Assessor Resource

MSACMT451A
Mistake proof a production process

Assessment tool

Version 1.0
Issue Date: April 2024


In a typical scenario a person needs to analyse the process that a team is responsible for and determine methods of mistake proofing it (i.e. ensuring it only produces product within an, acceptable range). After improvement activities have been undertaken these improvements need to be sustained.

This unit requires the application of skills associated information gathering and analysis. Initiative, enterprise and problem solving are also required to identify mistakes and determine strategies for elimating them. This unit also requires communication and team building skills to ensure mistake proofing strategies are implemented, and self management and learning skills to continually reflect on and integrate feedback about the effectiveness of strategies.

This unit covers the knowledge and skills needed to make changes which prevent errors and/or backsliding to a pre-improvement level of practice. In the CM environment, this unit would typically be done by a team leader, technical expert of similar person.

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, the range statement and the assessment guidelines for this training package.

Overview of assessment requirements

The person 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.

What critical aspects of evidence are required to demonstrate competency in this unit?

Evidence of actions taken to mistake proof the process should be available.

In what context should assessment occur?

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

Are there any other units which could or should be assessed with this unit or which relate directly to this unit?

This unit may be used as a stand alone unit or it may be assessed concurrently with any of:

MSACMT250A Monitor process capability

MSACMT450A Undertake process capability improvements

MSACMT650A Determine and improve process capability.

What method of assessment should apply?

Assessors must be satisfied that the person can consistently perform the unit as a whole, as defined by the elements, performance criteria, skills and knowledge. A holistic approach should be taken to the assessment.

Assessors should gather sufficient, fair, valid, reliable, authentic and current evidence from a range of sources. Sources of evidence may include direct observation, reports from supervisors, peers and colleagues, project work, samples, organisation records and questioning. Assessment should not require language, literacy or numeracy skills beyond those required for the unit.

The assessee will have access to all techniques, procedures, information, resources and aids which would normally be available in the workplace.

The method of assessment should be discussed and agreed with the assessee prior to the commencement of the assessment.

What evidence is required for demonstration of consistent performance?

Where evidence is from the application of baka-yoke to continuous improvement, then there should be evidence that it is practiced routinely and from a number of standardisation activities. Where the evidence is from an initial standardisation of a process, or a single, large and complex standardisation/change process the may provide sufficient evidence.

What are the specific resource requirements for this unit?

Access to an organisation using a competitive manufacturing approach.

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:

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

problem solving

analysis

team work

design conceptualisation.

Required knowledge:

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

Sometimes known as baka-yoke/poka-yoke, a manufacturing technique of preventing mistakes by designing the manufacturing process, equipment, tools and components/subassemblies etc 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

Procedures include all work instructions, standard operating procedures, formulas/recipes, batch sheets, temporary instructions and similar instructions provided for the operation of the plant. They may be written, verbal, 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 (e.g. 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 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/assessment reflects change 
Audit change at agreed period/cycle 
Take action on any observed deviation 
Observe changes 
Analyse process again if required to ensure improvements are sustained 

Forms

Assessment Cover Sheet

MSACMT451A - 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:

Signature:

Date:

Assessment Record Sheet

MSACMT451A - 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:

Signature:

Date:

Student signature:

Date: