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

MSS405022 Mapping and Delivery Guide
Design a process layout

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency MSS405022 - Design a process layout
Description
Employability Skills
Learning Outcomes and Application This unit of competency covers the skills and knowledge required to design a process layout, typically a cellular flow, for either a jobbing shop or a continuous process manufacturer. This unit provides the skill for a technical expert to apply the principles of competitive systems and practices to process design layout as distinct from volume production layout. While the application of the unit may be for an initial layout, in many cases it is likely to be for the redesign of an existing layout.The unit is written on the assumption that there is an existing process. Where this is not the case, then additional competency in equipment/process design and selection will also be required through units from an appropriate technical qualification or Training Package.This unit requires the application of skills associated with problem solving, initiative, enterprise, planning and organising in order to design a process for the manufacture of enterprise products that incorporates team operations, product flow, infrastructure and the layout of the physical environment and related technology. This unit has a strong emphasis on gathering, analysing and applying information.No licensing, legislative or certification requirements apply to this unit at the time of publication.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.

The unit should be assessed holistically and the judgement of competence shall be based on a holistic assessment of the evidence.

The collection of performance evidence is best done from a report and/or folio of evidence drawn from:

a single project which provides sufficient evidence of the requirements of all the elements and performance criteria

multiple smaller projects which together provide sufficient evidence of the requirements of all the elements and performance criteria.

A third-party report, or similar, may be needed to testify to the work done by the individual, particularly when the project has been done as part of a project team.

Assessment should use a real process layout project for an operational workplace.

Knowledge evidence may be collected concurrently with performance evidence or through an independent process such as workbooks, written assessments or interviews (provided a record is kept).

Assessment processes and techniques must be appropriate to the language, literacy and numeracy requirements of the work being performed and the needs of the candidate.

Conditions for assessment must include access to all tools, equipment, materials and documentation required, including relevant workplace procedures, product and manufacturing specifications associated with this unit.

Foundation skills are integral to competent performance of the unit and should not be assessed separately.

Assessors must satisfy the assessor competency requirements that are in place at the time of the assessment as set by the VET regulator.

The assessor must demonstrate both technical competency and currency.

Technical competence can be demonstrated through:

relevant VET or other qualification/Statement of Attainment AND/OR

relevant workplace experience

Currency can be demonstrated through:

performing the competency being assessed as part of current employment OR

having consulted with an organisation providing relevant environmental monitoring, management or technology services about performing the competency being assessed within the last twelve months.
Prerequisites/co-requisites
Competency Field Competitive systems and practices
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: Identify the products and processes used in the organisation
  • Obtain or develop a process map of the existing process.
  • Identify all/main products/classes of products.
  • Obtain forecast sales and sales pattern of products/classes.
  • Obtain profiles of products/classes.
  • Group the products/classes into compatible families.
       
Element: Engineer the process
  • Make a preliminary selection of required equipment/technology/ process for each process or product family.
  • Estimate required resource times for each family.
  • Calculate total resourcing required for each family.
  • Estimate appropriate lot size.
  • Determine viability of proposed families.
  • Examine draft proposal for possible improvements in process consistent with the competitive systems and practices strategy of the organisation.
       
Element: Design the infrastructure
  • Consult on layout needs with all stakeholders.
  • Identify physical infrastructure required by system.
  • Identify information and control infrastructure required.
  • Identify work organisation required.
  • Identify work health and safety (WHS) and other regulatory requirements to be taken into account.
  • Identify workforce development and training requirements.
  • Check the availability of required infrastructure and compatibility with requirements.
       
Element: Lay out the process
  • Draft proposed process flow map.
  • Draft proposed configuration diagram.
  • Draft proposed space plan/layout.
  • Check availability of services/structural suitability, as appropriate.
  • Validate proposed layout with all relevant stakeholders.
  • Layout the process/work cell.
  • Develop implementation plan in liaison with relevant stakeholders.
  • Review layout after implementation.
       


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.

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Identify the products and processes used in the organisation

1.1

Obtain or develop a process map of the existing process.

1.2

Identify all/main products/classes of products.

1.3

Obtain forecast sales and sales pattern of products/classes.

1.4

Obtain profiles of products/classes.

1.5

Group the products/classes into compatible families.

2

Engineer the process

2.1

Make a preliminary selection of required equipment/technology/ process for each process or product family.

2.2

Estimate required resource times for each family.

2.3

Calculate total resourcing required for each family.

2.4

Estimate appropriate lot size.

2.5

Determine viability of proposed families.

2.6

Examine draft proposal for possible improvements in process consistent with the competitive systems and practices strategy of the organisation.

3

Design the infrastructure

3.1

Consult on layout needs with all stakeholders.

3.2

Identify physical infrastructure required by system.

3.3

Identify information and control infrastructure required.

3.4

Identify work organisation required.

3.5

Identify work health and safety (WHS) and other regulatory requirements to be taken into account.

3.6

Identify workforce development and training requirements.

3.7

Check the availability of required infrastructure and compatibility with requirements.

4

Lay out the process

4.1

Draft proposed process flow map.

4.2

Draft proposed configuration diagram.

4.3

Draft proposed space plan/layout.

4.4

Check availability of services/structural suitability, as appropriate.

4.5

Validate proposed layout with all relevant stakeholders.

4.6

Layout the process/work cell.

4.7

Develop implementation plan in liaison with relevant stakeholders.

4.8

Review layout after implementation.

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 to design a layout for one (1) or more processes and to:

identify products and processes

engineer the process

design the infrastructure

lay out the process.

Must provide evidence that demonstrates sufficient knowledge to interact with relevant personnel and be able to design a process layout, including knowledge of:

customer requirements in terms of order size and order pattern

processing requirements for products

equipment capabilities and reliability

workforce capabilities and reliability

business requirements from layout

work health and safety (WHS) and other regulatory requirements

principles of process layout.

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.

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Identify the products and processes used in the organisation

1.1

Obtain or develop a process map of the existing process.

1.2

Identify all/main products/classes of products.

1.3

Obtain forecast sales and sales pattern of products/classes.

1.4

Obtain profiles of products/classes.

1.5

Group the products/classes into compatible families.

2

Engineer the process

2.1

Make a preliminary selection of required equipment/technology/ process for each process or product family.

2.2

Estimate required resource times for each family.

2.3

Calculate total resourcing required for each family.

2.4

Estimate appropriate lot size.

2.5

Determine viability of proposed families.

2.6

Examine draft proposal for possible improvements in process consistent with the competitive systems and practices strategy of the organisation.

3

Design the infrastructure

3.1

Consult on layout needs with all stakeholders.

3.2

Identify physical infrastructure required by system.

3.3

Identify information and control infrastructure required.

3.4

Identify work organisation required.

3.5

Identify work health and safety (WHS) and other regulatory requirements to be taken into account.

3.6

Identify workforce development and training requirements.

3.7

Check the availability of required infrastructure and compatibility with requirements.

4

Lay out the process

4.1

Draft proposed process flow map.

4.2

Draft proposed configuration diagram.

4.3

Draft proposed space plan/layout.

4.4

Check availability of services/structural suitability, as appropriate.

4.5

Validate proposed layout with all relevant stakeholders.

4.6

Layout the process/work cell.

4.7

Develop implementation plan in liaison with relevant stakeholders.

4.8

Review layout after implementation.

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.

Profiles of products include consideration of all of:

components/materials needed to manufacture

equipment/technology/processes required to manufacture

volume of activity to manufacture forecast amount

required operations equipment/technology/processes.

Required resource times include consideration of all of:

set-up time

equipment time

person time

process time.

Lot size includes one or more of:

external lot size

internal lot size

transfer batch size

kanban size.

Viability includes consideration of all of:

appropriate calculated processing times

adequacy of equipment utilisation

acceptable maintenance implications

ability to meet WHS requirements

ability to meet environmental requirements

compliance with any legislative and regulatory requirements

acceptable to stakeholders.

Stakeholders include one or more of:

customers

employees

equipment suppliers and contractors (especially if new equipment required)

regulatory authorities

local community representatives

utilities (e.g. water and power).

Physical infrastructure includes one or more of:

containers/packaging

material handling equipment (e.g. pipes, tanks, conveyors and hoppers)

utilities supply (e.g. steam, air, gas, electricity and water).

Information and control infrastructure includes one or more of:

quality assurance

statistical process control (SPC)/six sigma

planning systems/software

data collection and control systems/software.

Work organisation includes all of:

number of personnel

skills/capability mix of workforce.

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
Obtain or develop a process map of the existing process. 
Identify all/main products/classes of products. 
Obtain forecast sales and sales pattern of products/classes. 
Obtain profiles of products/classes. 
Group the products/classes into compatible families. 
Make a preliminary selection of required equipment/technology/ process for each process or product family. 
Estimate required resource times for each family. 
Calculate total resourcing required for each family. 
Estimate appropriate lot size. 
Determine viability of proposed families. 
Examine draft proposal for possible improvements in process consistent with the competitive systems and practices strategy of the organisation. 
Consult on layout needs with all stakeholders. 
Identify physical infrastructure required by system. 
Identify information and control infrastructure required. 
Identify work organisation required. 
Identify work health and safety (WHS) and other regulatory requirements to be taken into account. 
Identify workforce development and training requirements. 
Check the availability of required infrastructure and compatibility with requirements. 
Draft proposed process flow map. 
Draft proposed configuration diagram. 
Draft proposed space plan/layout. 
Check availability of services/structural suitability, as appropriate. 
Validate proposed layout with all relevant stakeholders. 
Layout the process/work cell. 
Develop implementation plan in liaison with relevant stakeholders. 
Review layout after implementation. 

Forms

Assessment Cover Sheet

MSS405022 - Design a process layout
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

MSS405022 - Design a process layout

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: