1

Identify proposed benefits/outcomes of new product/process

1.1

Confirm deliverables expected by customer

1.2

Confirm benefits expected by organisation

1.3

Identify any existing products with similar expectations

1.4

Note any relevant issues with existing similar products

2

Sketch a process map/flow chart of proposed process

2.1

Determine processes to be used

2.2

Identify order of process steps

2.3

Draw process map/flow chart of proposed process

2.4

Annotate key resources to map/flow chart

2.5

Examine map/flow chart for possible improvements

2.6

Redraw map/flow chart, as appropriate

3

Compare proposed process with current standard processes

3.1

Identify processes which will be new to/changed from/deleted from existing similar process used by the organisation

3.2

Identify materials which will be new to/changed from/deleted from existing similar process or the organisation

3.3

Identify areas of improvement in the existing similar process

3.4

Identify hazards and appropriate hazard controls

3.5

Develop procedures for new/modified steps

4

Draft procedures for new product/process

4.1

Locate appropriate template for procedures

4.2

Observe and record prototype

4.3

Draft procedures from successful prototype steps in appropriate format

5

Evaluate draft procedures

5.1

Keep tally of resources used

5.2

Compare production to procedures

5.3

Compare outcomes with expectations

5.4

Identify any required changes

5.5

Take appropriate action

6

Draft new procedures and obtain authorisation

6.1

Draft workable procedures

6.2

Obtain authorisation of new procedures, as required

6.3

Standardise procedures

Required skills

Required skills includes:

writing

developing procedures

evaluating outcomes

following authorisation procedures

communicating with relevant personnel

Required knowledge

Required knowledge includes:

use of production tools (e.g. one-off or multiple products)

limits of size which suggest easiest/most cost effective way to produce product

fibre/resin ratio

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.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

It is essential that the process and equipment be understood and that the importance of critical material properties, settings and readings is known. Competence must be demonstrated in the ability to recognise and analyse potential situations requiring action and then in implementing appropriate corrective action.

Consistent performance should be demonstrated. In particular look to see that:

a set of workable procedures have been developed

procedures have taken account of process mapping.

Competence must be demonstrated in the operation of all ancillary equipment to the level required for this unit of competency.

Context of and specific resources for assessment

Assessment will require the development of new manufacturing specifications/procedures for composite products or components.

Assessment will occur over a range of situations which will include disruptions to normal, smooth operation.

Method of assessment

A single assessment event is not appropriate. On-the-job assessment should be included as part of the assessment process wherever possible. Where assessment occurs off the job, judgement must consider evidence of the candidate's performance in a productive work environment that includes a sufficient range of appropriate tasks and materials to cover the scope of application for this unit.

Assessors should gather a range of evidence that is valid, sufficient, current and authentic. Evidence can be gathered through a variety of ways, including direct observation, supervisor's reports, project work, samples and questioning. Questioning techniques should not require language, literacy and numeracy skills beyond those required in this unit of competency.

The candidate must have access to all tools, equipment, materials and documentation required. The candidate must be permitted to refer to any relevant workplace procedures, product and manufacturing specifications, codes, standards, manuals and reference materials.

Guidance information for assessment

Assessment processes and techniques must be culturally appropriate and appropriate to the language and literacy capacity of the candidate and the work being performed.

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.

Procedures

Procedures may be written, verbal, computer-based or in some other form, and may include:

all work instructions

standard operating procedures

formulas/recipes

batch sheets

temporary instructions

any similar instructions provided for the smooth running of the plant

good operating practice as may be defined by industry codes of practice (e.g. Responsible Care) and government regulations

Deliverables expected by customer

Deliverables expected by customer may include:

technical specification

aesthetic requirements

other quality expectations

cost/price expectations

quantity and delivery schedules

Key resources

Key resources include:

materials

labour

time

money

Process map improvements

Improvements made from process maps are typically a reduction in wastes (muda) as defined by

over-production

delay

transportation

over-processing

excess inventory/work in progress (WIP)

excess motion

defects

untapped human potential

Logs and reports

Logs and reports may include:

paper or electronic based

verbal reports

items found which require action

Appropriate action

Appropriate action includes:

determining problems needing action

determining possible fault causes

rectifying problem using appropriate solution within area of responsibility

following through items initiated until final resolution has occurred

reporting problems outside area of responsibility to designated person

Typical problems

Typical problems may include:

multiple ways of doing the same job

waste built into procedures

aligning procedures with good practice

Health, safety and environment (HSE)

All operations to which this unit applies are subject to stringent HSE requirements, which may be imposed through state/territory or federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between Performance Criteria and HSE requirements, the HSE requirements take precedence