• MSACMT641A - Implement a continuous improvement system

Assessor Resource

MSACMT641A
Implement a continuous improvement system

Assessment tool

Version 1.0
Issue Date: March 2024


This unit covers the introduction of continuous improvement as a manufacturing strategy across an enterprise. Continuous improvement strategies are sometimes also known as kaizen in different manufacturing systems. The continuous improvement (kaizen) strategy is usually undertaken through special improvement 'events' that cover the identification of improvement opportunities and the undertaking of the improvement in a single exercise.

This unit primarily requires the application of skills associated with teamwork, problem solving, initiative and enterprise, and planning and organising skills in order to identify, implement and institutionalise kaizen activity. Communication skills are required to gather information and consult with team members and other stakeholders. This unit also requires aspects of self management and learning to ensure feedback and new learning is integrated into continual improvement.

Depending on starting point for the continuous improvement program in the enterprise other relevant units may need to be selected including:

MSACMT640A Manage 5S system in a manufacturing environment

MSACMC611A Manage people relationships

MSAPMSUP390A Use structured problem solving tools

MSACMT280A Undertake root cause analysis

This unit covers the knowledge and skills required to introduce and institutionalise continuous improvement (kaizen) to the organisation.

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 describes the underpinning knowledge and skills that must be demonstrated to prove competence. it is essential for assessment and must be read in conjunction with the performance criteria, the range statement and the assessment guidelines of the relevant training package

Overview of assessment requirements

Assessment should cover the ability to implement a continuous improvement (kaizen) strategy across a manufacturing enterprise as distinct from simply participating in kaizen events

What are the specific resource requirements for this unit?

Access to an organisation using or introducing kaizen.

In what context should assessment occur?

Assessment will need to occur in an organisation implementing a continuous improvement strategy (kaizen). Assessment should cover a sufficient period to observe the success of the continuous improvement strategy. Assessment may be by project or portfolio assessment.

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

Depending on starting point for the continuous improvement program in the enterprise other relevant units that could be assessed in conjunction with this unit include:

MSACMT640A Manage 5S system in a manufacturing environment

MSACMC611A Manage people relationships

MSAPMSUP390A Use structured problem solving tools

MSACMT280A Undertake root cause analysis

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?

Generally one significant kaizen event or a number of routine events, plus ongoing kaizen would be needed to generate sufficient evidence.


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

analysis

problem solving

teamwork

planning and organising

communication

documenting

Required knowledge

continuous improvement (kaizen) philosophy and process

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.

Scope

Scope of event may include:

description of the business

the target work process

what the key stakeholders seek from the kaizen event

a mission for the event

a set of goals

a statement of the do's and don'ts for the kaizen team

Whether to proceed

The decision to proceed (or otherwise) will be based on:

the focus of the kaizen event makes sense

the business case for doing the event is reasonable

the degree of support from management and employees

the setting and resources available to the event are adequate

the timing of the event will not interfere with business

specifics about the work process such as its overall operating cost and factor costs (eg labour, machine, raw materials) are available

Description of the target work process

The description of the work target process may include:

an overview that captures the purpose of the work process

essentials about the process (eg inputs, outputs, departments with which it coordinates)

a work process map that shows the sequence of operations that execute it

Procedures

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, 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 (eg Good Manufacturing Practice (GMP), Responsible Care) and government regulations.

Procedures also include required procedures under legislation or regulation. awards and enterprise agreements.

Authority

The authority will vary according to the problem encountered and may include:

internal or external technical specialist

designated manager

equipment supplier

regulatory authority

safety specialist

reference manuals

Waste

Waste (also known as muda in the Toyota Production System and its derivatives) is any activity which does not contribute to customer benefit/features in the product. Within manufacturing, categories of waste include:

excess production and early production

delays

movement and transport

poor process design

inventory

inefficient performance of a process

making defective items

Waste for this unit may include activities which do not yield any benefit to the organisation or any benefit to the organisations customers.

Solve performance issues

Solving performance issues includes:

generating improvement ideas (brainstorming/ask expert)

selecting most appropriate improvement ideas to proceed with

conducting experiments where required to test idea

making final selection of improvement ideas

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
Select process/area for kaizen event 
Select kaizen team for event 
Develop scope and direction for event 
Validate scope with stakeholders 
Determine whether to proceed with kaizen event 
Negotiate problem issues with undertaking identified improvement, or choose a different process or area for improvement activity 
Make infra structure and support arrangements for improvement event. 
Arrange for initial training in continuous improvement (kaizen) and related skills for employees involved in improvement event 
Facilitate the development of operating protocols for the team 
Build a description of the target work process 
Clarify points of disagreement/uncertainty through consultation and where required by reference to procedures or other relevant authority 
Analyse the process to quantify waste volumes and sources 
Consult individual operators in process or area asking for improvement ideas 
Solve performance issues 
Negotiate any differences between problems and proposed solutions and initial objectives of improvement event 
Develop plan(s) and obtain agreements to implement improvements 
Implement improvements 
Measure changes and calculate benefits 
Complete all relevant documentation 
Communicate achievements to stakeholders 
Arrange for additional continuous improvement (kaizen) events using different team members 
Arrange for ongoing continuous improvement (kaizen) events with previous kaizen team members 
Build a culture for ongoing continuous improvement (kaizen) 

Forms

Assessment Cover Sheet

MSACMT641A - Implement a continuous improvement system
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

MSACMT641A - Implement a continuous improvement system

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: