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Follow the links below to find material targeted to the unit's elements, performance criteria, required skills and knowledge

Elements and Performance Criteria

1. Analyse production systems
   • Acquire an 'as is' value map of the process for all major products.
   • Separate repeated products from specials.
   • Consult with production, maintenance, supervisory and management workforce on current production system and processes.
   • Establish rate of flow required to meet customer demand.
   • Identify process steps causing problems.
   • Analyse inventories within process and determine causes of high inventories.
   • Determine costs of problems and inventories.
   • Develop improved flow sequence and future value map.
2. Establish sequence
   • Identify equipment and processes which can be sequenced by co-location.
   • Identify equipment which is not suitable for co-location.
   • Identify pacemaker process.
   • Establish/review location of equipment for desired sequencing.
3. Initiate or develop flow system
   • Determine rate and variability of demand for product.
   • Compare capability of flow sequence to demand rate and variability.
   • Set flow rate to level demand at pacemaker and handle variability.
   • Identify trigger for pacemaker process.
   • Establish kanban system for other process parts.
4. Balance the work
   • Determine target time per product.
   • Standardise work processes and operations and establish procedures to monitor variation.
   • Adjust product/batch production to balance work.
   • Arrange for any required competency development of workforce.
   • Arrange for implementation of system.
   • Monitor operation of system and take action according to procedures.

Range Statement

This field allows for different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.
Competitive systems and practices include one or more of:	lean operations agile operations preventative and predictive maintenance approaches statistical process control systems, including six sigma and three sigma Just in Time (JIT), kanban and other pull-related operations control systems supply, value, and demand chain monitoring and analysis 5S continuous improvement (kaizen) breakthrough improvement (kaizen blitz) cause/effect diagrams overall equipment effectiveness (OEE) takt time process mapping problem solving run charts standard procedures current reality tree.
Inventories within process include one or more of:	cycle stock which reflects the replenishment quantity and frequency buffer stock to meet demand variability and forecast errors safety stock required to guard against quality and delivery failures upstream.
Balance the work means balancing one or more of:	time of production effort required by workforce and equipment work organisation job design quality considerations waste and other cost considerations between stations/ equipment/processes to achieve levelled pull within allowable time per product.

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Performance Evidence

Evidence required to demonstrate competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria and include the ability, for one or more work area/product families, to:

acquire a value stream map for current products and processes

analyse process

perform required calculations to determine flow rate and variability

correctly identify pacemaker process

balance the work

monitor implementation of a levelled pull system and suggest improvements.

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Knowledge Evidence

Must provide evidence that demonstrates sufficient knowledge to interact with relevant personnel and be able to develop or improve a pull system, including knowledge of:

technical and regulatory limits that must be adhered to in operations

processing requirements of products or services offered by the organisation

capabilities of equipment

capabilities and skills of the workforce

production planning techniques

methods of calculating rates of demand and flow of work (e.g. takt and pitch)

techniques for achieving a smooth and consistent flow of work

relationship of level of inventory to efficiency and muda (waste).

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