1 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 3 Produce and store wood chips

2 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 3 Produce and store wood chips ModulesTopics P&P3CR Basics of wood chips P&P3CR Maintenance P&P3CR SHE P&P3CR Standard Operating Procedures TC304Understanding the production and storage of wood chips TC304The feedstock and final products of the wood chip process TC304Process variations in the production of wood chips Total Notional Hours TC304Understanding Operating Procedures on the production of wood chips TC304Implementing Operating Procedures on the production of wood chips TC304First line maintenance TC304Applying SHE in the process Notional Hours

3 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 3 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 US: RM003Produce and store wood chips TC304 Understanding the production and storage of wood chips Be able to trace the material flow through the process Be able to identify each piece of machinery in this process Understand the fundamental operating principles of the process Understand the purpose of this process and how it fits into the overall process

4 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 3 Topic Specification: TC304 Understanding the production and storage of wood chips Collect Information Use Multi media Self Study Plant investigation Media search Interview experts Attend lectures Analyse, plan and make decisions Group Discussions Sketch Case studies Use checklists Develop recommendations Execute, test and evaluate Job assignment Make presentation Complete documents Draft a report Complete a questionnaire Learning ActivitiesTopic 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 machinery in this process Are able to trace the material flow through the process Understand the fundamental operating principles of the process Assignment Description WHATWHAT HOW 1.Learners are provided with relevant plant and machinery information / manuals 2.Inspect the plant and determine the flow of material through the plant 3.Draw a block diagram to show where the production and storage of wood chips fits into the papermaking 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 machinery used in the process, the fundamental operating principles of each machine and the total plant 6.Complete questionnaire to indicate findings Notional Hours 24 Individual or group training. Do self study to develop key plant operation questions. Answers are obtained by discussions with production experts and plant investigation.

5 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 3 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 US: RM003 Produce and store wood chips Know the typical specifications for the logs and wood chips Understand the properties of the logs and wood chips TC304 Understanding the feedstock and final products of the process Be able to carry out quality checks on the logs and wood chips Know the suppliers of logs and the customers (Internal and external) for the wood chips

6 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 3 Topic Specification: TC304 The feedstock and final products of the process Collect Information Use Multi media Self Study Media search Interview experts Attend lectures Analyse, plan and make decisions Group Discussions Educational games Case studies Use checklists Develop recommendations Execute, test and evaluate Job assignment Make presentation Draft a report Learning ActivitiesTopic assessment criteria The assessor will observe and confirm that learners: Know the suppliers of logs and the customers (Internal and external) for the product produced. Know the typical specifications for the logs and wood chips Understand the properties of the logs and wood chips Are able to carry out quality checks on the logs and wood chips Assignment Description WHATWHAT HOW Notional Hours 16 Individual or group training. Obtain basic product and supplier information by discussions with production experts. Apply knowledge in a practical quality check. Plant investigation 1.Learners are supplied with information on log quality 2.Have a facilitated group discussion in the storage area to determine: by whom logs are supplied and routes into the plant the typical grades and properties of the logs the typical properties and specifications used for the wood chips the internal and external customers for wood chips 3.Draw up a quality checklist for wood chips 4.Carry out quality checks on the wood chips using the checklist and report results. Complete documents Complete a questionnaire

7 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 3 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 US: RM003Produce and store wood chips Understand the effect of variations and deviations on the process and wood chips TC304 Understanding process variations in the production of wood chips Understand what process variations could occur in the process Be able to complete all log sheets Understand how a deviation in the properties of the logs will impact on the process

8 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 3 Topic Specification: TC304 Process variations in the production of wood chips Collect Information Use Multi media Self Study Media search Interview experts Attend lectures Analyse, plan and make decisions Group Discussions Educational games Case studies Use checklists Develop recommendations Execute, test and evaluate Job assignment Make presentation Draft a report Learning ActivitiesTopic assessment criteria The assessor will observe and confirm that learners: Are able to complete log sheets Understand what feed stock variations and process deviations can occur Understand what the effect of variations and deviations on the process and wood chips is Understand the broad rectification actions required Assignment Description WHATWHAT HOW 1.Learners are supplied with log sheets and assisted to complete them with the help of a production specialist. 2.Individually list the feed stock variations that could occur and the effect each type of variation could have on the final product and / or in downstream processes or products 3.In a facilitated discussion at the wood chip site, identify and list process deviations that could occur and the effect each type of deviation could have on the final product and / or in downstream processes or products 4.Tabulate all variations and deviations, their effects and broad rectification actions required and compile the information into a report Notional Hours 8 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. Plant investigation Complete documents Complete a questionnaire

9 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 3 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 US: RM003Produce and store wood chips TC304 Understanding Operating Procedures in the production of wood chips 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 Understand the reasons for different pre-checks Understand the reasons for having pre-check-, start- up-, normal running-, shutdown- and deviation correction procedures Understand the 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 reason for correcting deviations Understand the reasons for start-up procedures

10 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 3 Topic Specification: TC304 Understanding “Standard Operating Procedures” Collect Information Use Multi media Self Study Media search Interview experts Attend lectures Analyse, plan and make decisions Group Discussions Summarise Use checklists Develop recommendations Execute, test and evaluate Job assignment Make presentation Complete documents Draft a report Practical test Learning ActivitiesTopic 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 Assignment Description WHATWHAT HOW 1.Learners are supplied with the operating procedures for the plant and individual machines 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 practical test will proof competence Notional Hours 32 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. Plant investigation Educational games

11 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 3 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 US: RM003Produce and store wood chips TC304 Implementing Standard Operating Procedures in the production of wood chips Be able to do pre-checks on the process Be able to shut the process down Be able to start the process up Be able to maintain normal running conditions Be able to monitor the process Be able to bring process variations under control Be able to bring product variations under control

12 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 3 Topic Specification: TC304 Implementing “Standard Operating Procedures” Collect Information Use Multi media Self Study Media search Attend lectures Analyse, plan and make decisions Group Discussions Case studies Use checklists Develop recommendations Execute, test and evaluate Job assignment Make presentation Complete documents Draft a report Complete a test/questionnaire Learning ActivitiesTopic assessment criteria The assessor will observe and confirm that learners: Are able to: 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 Assignment Description WHATWHAT 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 monitor the process maintain normal running conditions bring process variations under control bring product variations under control hut the process down 2.Complete any relevant pre-check, start-up, etc. reports as normally required. Notional Hours 32 Group or individual training sessions where, through demonstration, the learner first observes the implementation of operating procedures and then implement the procedures himself under supervision Plant investigation Expert demonstration Summarise

13 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 3 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 US: RM003Produce and store wood chips Be able to carry out maintenance and pre- maintenance duties in this plant TC304 Perform first line maintenance Know documentation requirements for maintenance functions Be able to apply safety precautions and carry out blade changes on the chipper Know safety precautions when blade changes are done

14 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 3 Topic Specification: TC304Perform first line maintenance Collect Information Use Multi media Self Study Media search Attend lectures Analyse, plan and make decisions Group Discussions Case studies Use checklists Develop recommendations Execute, test and evaluate Job assignment Make presentation Complete documents Draft a report Complete a test/questionnaire Learning ActivitiesTopic assessment criteria The assessor will observe and confirm that learners: Understand the documentation requirements for maintenance functions in the wood chip area. Are able to carry out maintenance and pre-maintenance duties on the equipment. Know safety precautions when blade changes are done Are able to apply safety precautions and carry out blade changes on the chipper Assignment Description WHATWHAT HOW Individual or group training. Study given materials regarding first line maintenance. A discussion / demonstration of first line maintenance duties are facilitated at the machine. Carry out first line maintenance under supervision. 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 wood chip plant 3.A checklist is drawn up 4.Under supervision, carry out pre- maintenance and maintenance duties on equipment as prescribed 5.Complete pre-maintenance and maintenance reports / log sheets 6.Under supervision, carry out blade changes on the chipper Notional Hours 16 Plant investigation Expert demonstration Summarise

15 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 3 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 US: RM003Produce and store wood chips Know the safety standards, procedures and safety equipment relevant to the process Be able to identify all potential hazards and indicate actions to reduce/avoid hazards Know the relevant sections of the OHS Act TC304 Applying SHE in the process Understand the application of fire prevention, lock-out and emergency procedures Understand the potential environmental impact in producing wood chips

16 Commissioned by PAMSA and German Technical Co-Operation National Certificate in Paper & Pulp Manufacturing NQF Level 3 Topic Specification: TC304 Applying SHE in the process Collect Information Use Multi media Self Study Media search Interview experts Attend lectures Analyse, plan and make decisions Group Discussions Educational games Sketch Use checklists Develop recommendations Execute, test and evaluate Job assignment Make presentation Complete documents Draft a report Complete a test/questionnaire Learning ActivitiesTopic assessment criteria The assessor will observe and confirm that learners: Know the relevant OHS Act, safety standards, procedures, and equipment in the wood chip 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. Assignment Description WHATWHAT 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 the hazards, the impact of possible hazards and the plant’s impact on the environment. 5.A short presentation on the findings is made. Notional Hours 12 Learners obtain information through self study. Individuals evaluate the plant area for safety features, potential hazards and environmental impact. Plant investigation