ordinate and implement pulping plant shutdowns

FPPPUL330A Co-ordinate and implement pulping plant shutdowns

Equivalent

PPMPUL440 Troubleshoot and rectify pulping processes

FPPPUL440A Troubleshoot and rectify pulping processes

Equivalent

PPMQAS210 Apply basic quality practices FPPQAS210A Apply basic quality practices Equivalent

PPMQAS420 Co-ordinate in-process quality assurance

FPPQAS420A Co-ordinate in-process quality assurance

Equivalent

PPMQAS430 Oversee quality assurance process

FPPQAS430A Oversee quality assurance process

Equivalent

PPMREC210 Monitor and control chemical recovery operations

FPPREC210A Monitor and control chemical recovery operations

Equivalent

PPMREC320 Prepare and start up chemical recovery operations

FPPREC320A Prepare and start up chemical recovery operations

Equivalent

PPMREC330 Co-ordinate and implement chemical recovery shutdowns

FPPREC330A Co-ordinate and implement chemical recovery shutdowns

Equivalent



PPMREC440 Troubleshoot and rectify chemical recovery operations

FPPREC440A Troubleshoot and rectify chemical recovery operations

Equivalent

PPMREL210 Contribute to effective working relationships

FPPREL210A Contribute to effective working relationships

Equivalent

PPMRES210 Prepare and operate the woodchip production system

FPPRES210A Prepare and operate the woodchip production system

Equivalent

PPMRES250 Distribute woodchips FPPRES250A Distribute woodchips Equivalent

PPMRES260 Receive materials FPPRES260A Receive materials Equivalent

PPMRES270 Unload materials FPPRES270A Unload materials Equivalent

PPMRES340 Troubleshoot and rectify primary resource operations

FPPRES340A Troubleshoot and rectify primary resource operations

Equivalent

PPMSPR210 Monitor and control stock preparation systems

FPPSPR210A Monitor and control stock preparation systems

Equivalent

PPMSPR320 Prepare and start up stock preparation system for production

FPPSPR320A Prepare and start up stock preparation system for production

Equivalent

PPMSPR330 Co-ordinate and implement stock preparation system shutdown

FPPSPR330A Co-ordinate and implement stock preparation system shutdown

Equivalent

PPMSPR440 Troubleshoot and rectify stock preparation systems

FPPSPR440A Troubleshoot and rectify stock preparation systems

Equivalent

PPMSTM210 Monitor and control boiler operation

FPPSTM210A Monitor and control boiler operation

Equivalent

PPMSTM320 Manage steam boiler startup FPPSTM320A Manage steam boiler startup Equivalent

