Understand Process and Variables in Coating Paper and Board: Commissioned by PAMSA and German Technical Co-Operation

National Certificate in Paper & Pulp Manufacturing NQF Level 4
Understand process and variables in coating paper and board
Commissioned by PAMSA
and German Technical Co-Operation
Understand process and variables in coating paper and board

Topics
Notional Hours
Modules
P&P4EL
Basics of the coating process
BE410 Understanding the process and variable in coating paper and board BE410 Understanding the feedstock, intermediate and final products of the process BE410 Understanding variations in the process BE410 Applying sampling practices BE410 Understanding the purpose of auxiliary systems associated with the process BE410 Understanding Operating Procedures in the process BE410 Applying Standard Operating Procedures to the process BE410 Applying first line maintenance BE410 Applying SHE in the process Total Notional Hours
Commissioned by PAMSA and German Technical Co-Operation
23 10 10 10 8 12 12 10 5 100
P&P4EL
Quality
P&P4EL
Auxiliary systems
P&P4EL
Standard Operating Procedures
P&P4EL
Maintenance
P&P4EL
SHE
National Certificate in Paper & Pulp Manufacturing NQF Level 4 US: U0002 board Understand process and variables in coating paper and
Critical Cross-field Outcomes
Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development
BE410 Understanding the process and variable in coating paper and board
Understand the basic properties and characteristics of all chemicals used in the process
Understand the fundamental operating principles of the process
Be able to identify each piece of equipment in this process
Be able to trace the material flow through the process
Understand the purpose of this process and how it fits into the overall process

Topic Specification: BE410 Learning Activities
Use Multi media
The coating of paper and board in a coating machine Assignment Description Topic assessment criteria
The assessor will observe and confirm that learners: Understand the purpose of this process and how it fits into the overall process Are able to identify each piece of equipment in this process Are able to trace the material flow through the process Understand the fundamental operating principles of the process Understand the basic properties and characteristics of all chemicals used in the process
Collect Information
Self Study Plant investigation Media search Interview experts Attend lectures Group Discussions Sketch Case studies Use checklists Develop recommendations Job assignment Make presentation Complete documents Draft a report Complete a questionnaire
W H A T
Individual or group training. Do self study to develop key plant operation questions. Answers are obtained by discussions with production experts and plant investigation.
HOW
1. Learners are provided with relevant plant and equipment information / manuals 2. Inspect the plant and determine the flow of material through the plant 3. Draw a block diagram to show where this process fits into the overall process, specifically noting suppliers and customers of this plant 4. Draw a basic layout sketch of this area 5. In a discussion with a plant specialist, identify: the purpose of the process the different equipment used in the process the fundamental operating principles of each piece of equipment and the total plant the basic properties and characteristics of all chemicals within this process 6. Learners complete a questionnaire to indicate findings
Execute, test and evaluate
Analyse, plan and make decisions
Notional Hours 23 4
BE410 Understanding the feedstock, intermediate and final products of the process
Be able to construct a spreadsheet with throughputs, specifications, typical results and reasons for each specification Be able to carry out quality checks on the feedstock and final products Understand the properties of the feedstock, intermediate and final products Know the typical specifications for the feedstock, intermediate and final products Know the suppliers of feedstock and the customers for the products produced.


Use Multi media
The feedstock, intermediate and final products of the process Assignment Description Topic assessment criteria
The assessor will observe and confirm that learners: Know the suppliers of feedstock and the customers for the products produced. Know the typical specifications for the feedstock, intermediate and final products Understand the properties of the feedstock, intermediate and final products Are able to carry out quality checks on the feedstock and final products Are able to construct a spreadsheet with throughputs, specifications, typical results and reasons for each specification
Collect Information
Self Study Plant investigation Media search Interview experts Attend lectures Group Discussions Educational games Case studies Use checklists Develop recommendations Job assignment Make presentation Complete documents Draft a report Complete a questionnaire
W H A T
Individual or group training. Obtain basic product and supplier information by discussions with production experts. Apply knowledge in a practical quality check.
HOW
1. Learners are supplied with information on feedstock quality 2. Have a facilitated group discussion in the plant to determine: by whom feedstock is supplied and routes into the plant The reasons for quality standards in raw materials, intermediates and final products the typical grades and properties of the feedstock the typical properties and specifications used for the intermediate and final products the customers for the products produced 3. Construct a spreadsheet with throughputs, specifications, typical results and reasons for each specification 4. Carry out quality checks on the final products using the checklist/spreadsheet and report findings
Notional Hours 10 6
BE410 Understanding variations in the process

Know the effect of variations and deviations on the process and products Understand what process variations could occur in the process Understand how a deviation in the properties of the feedstock will impact on the process Understand what feedstock variations could occur in the process Be able to complete all log sheets

Use Multi media
Variations in the process Assignment Description Topic assessment criteria

The assessor will observe and confirm that learners: Are able to complete all log sheets. Understand what feedstock variations could occur in the process Understand how a deviation in the properties of the feedstock will impact on the process Understand what process variations could occur in the process Know the effect of variations and deviations on the process and products
Collect Information
Self Study Plant investigation Media search Interview experts Attend lectures Group Discussions Educational games Case studies List / Tabulate Develop recommendations Job assignment Make presentation Complete documents Draft a report Complete a questionnaire
W H A T
Individual or group training. Use the information on the feed stock obtained earlier to list quality variations. A facilitated discussion to identify possible process deviations and the downstream effects.
HOW
1. Learners are supplied with log sheets and assisted to complete them with the help of a production specialist 2. Individually list the feedstock variations that could occur and the effect each type of variation could have on the final products and / or in downstream processes or products 3. In a facilitated discussion at the site, identify and list process deviations that could occur and the effect each type of deviation could have on the final products and / or in downstream processes or products 4. Tabulate all variations and deviations, their effects and the broad rectification action required and compile the information into a report
Notional Hours 10 8
BE410 Applying sampling practices Critical Cross-field Outcomes
Be able to interpret the test results in terms of the impact on the process and customers
Be able to construct a basic spreadsheet for sources and sample results
Be able to do sampling according to plant standards
Understand the principles of sampling used in the coating process

Collect Information
Use Multi media Self Study Plant investigation Expert demonstration Interview experts Attend lectures Group Discussions Educational games Case studies List / tabulate Develop recommendations Job assignment Make presentation Complete documents Draft a report Complete a test 1. Learners are given a lecture on the statistical basis of sampling practice and tied into the sampling practice in the coating area. 2. A typical sampling procedure is outlined and a simple checklist compiled 3. Learners view a demonstration of sampling and take a full range of samples under supervision 4. The results of samples are compared to specifications and typical values previously obtained 5. A short report outlines findings
Apply sampling practices Assignment Description Topic assessment criteria

The assessor will observe and confirm that learners: Understand the principles of sampling used in the coating process Are able to do sampling according to plant standards Are able to construct a basic spreadsheet for different sources and sample results Are able to interpret the test results in terms of the impact on the process and customers
W H A T
Learners are given a short lecture on the statistical basis of sampling practice. Sampling is demonstrated and then done under supervision. A spreadsheet showing required and typical feedstock and final product qualities is drawn up.
HOW
Notional Hours 10 10
BE410 Understanding the purpose of auxiliary systems associated with the process
Understand the fundamental operating principles associated with the auxiliary systems
Be able to identify each piece of equipment in each auxiliary system associated with this process
Understand the purpose of each auxiliary system and how it fits into the process
11

Use Multi media
Purpose of auxiliary systems associated with the process Assignment Description Topic assessment criteria
The assessor will observe and confirm that learners: Understand the purpose of each auxiliary system as well as the fundamental operating principles associated with the systems. Are able to identify the components of the systems.
Collect Information
Self Study Plant investigation Media search Interview experts Attend lectures Group Discussions Sketch Summarise Use checklists Develop recommendations Job assignment Make presentation Complete documents Draft a report Complete a test/questionnaire
W H A T
Individual or group training. Do self study to develop key plant operation questions. Answers are obtained by discussions with production experts and plant investigation.
HOW
1. Inspect the equipment and determine the interaction of each auxiliary system with the plant 2. Draw a block diagram showing the main components of each auxiliary system relevant to the plant. 3. In a discussion with a specialist on the auxiliary system, identify: what the purpose of the system is how it supports the process the different components of the system, and the fundamental operating principles of the system 4. Compile all the obtained information in a short report
Notional Hours 8 12
BE410 Understanding Operating Procedures in the process
Understand the sequence and reason for correcting deviations Understand the sequence and reason for shut-down and emergency shut-down procedures Understand the reason for maintaining normal running conditions and the consequences of losses caused by inefficient operation Understand the sequence and reasons for every precheck Understand the sequence and reasons for start-up procedures

Understand the reasons for having pre-check-, start-up-, normal running-, shutdown- and deviation correction procedures Understand the different responsibilities in terms of compiling, authorization, layout / format and safety procedures contained in the Standard Operating Procedures Know any other plant / process rules and regulations applicable to the plant
Know the purpose of Standard Operating Procedures
13

Use Multi media
Understanding Standard Operating Procedures Assignment Description Topic assessment criteria

