Unit of Competency Mapping – Information for Teachers/Assessors – Information for Learners

ICPSU583C Mapping and Delivery Guide
Troubleshoot and optimise the production process

Version 1.0
Issue Date: April 2024


Qualification -
Unit of Competency ICPSU583C - Troubleshoot and optimise the production process
Description This unit describes the performance outcomes, skills and knowledge required to troubleshoot and optimise the production process. This unit focuses on the systems analysis and design.
Employability Skills This unit contains employability skills.
Learning Outcomes and Application This unit requires the individual to troubleshoot and optimise the production process. The individual will evaluate and recommend changes to the production process and adjust and tune machinery to make efficiency gains.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.
Prerequisites/co-requisites
Competency Field Support
Development and validation strategy and guide for assessors and learners Student Learning Resources Handouts
Activities
Slides
PPT
Assessment 1 Assessment 2 Assessment 3 Assessment 4
Elements of Competency Performance Criteria              
Element: Evaluate production for efficiency purposes
  • Machine operations, staff and production process organisation are evaluated on an ongoing basis to make production efficiency gains
  • Production schedule is analysed according to production output, inventory, procurements, time constraints, supply capacities and requirements
  • Quality standards and safe work practices are examined to ensure compliance
  • Changeover/make ready processes are reviewed for production efficiency gains
  • Recommendations covering the above areas are developed and documented
       
Element: Optimise production efficiency
  • Compliance to specified requirements is checked to ensure efficiency is maintained
  • Non-compliance is identified and investigated to determine causes
  • Production standards or machines are set and/or changed according to enterprise procedures
  • Changeover/ make ready times and processes are monitored to ensure times are maintained or improved
  • Production schedule is monitored and adjusted according to production output, inventory, procurements, time constraints and supply capacities and requirements to ensure efficiency is maintained
       
Element: Troubleshoot production efficiency problems
  • Corrective or preventive action is implemented where appropriate
  • Changes are communicated to relevant personnel in a logical and easily understood manner
  • Changes are monitored and adjusted to confirm improvement to production efficiency
       
Element: Troubleshoot material and machining problems
  • Evaluation of material or product structure is conducted to identify options for production and required tuning and adjustments are completed
  • Idiosyncrasies of machines are reviewed and adjustments or tuning undertaken to compensate or to exploit the idiosyncrasy within the manufacturer's specifications
  • Options are assessed to determine most effective/efficient method of production, ensuring highest quality and yield from materials and ease of production
  • Options and recommendations are documented for future reference according to enterprise procedures
       
Element: Document changes and remedies
  • Changes to the production process are documented according to enterprise procedures
  • Adjustments to machines are recorded according to enterprise procedures
  • Documentation is circulated according to enterprise procedures, if required
       


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:

recommend and implement new, more efficient production processes and troubleshoot problems within the production process that effect efficiency gains

produce a portfolio that demonstrates that each element has been carried out. This should include records of standards and monitoring procedures and evidence that they are being effectively carried out

production efficiencies are confirmed through discussions with senior management and review of workplace documentation

evidence for assessment may be gathered from assessment of the unit of competency alone or through an integrated assessment activity.

Context of and specific resources for assessment

Assessment must ensure:

assessment may take place on the job, off the job or a combination of these. Off the job assessment must be undertaken in a closely simulated workplace environment.

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:

BSBFLM509A Promote continuous improvement.


Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assignment, 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 documenting recommendations to optimise the production process

collecting, analysing and organising information by reviewing the production schedule and evaluating its effectiveness

planning and organising activities by determining the most effective production processes

teamwork when communicating with colleagues over changes to production

mathematical ideas and techniques by determining optimised yield for machinery

problem-solving skills by compensating or optimising machine idiosyncrasies

use of technology by evaluating machine operations and making changes to improve the production process

Required knowledge

setting quality standards

setting the criteria for inspection of print quality set

the quality of artwork/film bearing on the quality of the printed product

quality standards that have been set by the customer

inspection specifications determined by standards

identifying production requirements and capacities

job requirements that determine the production processes

identifying special production requirements and possible problems

criteria that are used to determine the availability of machines, materials and labour

OHS concerns that need to be considered when planning production

causes of failure

common causes of failure in each production area that need to be monitored

procedures that have you implemented to minimise the effect of these

revising schedules

monitoring and amending production schedules if required

consideration that is given to revising production schedules to take into account customer requirements and job complexity

evaluating re-work methods

responsibility for evaluating the re-work of unacceptable items

method of re-work that has been determined

criteria that have been set to monitor the re-work

requirements that have been established for the inspection of re-working material to customer's specifications

determining unacceptable items and evaluating production procedures

determining the cause of unacceptable items

records that are kept of acceptable and rejected items

records that are kept for the reason for the rejection

determining the cause for the rejection and how have you rectified the problem

quality improvements

information that needs to be monitored so as to maintain standards

monitoring quality standards

enterprise improvements affect on quality standards

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.

Production context may include:

production processes and associated machines/equipment include those generally operating in the various sectors of the printing and graphic arts industry.

Production schedules may include:

production schedules may apply to daily or production runs, including repetitive production runs, short runs and quick changes.

Range of processes may include:

applies to the development of complex new processes or the modification of existing complex processes based on significant judgement. Applies to the overall production process.

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
Machine operations, staff and production process organisation are evaluated on an ongoing basis to make production efficiency gains 
Production schedule is analysed according to production output, inventory, procurements, time constraints, supply capacities and requirements 
Quality standards and safe work practices are examined to ensure compliance 
Changeover/make ready processes are reviewed for production efficiency gains 
Recommendations covering the above areas are developed and documented 
Compliance to specified requirements is checked to ensure efficiency is maintained 
Non-compliance is identified and investigated to determine causes 
Production standards or machines are set and/or changed according to enterprise procedures 
Changeover/ make ready times and processes are monitored to ensure times are maintained or improved 
Production schedule is monitored and adjusted according to production output, inventory, procurements, time constraints and supply capacities and requirements to ensure efficiency is maintained 
Corrective or preventive action is implemented where appropriate 
Changes are communicated to relevant personnel in a logical and easily understood manner 
Changes are monitored and adjusted to confirm improvement to production efficiency 
Evaluation of material or product structure is conducted to identify options for production and required tuning and adjustments are completed 
Idiosyncrasies of machines are reviewed and adjustments or tuning undertaken to compensate or to exploit the idiosyncrasy within the manufacturer's specifications 
Options are assessed to determine most effective/efficient method of production, ensuring highest quality and yield from materials and ease of production 
Options and recommendations are documented for future reference according to enterprise procedures 
Changes to the production process are documented according to enterprise procedures 
Adjustments to machines are recorded according to enterprise procedures 
Documentation is circulated according to enterprise procedures, if required 

Forms

Assessment Cover Sheet

ICPSU583C - Troubleshoot and optimise the 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

ICPSU583C - Troubleshoot and optimise the 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: