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Simulated workplace
Scenario · Quality and Laboratory

Investigate the Apex Level flow failure and check pack weights

You are a laboratory technician in Quality and Laboratory.

Intermediate3 to 4 hours7 tasks
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Home/Scenarios/Investigate the Apex Level flow failure and check pack weights
The situation

What has happened

Batch B26-4418 of Apex Level, 1,200 bags, failed the flow table test at 128 mm against a specification of 140 to 160 mm and is on hold in the quarantine bay under NCR-26-071. The batch record shows the blend ran on blender 2 on the night shift with a 15 minute stop for a tripped motor. The cellulose ether additive came from a new supplier lot received the day before. Sanjay Pillai wants a retest of the retained sample, a root cause analysis with the night shift operators and a recommended disposition. He also wants the 20 bag pack weight check completed on the held pallets, because a hardware customer has queried bag weights and the trade measurement rules for pre-packaged goods apply.

Your brief. Retest the retained sample, analyse the batch record and raw material lots, run a structured root cause analysis, complete and record the pack weight check against the labelled weight requirements and recommend a disposition for the batch with corrective actions under the nonconformance procedure.
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Tasks

Deliverables

  • Retest results in the quality test register
  • Root cause analysis record
  • Pack weight check record with the trade measurement comparison
  • Disposition recommendation and corrective action list for Sanjay Pillai

Documents to use

Systems to use

Quality Test and Nonconformance Register

Holds test results for raw materials, batches and precast elements and the nonconformance reports raised against them.

Batch and Production Log

Records every blending batch and precast pour with recipe, quantities, times, operator and release status.

For trainers and assessors

Units of competency

Current on training.gov.au for the Manufacturing Training Package as at 10 September 2026.

MSMSUP292Sample and test materials and product
MSMSUP390Use structured problem-solving tools
MSMTMINS404Inspect a range of pre-packaged products
MSMSUP309Maintain and organise workplace records
MSMSUP303Identify equipment faults

Qualifications

MSM30116Certificate III in Process Manufacturing
MSM40116Certificate IV in Process Manufacturing
Assessor notes

What to look for

Evidence guide

Look for the test method followed and results recorded accurately, a root cause analysis that is supported by evidence from the batch record and the lot documentation rather than assumption, a pack weight check applied against the correct requirements, and a disposition that follows the procedure options. Corrective actions must address the root cause and have owners and dates.

The student's evidence summary lists every record they created or changed in the systems named above, their notes and the tasks they ticked. Verify it against the deliverables and your own assessment tool.