PPMSTM330 Shut down and bank steam boiler

FPPSTM330A Shut down and bank steam boiler

Equivalent

PPMSTM440 Troubleshoot and rectify boiler plant systems

FPPSTM440A Troubleshoot and rectify boiler plant systems

Equivalent

PPMSUS210 Apply sustainable work practices/policies

FPPSUS210A Apply sustainable work practices/policies

Equivalent

PPMSUS510 Develop workplace policy and procedures for sustainability

FPPSUS510A Develop workplace policy and procedures for sustainability

Equivalent

PPMWAR250 Store product FPPWAR250A Store product Equivalent

PPMWAR255 Prepare and dispatch product

FPPWAR255A Prepare and dispatch product

Equivalent

PPMWAR280 Warehouse product packaging

FPPWAR280A Warehouse product packaging

Equivalent

PPMWAS210 Operate water systems FPPWAS210A Operate water systems Equivalent

PPMWAS340 Troubleshoot and rectify water systems

FPPWAS340A Troubleshoot and rectify water systems

Equivalent

PPMWEO210 Monitor and control wet end operations

FPPWEO210A Monitor and control wet end operations

Equivalent

PPMWEO320 Prepare and start up wet end operations

FPPWEO320A Prepare and start up wet end operations

Equivalent

PPMWEO330 Co-ordinate and implement wet end shutdown

FPPWEO330A Co-ordinate and implement wet end shutdown

Equivalent

PPMWEO440 Troubleshoot and rectify wet end systems

FPPWEO440A Troubleshoot and rectify wet end systems

Equivalent

PPMWPO210 Monitor and control waste paper operations

FPPWPO210A Monitor and control waste paper operations

Equivalent



PPMWPO320 Prepare and start up waste paper operations

FPPWPO320A Prepare and start up waste paper operations

Equivalent

PPMWPO330 Co-ordinate and implement waste paper shutdown

FPPWPO330A Co-ordinate and implement waste paper shutdown

Equivalent

PPMWPO440 Troubleshoot and rectify waste paper operations

FPPWPO440A Troubleshoot and rectify waste paper operations

Equivalent



Key work and training requirements the industry

Organisations across the industry utilise the training package as an integral component supporting

their workforce development strategy. The qualifications and units of competency are applied as a

best practice framework in achieving the desired business outcomes. This framework supports

linkages to a number of best practice compliance requirements for Workplace Health Safety and

Environment and Quality systems.

Key work requirements

Productivity

Pulp and paper production in Australia is a 24/7 operation. Key work requirements are focussed on activities that ensure continuous production and maximise productivity, while satisfying requirements for safety and quality. Meeting productivity requirements requires continuous examination and adjustment of process variables, achievement of key performance indicators, quality and output targets, minimisation of delays and downtime, minimisation of landfill and waste water, optimisation of resource use including water, chemicals, energy,

There are three main operational levels with specific work requirements as follows:

Operator/production support – activities that monitor & control equipment & processes

Operator/technician – activities involving start-up & shut down of equipment & processes

Senior operator/production specialist – activities that troubleshoot & rectify equipment &

processes

A fourth level focusses on overseeing & supervising/ managing operations.

Work is conducted within a just in time manufacturing and lean manufacturing environment. Each

operational level has specific training requirements, discussed under Key training requirements

section.

Safety

Safety is of paramount importance in the pulp and paper manufacturing sectors and a key work

requirement. Operators and technicians work in close proximity to large, high speed plant,

equipment and vehicles containing many moving parts. They frequently use load shifting

equipment to move products and equipment. Heat, light, noise, dust, fumes, chemicals, steam

and gas, latent energy and confined spaces are also present as potential hazards.

Work must be performed in accordance with various guidelines and procedures covering fatigue,

stress, ergonomics, workplace conduct, manual handling. Risk control and mitigation includes

policies and procedures for safe work, use of Personal Protective Equipment (PPE) and safety

equipment, hazard elimination or substitution or re-engineering of processes.

Key training requirements

In the context of the three main operational levels there is a distinct focus on three key areas for

training, as follows:

Safety

The nature of the processes involved demand that safety training is a vital part of every job role,

particularly for induction of new entrants to the workplace. Training needs typically include



hazard identification and control, risk mitigation, safe work practices, pre-start and operational

checks, personal protective and safety equipment, housekeeping, emergency and evacuation

response and incident reporting. Safety extends to environmentally sustainable work practices

where skill development focusses on optimisation of resources such as water and energy,

recycling, effluent control, and skills for environmental monitoring and compliance. The industry

has high environmental compliance requirements and workers generally are trained to high

operating standards that meet the requirements of ISO:9001 quality management system. Skill

standards in PPM support and are utilised to meet safety, quality and environmental compliance

requirements.

Implementation of workplace health and safety is also discussed in a later section.

Quality

Product quality is a prime focus for pulping, since pulp is a resource used for manufacture of

paper. Paper manufacturers produce products to ever tighter tolerances and finishes in order to

satisfy increasingly stringent demands of consumers.

Support operators charged with monitoring and controlling production equipment and processes

need skills to analyse the impact of process variables (e.g. altering critical process inputs and line

speed) on product quality. They need to identify product faults and rectify them by making

adjustments to the production process, whilst being aware of the potential impact on other parts

of the downstream processes. They need good communication skills to record shift data and

convey information upstream and downstream.

Operator/technicians set and start up equipment. They may conduct sampling and testing to

ensure products meet required specifications. Key training requirements include measurement

and testing for product conformance.

Productivity

At production support level, operator training is strongly focussed on process variables that impact

on productivity. As with quality targets, operators make appropriate adjustments to optimise

production. They also need skills to conduct routine maintenance on plant and equipment, as part

of a planned maintenance regime to achieve maximum run time.

Planned and unplanned shutdowns can have a significant impact on production output.

Operator/technicians need skills to conduct planned shutdowns efficiently according to schedule.

They also need skills to respond to unplanned shutdowns, identifying symptoms and analysing the

cause and potential impact of these stoppages.

Senior operator/production specialists are highly skilled technicians. They require training in

troubleshooting, fault-finding and diagnostics to accurately analyse process and equipment

problems that can impact on productivity and quality.

Development of problem solving skills is vital for the continuous operation of machinery and

processes. Variables can include duration, frequency and continuity, deterioration rates, product

quality issues, nature, location and impact of the problem on production. Actions or responses

can include making rectifying the problem within a given level of responsibility, making process

adjustments, or reporting the problem to an authorised person.



Communication

Effective interpersonal and communication skills are essential to every job role and therefore a key

training requirement for industry. They relate to many aspects of work including orientation to the

organisation, performing operational processes, following procedures and instructions, interacting

with workers and supervisers, quality assurance, problem solving and troubleshooting, WHS, taking

part in meetings, undertaking training and training others on the job.

Employees at all levels need to communicate effectively with a range of individuals and groups

including team leaders supervisors and managers, production and technical staff, maintenance,

WHS and quality assurance personnel.

Core interpersonal skills include verbal and non-verbal language, hand or other agreed signals, eye

contact, active listening, questioning and use of electronic communication devices, such as two-way

radios.

Key training for operators and support staff relates to reading and interpreting routine information,

including work and quality procedures, work instructions, manuals, checklists, process and

instrument diagrams and illustrations, signage, and safety data sheets. Supervisors, managers and

specialist technical staff need advanced skills to critically read, analyse and evaluate procedures,

guidelines and reports.

Writing skills for operators and technicians including recording production, process and quality

information on proformas, reporting hazards and incidents, faults and downtime. Higher level

written skills are needed by supervisors, managers and specialist technical staff, who are required

to produce reports for a range of issues including production output, plant and equipment

operation, risk assessments, workplace inspections, maintenance and testing, training,

environmental monitoring.

ForestWorks’ response

ForestWorks has responded to these training needs by ensuring they are reflected throughout all

the qualifications and units of competency. Quality assurance and WHS skills are included in core

unit groups for each qualification. This was in direct response to industry needs, as is the inclusion

of units for problem solving and environmentally sustainable work practices.



Regulation and licencing implications for implementation

In several states licences are required for a range of occupations. These are aimed at securing

consistent operating standards for individuals in high risk activities, such as boiler operation.

Where units of competency contain regulatory information or align to licensing, RTOs, trainers and

assessors must be suitably qualified to deliver the training. This usually means that trainers and

assessors must have the relevant vocational competencies, at least to the level being delivered or

assessed, and can demonstrate current industry skills directly relevant to the training/assessment

being undertaken.

Licensing/registration requirements for particular job functions described in units of competency

vary significantly. There are variations between States and Territories, and between individual

workplaces, depending on the equipment and processes being used.

Organisations delivering training must determine the applicable licensing requirements associated

with the equipment being used, and in the relevant States and Territories.

To assist this process, units of competency will contain one of the following statements:

In the case of no licensing requirements:

No licensing, legislative, regulatory, or certification requirements apply to this unit at the time of

publication.

In cases where a licence, certification or other regulatory/legislative compliance is required:

Licensing, legislative, regulatory or certification requirements apply to this unit in some states

and territories at the time of publication, and may differ according to jurisdiction.

If the use of load shifting equipment is required as an adjunct to performing activities in a unit, the

relevant units of competency for load shifting should also be accessed and are to be met

concurrently or prior to the achievement of this unit.



Implementation information

What is a training package?

Training packages specify the skills and knowledge required to perform at the required standard in

the workplace. It is the trainers and supervisors who develop the learning strategies, which take

into consideration learner needs, abilities and circumstances.

Training packages include nationally endorsed competency standards, assessment requirements

and qualifications for a specific industry’s use.

Training packages may also include skill sets, made up of a combination of units of competency

that link to a licence or regulatory requirement, or a specific industry need. Skill sets are most

useful when acquired to build upon a qualification. PPM Release 1.0 contains no skill sets.

Each training package:

Provides a consistent set of criteria for performance on the job as well as performance

knowledge and evidence requirements

Enables national recognition of workplace competencies

Supports work related learning and assessment.

Compliance with the Australian Qualifications Framework (AQF)

Units of competency within the Pulp and Paper (PPM) Manufacturing Industry Training Package

are aligned to levels within the Australian Qualifications Framework (AQF). The AQF provides a

comprehensive, nationally consistent framework for all qualifications in Australia.

For a full explanation of the AQF, see the AQF Implementation Handbook:

http://www.aqf.edu.au/wp-content/uploads/2013/05/AQF-2nd-Edition-January-2013.pdf

AQF Qualifications Pathways Policy

In line with requirements of the AQF Pathways Policy, all qualifications within the PPM Pulp and

Paper Manufacturing Industry Training Package can be achieved by a variety of pathways and

delivery methods, either on-the-job or through a combination of on and off-the-job training and

recognition processes. The AQF Qualifications Pathways Policy builds into the Australian

Qualifications Framework’s capacity to genuinely support students’ lifelong learning. It is

Australia’s national policy on qualifications pathways.

The purpose of the policy is to maximise the credit that students can gain for learning already

undertaken. It aims to:

Enhance student progression into and between AQF qualifications

Recognise the multiple pathways that students take to gain AQF qualifications and that

learning can be formal, non-formal or informal

Support the development of pathways in qualifications design

Entry requirements are the knowledge, skills or experience required to enter a qualification. They

may be expressed as units of competency or vocational experience or a combination of both and

must be demonstrated prior to commencing the qualification.

http://www.aqf.edu.au/wp-content/uploads/2013/05/AQF-2nd-Edition-January-2013.pdf



Qualifications within the PPM Pulp and Paper Manufacturing Industry Training Package are

available at AQF levels 1-5 and are suitable to be undertaken as an Australian Apprenticeship.

The qualification packaging provides clear and unambiguous pathways to a range of specific job

roles within the industry. Learner transition between the pulp and papermaking industry sectors

is supported by the PPM Training Package.

The qualifications in this package provide multiple entry and transition opportunities between

education sectors. There are no formal transition arrangements between the secondary school,

vocational education and training sector and the higher education sector for the Pulp and Paper

Manufacturing (PPM) training package. However, FWP50115 Diploma of Pulp and Paper Process

Management may provide a reciprocal pathway between VET and higher education. This is

particularly relevant with respect to chemical engineering undergraduate and short course

programs offered by the Australian Pulp and Paper Institute (APPI).

The following chart details the pathways learners can take to progress into and between

qualifications.

Pathways chart


12

units

PPM40116 Certificate IV in

Pulping Operations

10

units

PPM40216 Certificate IV in

Papermaking Operations

PPM30116 Certificate III in

Pulping Operations

13

units

PPM30216 Certificate III in


PPM20116 Cert II Pulping

Operations

11

units

PPM20216 Certificate II in




Industry sectors and occupational outcomes of qualification

The industry consists of two main sectors, these being:

pulp production

papermaking

A wide range of paper and paper products are produced within the following main categories:

packaging and industrial paper

personal hygiene products

printing and communications paper

newsprint

These products are produced using pulp from both Australian paper recycling and sustainably

managed wood sources, with some pulp imported to supplement domestic supply.

The industry is characterised by a combination of pulp and papermaking enterprises. Some

produce wood pulp and /or recycled paper, some only paper products and a few produce both.

The sector is highly concentrated, with employment based in no more than twenty operating mills

located across the lower South Australian-Victorian border, Latrobe Valley region, Melbourne

metro and Tasmania, as well as across New South Wales and South-East Queensland. Critical skills

for workers are needed to facilitate continuous operation of complex equipment and processes

across multiple technologies, including troubleshooting and rectification of systems and processes.

The units of competency and qualifications in the PPM Pulp and Paper Manufacturing Industry

Training Package cover a diverse range of work activities within each major sector. Job roles are

mainly linked to specialist functions, most of which are shown below:

Pulping

Chemical preparation

Chemical recovery operations

Electrical power generation

Pulping operations

Primary resource operations

Steam generation

Stock preparation

Waste paper operations

Water services

Papermaking

Chemical preparation

Chemical recovery operations

Electrical power generation

Dry end operations

Coated paper processes

Finishing and converting

Steam generation

Water services

Wet end operations

The following table illustrates how qualifications are used to achieve occupational outcomes in the

pulp and paper manufacturing industry. Generally, Certificate II is used for induction to the

industry as a production support operator; Certificate III is used for experienced

operators/technicians, Certificate IV is for senior technician who troubleshoot and provide

oversight of process and make process modifications; and the Diploma is for supervisors,

managers and specialist roles.


Forest and Wood Products Training Package Page 19 of 27

Occupational outcomes for PPM Pulp and Paper Manufacturing Training Package

Qualification PPM20116 Cert II

Pulping Operations

PPM20216

Certificate II in

Papermaking

Operations

PPM30116

Certificate III in

Pulping Operations

PPM30216

Certificate III in

Papermaking

Operations

PPM40116

Certificate IV in

Pulping

Operations

PPM40216

Certificate IV in

Papermaking

Operations

PPM50116 Diploma of

Pulp and Paper Process

Management

Level Operator/production support Operator/technician Senior operator/production specialist Supervision, line &

function management.

Focus Monitor & control equipment & processes Start-up & shut down equipment & processes Troubleshoot & rectify Oversee & supervise/

manage operations

Job roles Production support

employee in:

hydrapulping pulping machine

operations machine

operations pulp handling bale handling fibre preparation stock preparation

Production support employee in: machine

operation fibre preparation stock preparation winding

operations dryer operation bale handling folder operation rewinding

operations wrapping machine

ops plant support wet end support; dry end support paper products

Production operator or technician in: pulping operations waste paper

recycling primary resources stock preparation

& handling fibre preparation

Production operator or technician in: stock preparation

& handling fibre preparation wet end operations dry end operations finishing &

converting coating systems

operator winder/reel & roll

operations packaging/folding dry end testing

Production specialist in: pulping

operations waste paper

recycling primary

resources operations

stock preparation & handling

fibre preparation

Production specialist in: fibre/stock

preparation & handling

wet end operations

dry end operations

coated paper treatments

finishing & converting

winding & rewinding

quality testing

Supervisor, manager or coordinator, such as: line supervisor production manager senior operator (all

sections) crew/team leader support operations

coordinator quality assurance

specialist sustainability

coordinator/ manager project coordinator /

manager training coordinator

Common specialisations Electricity generation/turbine operations assistant Steam generation/boiler assistant Water services assistant Chemical recovery assistant

Common specialisations Electricity generation/turbine operator Steam generation/boiler operator Water services operator Chemical recovery operator

Common specialisations Electricity generation/turbine senior operator Steam generation/boiler senior operator Chemical recovery senior operator



Endorsed and non-endorsed components

Training packages consist of Australian Government endorsed components and non-endorsed

quality assured Companion Volume Implementation Guides.

The endorsed components include the following:

Units of competency

Assessment requirements (associated with each unit of competency)

Qualifications

Credit arrangements

The endorsed components of Training Packages can be found on the national register

http://training.gov.au.

The Companion Volume Implementation Guide is available at www.forestworks.com.au. It

contains overview information about the entire training package. It also contains key

implementation information for use by Registered Training Organisations (RTOs).

Explanation of any mandatory entry requirements for qualifications

There are no mandatory entry requirements for qualifications within the PPM Pulp and Paper

Manufacturing Industry Training Package. Entry requirements have been removed unless there is

evidence of a mandatory industry requirement for one job role to be held before commencing

another. This is to ensure that qualifications stand alone and that they promote equitable access

and progression for learners.

The majority of training in the forestry and pulp and paper industry is undertaken in conjunction

with an existing workplace role. It involves competency based training with the aim for the

learner to be able to do specified tasks to a specified standard. Work skills can be formally

recognised, no matter whether they are gained through training or through direct work activity.

Credit arrangements

Entry into higher qualifications may be gained through progression from a lower level PPM

qualification or by recognition of existing industry experience or qualifications.

There are no formal credit arrangements for qualifications in PPM. PPM qualifications such as

FWP50115 Diploma of Pulp and Paper Process Management may be recognised for part or full

credit in chemical engineering undergraduate and short course programs such as those offered by

the Australian Pulp and Paper Institute (APPI).

http://training.gov.au/

http://www.forestworks.com.au/



Access and equity considerations

Equity is about ensuring that all people and all groups of people are able to participate, to have

the opportunity to reach their potential, make choices and receive responsive and appropriate

products and services. In other words, the destination for all learners is the same but the journey

may be different.

Good vocational education, training and assessment includes making adjustments to what is done

to meet the learning and assessment needs of individuals. An open mind, common sense and

tailoring training and assessment to individual circumstances should ensure individuals achieve

the standards employers and RTOs expect.

The design of training packages allows every individual to have access to the assessment process

so there are no barriers for learners.

An adjustment is any measure or action that a learner requires because of their disability, which

has the effect of assisting the learner to access and participate in education and training on the

same basis as learners without a disability. A reasonable adjustment achieves this purpose while

taking into account factors such as the nature of the learner’s disability, the views of the learner,

the potential effect of the adjustment on the learner and others, and the costs and benefits of

making the adjustment.

Reasonable adjustments need only be that – reasonable. It is about identifying what adjustments

might reasonably be made and how they may be put into place.

Assessment processes and techniques should be modified for distance-based learners, be

culturally appropriate and suitable to the communication skill level, language, literacy and

numeracy capacity of the candidate and the work being performed.

Where applicable, physical resources should include equipment modified for people with specific

needs as well as assistance to support their participation in the assessment process.

Access and equity adjustments must align with industry’s realistic requirements to undertake the

job role.



Foundation skills

Foundation skills describe the language, literacy, numeracy and employment skills that are

essential to performance in the workplace.

Foundation skills are now identified explicitly in units of competency to assist trainers in

supporting learners to achieve successful outcomes. Foundation skills that are not explicitly

described in the performance criteria are listed in the ‘foundation skills’ section of the unit of

competency.

The Australian Core Skills Framework (ACSF) can be used wherever performance in the five core

skills of learning, reading, writing, oral communication and numeracy is described or discussed.

Information about the ACSF can be found on the Australian Government Department of Industry

and Science website:

http://www.industry.gov.au/skills/ForTrainingProviders/AustralianCoreSkillsFramework/Pages/de

fault.aspx

There is also a range of resources available on the ForestWorks website to assist trainers with

foundation skill development: http://www.forestworks.com.au/skills-standards/resources/find-a-

resource#resources-for-foundation-skill-development

Advice on any workplace health and safety implications in the industry

Workplace health and safety is a major focus for the industry and consequently features strongly

in all industry training. All units and qualifications include a significant component for safety,

which must be included in learning and assessment.

