• MSL934002A - Apply quality system and continuous improvement processes

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

MSL934002A Mapping and Delivery Guide
Apply quality system and continuous improvement processes

Version 1.0
Issue Date: March 2024


Qualification -
Unit of Competency MSL934002A - Apply quality system and continuous improvement processes
Description This unit of competency covers the exercise of good laboratory practice and effective participation in quality improvement teams. Personnel are required to ensure the quality and integrity of their own work, detect non-conformances and work with others to suggest improvements in productivity and quality.
Employability Skills This unit contains employability skills.
Learning Outcomes and Application This unit of competency is applicable to laboratory technicians working in all industry sectors who contribute to quality improvements in areas or processes associated with their own job function and/or specialisation. This unit of competency is relevant to experienced technical officers who may work individually or as part of a team.Industry representatives have provided case studies to illustrate the practical application of this unit of competency and to show its relevance in a workplace setting. These are found at the end of this unit of competency under the section 'This competency in practice'.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.
Prerequisites/co-requisites
Competency Field
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: Satisfy quality system requirements in daily work
  • Access information on quality system requirements for own job function
  • Record and report quality control data in accordance with quality system
  • Follow quality control procedures to ensure products, or data, are of a defined quality as an aid to acceptance or rejection
  • Recognise and report non-conformances or problems
  • Conduct work in accordance with sustainable energy work practices
  • Promote sustainable energy principles and work practices to other workers
       
Element: Analyse opportunities for corrective and/or optimisation action
  • Compare current work practices, procedures and process or equipment performance with requirements and/or historical data or records
  • Recognise variances that indicate abnormal or sub-optimal performance
  • Collect and/or evaluate batch and/or historical records to determine possible causes for sub-optimal performance
  • Use appropriate quality improvement techniques to rank the probabilities of possible causes
       
Element: Recommend corrective and/or optimisation actions
  • Analyse causes to predict likely impacts of changes and decide on the appropriate actions
  • Identify required changes to standards and procedures and training
  • Report recommendations to designated personnel
       
Element: Participate in the implementation of recommended actions
  • Implement approved actions and monitor performance following changes to evaluate results
  • Implement changes to systems and procedures to eliminate possible causes
  • Document outcomes of actions and communicate them to relevant personnel
       
Element: Participate in the development of continuous improvement strategies
  • Review all relevant features of work practice to identify possible contributing factors leading to sub-optimal performance
  • Identify options for removing or controlling the risk of sub-optimal performance
  • Assess the adequacy of current controls, quality methods and systems
  • Identify opportunities to continuously improve performance
  • Develop recommendations for continual improvements of work practices, methods, procedures and equipment effectiveness
  • Consult with appropriate personnel to refine recommendations before implementation of approved improvement strategies
  • Document outcomes of strategies and communicate them to relevant personnel
       


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

Assessors should ensure that candidates can:

use the enterprise's quality systems and business goals as a basis for decision making and action

apply all relevant procedures and regulatory requirements to ensure the quality and integrity of the products/services or data provided

apply and promote sustainable energy principles and work practices

detect non-conforming products or services in the work area

follow enterprise procedures for documenting and reporting information about quality

contribute effectively within a team to recognise and recommend improvements in productivity and quality

apply effective problem solving strategies

implement and monitor improved practices and procedures.

Context of and specific resources for assessment

This unit of competency is to be assessed in the workplace or simulated workplace environment.

This unit of competency may be assessed with:

MSL924001A Process and interpret data

MSL954001A Obtain representative samples in accordance with sampling plan

relevant MSL974000 series units of competency

relevant MSL975000 series units of competency.

Resources may include:

enterprise quality manual and procedures

quality control data/records

customer complaints and rectifications

candidate's supervisors and peers.

Method of assessment

The following assessment methods are suggested:

review of documentation completed by the candidate as part of regular quality control

feedback from supervisors and/or customers regarding quality of products/services and/or data regularly provided by the candidate

observation of the candidate's performance and participation in quality improvement teams over time in the workplace

review of reports from quality improvement teams where the candidate's role is clearly outlined and verified

verified reports of improvements suggested and implemented by the candidate individually.

Those aspects of competency dealing with improvement processes could be assessed by the use of suitable simulations and/or a pilot plant and/or a range of case studies and scenarios.

In all cases, practical assessment should be supported by questions to assess essential knowledge and those aspects of competency which are difficult to assess directly.

Where applicable, reasonable adjustment must be made to work environments and training situations to accommodate ethnicity, age, gender, demographics and disability.

Access must be provided to appropriate learning and/or assessment support when required.

The language, literacy and numeracy demands of assessment should not be greater than those required to undertake the unit of competency in a work like environment.

This competency in practice

Industry representatives have provided the case studies below to illustrate the practical application of this unit of competency and to show its relevance in a workplace setting.

Manufacturing

A quality improvement team at a chemical manufacturing plant was asked to propose a way of minimising the cost of disposing of chromium rich waste. Using appropriate techniques, the team narrowed the alternatives down to the option of burning the waste stream. An experienced technician agreed that this was feasible, but suggested that because the waste was petroleum high in chromium the team should consider the environmental implications. Subsequent research indicated that the permitted chromium levels in the incinerated air waste stream would not exceed 10 ppm, which was less than the air emission standards for the plant. The technician analysed samples of the air waste stream and determined that the chromium levels were below the regulatory standards. He/she then supported the team's suggestion.

Environmental

The manager of an environmental testing laboratory believed that the team of laboratory technicians relied too much on external direction. As a result, the manager requested that whenever technicians asked for assistance they should also be ready to suggest a solution to the problem if at all possible. This strategy was implemented in a non-threatening manner and was accepted by the team. In time, the manager noted that many of the suggestions for solving problems and improving work practices that came from the team were effective and reasonable. Their skill in making realistic recommendations came from their familiarity with many of the issues that needed to be considered. It became the norm that the laboratory technicians were given public credit for suggesting successful strategies that improved safety, productivity and staff morale.

Food processing

A company that produces apple juice uses 30-35% hydrogen peroxide (H2O2) to sterilise packaging. A mist of atomised H2O2 is sprayed into pre-formed cartons and later removed with a jet of hot sterile air. The laboratory manager was concerned that some batches of product were not sterile after standing at room temperature for several days. The cause of the failure in the sterilisation procedure was not apparent and a technical officer was asked to investigate this problem.

The technical officer examined each unit operation of juice manufacture and determined that the application of H2O2 was a critical sterilisation point where failure could occur. The concentration of H2O2 in the atomiser and in opened containers was unpredictable and several problems were found to contribute to this. H2O2 was left in the atomiser for up to several days between packaging runs. Containers of H2O2 were not always used sequentially, some being opened and then not used for a long time. The containers were stored at room temperature after opening and some may have become contaminated with atmospheric particulates that catalyse the breakdown of H2O2.

The recommendations that emerged from the investigation were that:

fresh H2O2 should be used at the beginning of each packaging run

only one stock container of H2O2 should be open at any one time and stored chilled, with residuals discarded after 14 days

care should be taken to exclude foreign material from the opened vessels of H2O2 and the atomiser.

In summary, the intolerance of the company to even low incidences of faulty product and the competency of the technical officer to investigate the processing stream resulted in increased product quality without significant cost.


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

Required skills include:

applying problem solving techniques and strategies

applying statistical analysis and statistical sampling procedures

detecting non-conforming products or services in the work area

documenting and reporting information about quality

contributing effectively within a team to recognise and recommend improvements in productivity and quality

implementing and monitoring improved practices and procedures

Required knowledge

Required knowledge includes:

specifications for laboratory products and services in the candidate's work area

quality requirements associated with the individual's job function and/or work area

scientific and technical knowledge underpinning the processes, procedures, equipment and instrumentation associated with the candidate's work tasks and duties

workplace procedures associated with the candidate's regular technical duties

sustainable energy principles

relevant health, safety and environment requirements

layout of the enterprise, divisions and laboratory

organisational structure of the enterprise

lines of communication

role of laboratory services to the enterprise and customers

Specific industry

Additional knowledge requirements may apply for different industry sectors. For example:

Biomedical sector:

ethical requirements dealing with patient confidentiality

animal welfare legislation and codes of practice

guidelines for pre-transfusion testing

gene technology regulations for large scale, small scale and planned release of genetically manipulated organisms

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.

Codes of practice

Where reference is made to industry codes of practice, and/or Australian/international standards, it is expected the latest version will be used

Standards, codes, procedures and/or enterprise requirements

Standards, codes, procedures and/or enterprise requirements may include:

Australian and international standards, such as:

AS ISO 17025-2005 General requirements for the competence of testing and calibration laboratories

AS/NZS ISO 10005:2006 Quality management systems - Guidelines for quality plans

AS/NZS ISO 10012:2004 Measurement management systems - Requirements for measurement processes and measuring equipment

AS/NZS ISO 9000 Set:2008 Quality management systems set

AS 1199 Sampling procedures and tables for inspection by attributes

BS 5750 Quality systems

Australia New Zealand Food Standards (ANZFS) Code

Australian code of good manufacturing practice for medicinal products (GMP)

customer specific requirements/standards

enterprise and customer product specifications

National Association of Testing Authorities (NATA) Accreditation programs requirements

National Health and Medical Research Council (NHMRC) Guidelines

national measurement regulations and guidelines

principles of good laboratory practice (GLP)

quality manuals and procedures

Therapeutic Goods Regulations 1009

Quality control procedures

Quality control procedures may include:

standards imposed by regulatory and licensing bodies

enterprise quality procedures

working to a customer brief or batch card and associated quality procedures

checklists to monitor job progress against agreed time, costs and quality standards

preparation of sampling plans

the use of hold points to evaluate conformance

the use of inspection and test plans to check compliance

Methods for statistical analysis

Methods for statistical analysis may include:

means

median

mode

ranges

standard deviations

statistical sampling procedures

Problem solving techniques

Problem solving techniques may include:

identifying inputs and outputs

sequencing a process

identifying and rectifying a problem step

root cause analysis

implementing preventative strategies

Quality improvement tools and techniques

Quality improvement tools and techniques may include:

run charts, control charts, histograms and scattergrams to present routine quality control data

plan, do, check, act (PDCA)

Ishikawa fishbone diagrams and cause and effect diagrams

logic tree

similarity/difference analysis

Pareto charts and analysis

force field/strength weakness opportunities threats (SWOT) analysis

Sustainable energy principles and work practices

Sustainable energy principles and work practices may include:

examining work practices that use excessive electricity

switching off equipment when not in use

regularly cleaning filters

insulating rooms and buildings to reduce energy use

recycling and reusing materials wherever practicable

minimising process waste

Communication

Communication may involve:

supervisors, managers and quality managers

administrative, laboratory and production personnel

internal/external contractors, customers and suppliers

Reporting

Reporting may include:

verbal responses

data entry into laboratory or enterprise database

brief written reports using enterprise proformas

Quality improvement opportunities

Quality improvement opportunities could include improved:

production processes

hygiene and sanitation procedures

reductions in waste and re-work

laboratory layout and work flow

safety procedures

communication with customers

methods for sampling, testing and recording data

Occupational health and safety (OHS) and environmental management requirements

OHS and environmental management requirements:

all operations must comply with enterprise OHS and environmental management requirements, which may be imposed through state/territory or federal legislation - these requirements must not be compromised at any time

all operations assume the potentially hazardous nature of samples and require standard precautions to be applied

where relevant, users should access and apply current industry understanding of infection control issued by the National Health and Medical Research Council (NHMRC) and State and Territory Departments of Health

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
Access information on quality system requirements for own job function 
Record and report quality control data in accordance with quality system 
Follow quality control procedures to ensure products, or data, are of a defined quality as an aid to acceptance or rejection 
Recognise and report non-conformances or problems 
Conduct work in accordance with sustainable energy work practices 
Promote sustainable energy principles and work practices to other workers 
Compare current work practices, procedures and process or equipment performance with requirements and/or historical data or records 
Recognise variances that indicate abnormal or sub-optimal performance 
Collect and/or evaluate batch and/or historical records to determine possible causes for sub-optimal performance 
Use appropriate quality improvement techniques to rank the probabilities of possible causes 
Analyse causes to predict likely impacts of changes and decide on the appropriate actions 
Identify required changes to standards and procedures and training 
Report recommendations to designated personnel 
Implement approved actions and monitor performance following changes to evaluate results 
Implement changes to systems and procedures to eliminate possible causes 
Document outcomes of actions and communicate them to relevant personnel 
Review all relevant features of work practice to identify possible contributing factors leading to sub-optimal performance 
Identify options for removing or controlling the risk of sub-optimal performance 
Assess the adequacy of current controls, quality methods and systems 
Identify opportunities to continuously improve performance 
Develop recommendations for continual improvements of work practices, methods, procedures and equipment effectiveness 
Consult with appropriate personnel to refine recommendations before implementation of approved improvement strategies 
Document outcomes of strategies and communicate them to relevant personnel 

Forms

Assessment Cover Sheet

MSL934002A - Apply quality system and continuous improvement processes
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

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Assessor name:

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Assessment Record Sheet

MSL934002A - Apply quality system and continuous improvement processes

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:

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