Prepare, blend and pack batch B26-4430

You are a process operator on the afternoon shift in the Blending and Packing Plant.

Simulated workplaceEntry missionCAQA Apex Manufacturing

What is going on

Afternoon shift starts at 2:00 pm and the schedule shows batch B26-4430 of Apex Flex tile adhesive, 1,800 bags, following a private label product on blender 1. The changeover checklist for the previous product has not yet been signed. The packer dust extraction filter bags were replaced this morning and the gauge needs to be checked. Kieran Bosworth is supervising but is also covering the bulk bag station, so you will run the batch yourself. Mei-Lin Chau is in the laboratory until 6:00 pm. The recipe register shows recipe version 6 for Apex Flex, and the sand lot on the hopper is SL-2263.

Darren Okafor, Production Manager, Blending
Subject: Run batch B26-4430 on afternoon shift

We need batch B26-4430 of Apex Flex tile adhesive prepared and packed this afternoon. Kieran will supervise but I want you to run the batch from start to finish, including the changeover from the private label product, the raw material weighing, the blend, the sample to the laboratory and the pack weight checks. Follow the batch preparation, blending and packing procedure and record everything in the batch and production log. Do not start packing until Mei-Lin records a pass unless the product is on the pre-approved list. Report any deviation to Kieran before continuing.

Your brief

Complete the changeover, prepare and blend the batch to the current recipe, take the sample, obtain release, pack 1,800 bags with pack weight checks within tolerance, and complete the batch record and batch log so that the batch is fully traceable and any deviation is recorded and reported.

Work through it

You do not need to do it all. Doing a few of these will show you what the work is like. Your ticks and notes stay on this device.

Read the batch preparation, blending and packing procedure and confirm the batch order, product, recipe version and batch size against the production schedule.
Complete and sign the changeover checklist for the previous product, then check the dust extraction gauge on the packer and the daily scale check, and record both.
Weigh and load each raw material in the recipe order, recording every supplier lot number on the batch record at the time it is loaded.
Run the blend for the full recipe time, record the start and stop times, and take the batch sample from the discharge using the sampling method in the procedure.
Deliver the sample to Mei-Lin Chau with the label completed and create the batch in the batch and production log with status Awaiting test.
Once release is recorded in the quality test register, set the packer to the target weight and complete pack weight checks at the start and every 30 minutes, recording results.
Complete every field on the batch record, update the batch log with quantity packed and pallets, and hand the record to Kieran Bosworth for review and signature.
Report any deviation you encountered, such as a blender stop or a low pack weight, on the batch record and to the supervisor before continuing.

My notes: what did I enjoy, and what surprised me?

What someone in this role would produce

Signed changeover checklist
Completed batch record with lot numbers, times and pack weight checks
Batch and production log entry with final status
Short deviation note or a statement that no deviation occurred

Printing this is a record of what you explored. It is not a certificate or a qualification.