Assessor Resource

Mistake proof a production process

Assessment tool

Version 1.0
Issue Date: November 2018

This unit may be undertaken by any person although typically it would be held by a team leader.

In a typical scenario a team leader, or a work team, needs to analyse the process they are responsible for and determine methods of ensuring it only produces product that meets the job's quality standards. This unit is from the Competitive Manufacturing Initiative group of competency standards.

This unit describes the performance outcomes, skills and knowledge required to focus on preventing errors/backsliding to a previous behaviour.

You may want to include more information here about the target group and the purpose of the assessments (eg formative, summative, recognition)

Employability Skills

This unit contains employability skills.

Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

The Evidence Guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Evidence of the ability to:

the competent team leader will be able to analyse their process and implement systems to ensure the process is mistake proof and the operators work in a predictable way with little or no chance of mistake. Evidence of actions taken to mistake proof the process should be available

one complex project on standardisation of a process or several simpler projects will be needed to gain sufficient evidence.

Context of and specific resources for assessment

Assessment must ensure:

assessment needs to occur in a workplace implementing competitive manufacturing or by using a suitable project

access to an organisation using a competitive manufacturing approach.

Method of assessment

A range of assessment methods should be used to assess practical skills and knowledge. The following examples are appropriate for this unit:

direct questioning combined with review of portfolios of evidence and third party workplace reports of on-the-job performance by the candidate.

Guidance information for assessment

Holistic assessment with other units relevant to the industry sector, workplace and job role is recommended, for example:

ICPSU684C Determine and improve process capability.

Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assingnment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)

Assessment Tasks

Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.

Required skills

OHS in relation to operating machinery such as safely switching off machinery before cleaning is started

communication of ideas and information by liaising with relevant people to have systems/procedures changed to implement solution

collecting, analysing and organising information by liaising with team members and other people to develop mistake proof method of performing operation

planning and organising activities by implementing a permanent fix

teamwork when liaising with team members and other people to develop mistake proof method of performing operation

mathematical ideas and techniques by implementing a permanent fix

problem-solving skills by modifying solution to improve outcomes

use of technology by seeking improvements

Required knowledge

communication ability to discuss items with both operators and technical support personnel

problem solving



design conceptualisation

understanding of their process

factors in the process which may cause variability

methods of controlling the variability in the process

mistake proofing methods relevant to the process/product

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Mistake proofing may include:

sometimes known as baka-yoke/poka-yoke - a manufacturing technique of preventing mistakes by designing the manufacturing process, equipment, tools and components/subassemblies so that an operation literally cannot be performed incorrectly; an attempt to perform incorrectly, as well as being prevented, is usually met with a warning signal of some sort.

Procedures may include:

procedures includes all work instructions, standard operating procedures, formulas/recipes, batch sheets, temporary instructions and similar instructions provided for the smooth running of the plant. They may be written, oral, computer-based or in some other form

for the purposes of this Training Package, procedures also includes good operating practice as may be defined by industry codes of practice (eg Good Manufacturing Practice (GMP), Responsible Care) and government regulations.

Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.

Observation Checklist

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Identify sources of variability/non-conformance in the process 
Identify critical control points in the process 
Analyse causes of variability/non-conformance 
Liaise with team members and other people to develop mistake proof method of performing operation 
Test and validate mistake proofing 
Liaise with relevant people to have systems/procedures changed to implement solution 
Liaise with relevant people to implement the solution 
Liaise with relevant people to ensure the workforce has an appropriate skills set 
Follow through to ensure implementation occurs 
Critically observe the implementation 
Compare the results of the implementation against the expected outcomes 
Modify solution to improve outcomes 
Ensure procedures reflect change 
Ensure training and assessment reflect change 
Audit change at agreed period/cycle 
Take action on any observed deviation 
Observe changes against enterprise expectations for production 
Analyse process against enterprise expectations for production 


Assessment Cover Sheet

ICPSU486C - Mistake proof a production process
Assessment task 1: [title]

Student name:

Student ID:

I declare that the assessment tasks submitted for this unit are my own work.

Student signature:

Result: Competent Not yet competent

Feedback to student









Assessor name:



Assessment Record Sheet

ICPSU486C - Mistake proof a production process

Student name:

Student ID:

Assessment task 1: [title] Result: Competent Not yet competent

(add lines for each task)

Feedback to student:









Overall assessment result: Competent Not yet competent

Assessor name:



Student signature: