Filter Rod Maker Production Preparation Training

Objectives:
• Understand the role and importance of the Filter Rod Maker in production. • Identify key workplace health and safety (OHS Act) regulations. • Recognise the basic components of filter rod manufacturing equipment. • Demonstrate awareness of personal protective equipment (PPE) requirements.

Topics:
• Overview of the tobacco industry and filter rod production line. • Introduction to the SAQA Unit Standard 114223 and course expectations. • Fundamental principles of workplace safety and hazard identification. • Types and functions of PPE specific to the production environment. • Basic machine components and their general purposes. • Site-specific safety protocols and emergency procedures.

Objectives:
• Identify and describe the raw materials used in filter rod production. • Interpret basic quality specifications and standards for incoming materials. • Perform simple visual and manual checks on material batches. • Understand the impact of material quality on final product integrity.

Topics:
• Types of filter tow (acetate, polypropylene) and their properties. • Introduction to plasticisers and other additives. • Understanding material specification sheets and certificates of analysis. • Procedures for receiving, storing, and handling raw materials. • Common material defects and their identification. • Documentation and reporting of non-conforming materials.

Objectives:
• Identify the main sections of the filter rod making machine (e.g., tow bale opener, blooming unit, rod former). • Understand the sequence of operations from tow to formed rod. • Perform basic pre-start checks and safety verifications. • Assist in simple machine setup procedures under supervision.

Topics:
• Detailed walk-through of the filter rod machine layout and workflow. • Function of the crimping unit, rod forming chamber, and wrapping mechanism. • Introduction to machine settings and parameters (e.g., tow weight, rod circumference). • Pre-operational inspection checklist and lubrication points. • Basic principles of machine threading and start-up sequence. • Introduction to machine control panels and indicators.

Objectives:
• Execute a standardised production start-up procedure. • Monitor machine performance using gauges and visual checks. • Make minor adjustments to machine settings to maintain basic quality parameters. • Identify and respond to common operational alarms or stoppages.

Topics:
• Step-by-step production start-up protocol. • Monitoring key process variables: rod firmness, circumference, and appearance. • Adjusting tow feed tension and blooming air pressure. • Responding to breaks in the tow band or wrapping paper. • Recording initial production data on run sheets. • Principles of maintaining consistent production flow.

Objectives:
• Conduct in-process quality checks on filter rods as per standard procedures. • Withdraw and prepare samples for laboratory testing. • Classify common production defects and identify their probable causes. • Initiate corrective actions for minor quality deviations.

Topics:
• Standard operating procedures for rod sampling and testing frequency. • Use of basic measuring equipment (callipers, scales). • Recognising defects: soft/hard rods, wrinkles, loose wraps, diameter variations. • Root cause analysis for common defects linked to machine settings or materials. • Completing quality control documentation and non-conformance reports. • Communication protocols with quality assurance personnel.

Objectives:
• Assist in executing a product changeover (e.g., rod length, circumference). • Apply systematic troubleshooting to resolve frequent minor machine faults. • Perform basic preventative maintenance tasks as per schedule. • Understand the importance of machine cleanliness and housekeeping.

Topics:
• Changeover procedures for different rod specifications. • Troubleshooting guides for common issues: wrapping paper breaks, poor rod formation. • Lock-out tag-out (LOTO) procedures for minor interventions. • Scheduled maintenance tasks: cleaning filters, checking belts and guides. • Safe use of hand tools for adjustments. • 5S principles and daily cleaning routines for the work area.

Objectives:
• Integrate all learned skills in a simulated or supervised production run. • Demonstrate competency in a full production cycle from setup to shutdown. • Review key knowledge and procedures for final assessment. • Develop a personal action plan for continuous improvement in the role.

Topics:
• Supervised practical exercise: complete setup, production run, quality checks, and safe shutdown. • Scenario-based problem-solving for combined faults. • Review of critical safety procedures, quality standards, and machine operations. • Guidance on the format and requirements of the final competency assessment. • Discussion on the role's contribution to overall plant efficiency and quality. • Compilation of a portfolio of evidence and reflective learning journal entries.