The assessor will observe and confirm that learners: Know the purpose of these procedures Know other applicable plant rules and regulations Understand the reason for responsibility control and document control procedures Understand the reasons for having pre-checks start-up procedures maintaining normal running condition procedures and the consequences of losses caused by inefficient operation shut-down and emergency shut-down procedures correcting deviation procedures Know procedures and sequences in detail or in terms of key steps as required
Collect Information
Self Study Plant investigation Media search Interview experts Attend lectures Group Discussions Educational games Summarise Use checklists Develop recommendations Job assignment Make presentation Complete documents Draft a report Complete a theoretical test
W H A T
A facilitated group discussion is used to clarify the logic behind controlled procedure systems. Individual procedures are studied in detail or in terms of key steps as indicated. Indices and summaries for procedures are created for easy future reference.
HOW
1. Learners are supplied with the operating procedures for the plant and individual equipment and any other relevant plant rules and regulations 2. In a facilitated group, the document control system is shortly explained. The purpose of the procedures, responsibility control, document control and having procedures for each operating phase (pre-check, etc.) is discussed and summarised 3. Procedures and sequences are studied in detail (esp. emergency procedures) or in terms of key steps as required. Practical understanding and knowledge is essential 4. Learners should compile a file containing an index (with subheadings / keywords as necessary) of each procedure 5. A theoretical test will proof competence
BE410 Applying Standard Operating Procedures to the process
Be able to bring product variations under control Be able to shut the process down Be able to bring process variations under control Be able to maintain normal running conditions Be able to monitor the process Be able to start the process up Be able to do pre-checks on the process Be able to use and interpret instrument readings

15

Use Multi media
Applying Standard Operating Procedures Assignment Description Topic assessment criteria

The assessor will observe and confirm that learners: Are able to: use and interpret instrument readings do pre-checks on the process start the process up monitor the process maintain normal running conditions bring process and product variations under control shut the process down
Collect Information
Self Study Plant investigation Media search Expert demonstration Attend lectures Group Discussions Summarise Case studies Use checklists Develop recommendations Job assignment Make presentation Complete documents Draft a report Complete a practical test
W H A T
Group or individual training sessions where, through demonstration, the learner first observes the implementation of operating procedures and then implements the procedures himself under supervision
HOW
1. By using relevant checklists and operating procedures, learners will first observe and then, under supervision, implement the following procedures: do pre-checks on the process start the process up use and interpret any instrument readings monitor the process maintain normal running conditions bring process and product variations under control shut the process down 2. Complete any relevant pre-check, start-up, etc. reports as normally required 3. A practical test will proof competence
Critical Cross-field Outcomes BE410 Applying first line maintenance
Be able to carry out maintenance and pre-maintenance duties on the process
Know documentation requirements for maintenance functions
17

Use Multi media
Applying first line maintenance Assignment Description Topic assessment criteria

The assessor will observe and confirm that learners: Understand the documentation requirements for maintenance functions Are able to carry out maintenance and pre-maintenance duties on the process.
Collect Information
Self Study Plant investigation Media search Expert demonstration Attend lectures Group Discussions Summarise Case studies Use checklists Develop recommendations Job assignment Make presentation Complete documents Draft a report Complete a test/questionnaire
W H A T
Individual or group training. Study given materials regarding first line maintenance. A discussion / demonstration of first line maintenance duties are facilitated at the plant. Carry out first line maintenance under supervision.
HOW
1. Learners are supplied with documentation required for first line maintenance on the plant and machines 2. A discussion / demonstration of typical first line maintenance procedures and their sequence is facilitated in the plant 3. A checklist is drawn up 4. Under supervision, carry out premaintenance and maintenance duties on equipment as prescribed 5. Complete pre-maintenance and maintenance reports / log sheets
BE410 Applying SHE in the process

Understand the potential environmental impact of the process
Be able to identify all potential hazards and indicate actions to reduce/avoid hazards
Know the relevant sections of the OHS Act
Understand the application of fire prevention, lock-out and emergency procedures
Know the safety standards, procedures and safety equipment relevant to the process
19

Use Multi media
Applying SHE in the process Assignment Description Topic assessment criteria

The assessor will observe and confirm that learners: Know the relevant OHS Act, safety standards, procedures, and equipment in the plant. Understand the application of fire prevention, lock-out and emergency procedures in the plant, as well as the potential environmental impact of the process. Are able to identify all potential hazards in the process and indicate actions to reduce / avoid / minimise the impact of hazards.
Collect Information
Self Study Plant investigation Media search Interview experts Attend lectures Group Discussions Educational games Case studies Use checklists Develop recommendations Job assignment Make presentation Complete documents Draft a report Complete a test/questionnaire
W H A T
Learners obtain information through self study. Individuals evaluate the plant area for safety features, potential hazards and environmental impact.
HOW
1. Learners are supplied with a copy of the safety procedures and the relevant section of the OHS Act 2. Learners individually undertake a plant inspection and identify all potential hazards. They also assess the potential impact of the plant on the environment. 3. Learners should also sketch the area and indicate the position of all safety equipment and safety features (e.g. alarm buttons, emergency exists) on it 4. Recommendations are made to reduce / avoid these hazards, the impact of possible hazards and the plants impact on the environment 5. A short presentation on the findings is made
Notional Hours 5 20

Understand Process and Variables in Coating Paper and Board: Commissioned by PAMSA and German Technical Co-Operation

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National Certificate in Paper & Pulp Manufacturing NQF Level 4