Commonwealth, State or Territory legislation and regulations, as well as organisational safety

policies and procedures, encompass areas such as the following:

personal protective equipment and clothing

safe work practices

safety equipment

first aid equipment

firefighting equipment

hazard and risk control

fatigue management

handling and elimination of hazardous chemicals, materials and substances

manual handling including shifting, lifting and carrying

Throughout Australia the regulations for workplace health and safety may differ slightly from state

to state. A regulating body exists in each state and territory to enforce the relevant workplace

health and safety laws. For further information abound workplace health and safety laws and

regulations in your state, please see the corresponding website:

ACT - http://www.worksafe.act.gov.au/health_safety

NSW - http://www.workcover.nsw.gov.au

http://www.industry.gov.au/skills/ForTrainingProviders/AustralianCoreSkillsFramework/Pages/default.aspx

http://www.industry.gov.au/skills/ForTrainingProviders/AustralianCoreSkillsFramework/Pages/default.aspx

http://www.forestworks.com.au/skills-standards/resources/find-a-resource#resources-for-foundation-skill-development

http://www.forestworks.com.au/skills-standards/resources/find-a-resource#resources-for-foundation-skill-development

http://www.worksafe.act.gov.au/health_safety

http://www.workcover.nsw.gov.au/



VIC - http://www.worksafe.vic.gov.au/

QLD - https://www.worksafe.qld.gov.au/

SA - http://www.safework.sa.gov.au/

WA - http://www.commerce.wa.gov.au/WorkSafe/

TAS - http://www.worksafe.tas.gov.au/home

NT - http://www.worksafe.nt.gov.au/home.aspx

Resource and equipment list

The resources and equipment required for a unit of competency are listed in the assessment

requirements of individual units of competency.

Due to the size and cost of the equipment and processes, practical training generally needs to be

conducted on-site. Enterprises often partner with a Registered Training Organisation to deliver

training and a few companies have registered as RTOs.

Other resources and equipment for learning and assessment include:

training and assessment plans

personal protective and safety equipment

tools and dedicated equipment

measuring and testing devices

chemicals and other consumables and resources for process operations

manufacturers’ specifications

proforma documents for recording and reporting data and information

electronic and other control systems, including analogue and digital instrumentation

standard operating procedures and workplace policies

workplace health and safety information

emergency response equipment

Resources are generally made available to the student by the RTO delivering the training. All

equipment must meet Australian standards for safety and be well maintained. Documents may be

paper based or electronic and reasonable adjustments should be made for those with special

needs.

Learning resources are available for certain units of competency within the PPM Pulp and Paper

Manufacturing Industry Training Package. For further information about resources available,

please see the ForestWorks website:

http://www.forestworks.com.au/skills-standards/resources/find-a-resource

http://www.worksafe.vic.gov.au/

https://www.worksafe.qld.gov.au/

http://www.safework.sa.gov.au/

http://www.commerce.wa.gov.au/WorkSafe/

http://www.worksafe.tas.gov.au/home

http://www.worksafe.nt.gov.au/home.aspx




Legal considerations for learners in the workplace/on placements

The majority of training in the industry is undertaken by workers once they are employed. As a

consequence, the legal considerations of these learners are covered by their employment

contract.

Links to other relevant documents

Innovation hub

www.forestworks.com.au/innovation

Innovation skill sets

http://www.forestworks.com.au/innovation/innovation-skill-sets

ForestWorks website

www.forestworks.com.au/ltd

Training.gov.au

training.gov.au/Home

ForestWorks resources

www.forestworks.com.au/skills-standards/resources/find-a-resource

http://www.forestworks.com.au/innovation

http://www.forestworks.com.au/innovation/innovation-skill-sets

http://www.forestworks.com.au/ltd




National Office 559A Queensberry Street (PO Box 612) North Melbourne, Victoria 3051 FREECALL 1800 177 001 Melbourne 03 9321 3500 Sydney 02 8898 6990 Launceston 03 6331 6077 Adelaide 08 8219 9028 [email protected] www.forestworks.com.au ABN 39 946 785 543

Example

ForestWorks ISC activities are assisted by funding provided by the Australian Government through the Department of Education And Training