This unit provides the skill for a technical expert to apply the principles of competitive manufacturing to process as distinct from a 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 manufacturing 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 gathering, analysing and applying information.

ELEMENT

PERFORMANCE CRITERIA

1. Identify the products and processes used in the enterprise

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 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 manufacturing strategy of the enterprise

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 workforce development and training requirements

3.6. Check the availability of required infrastructure and compatibility with requirements

4. Layout 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

Required skills

analysis

problem solving

planning and organising

verbal and written communication

calculations

Required knowledge

processing requirements of products and jobs

capabilities of equipment

abilities and skills of workforce

business requirements from layout

The Evidence Guide describes the underpinning knowledge and skills that must be demonstrated to prove competence. it is essential for assessment and must be read conjunction in conjunction with the performance criteria, the range statement and the assessment guidelines of the relevant training package

Overview of assessment requirements

The assessment should confirm the ability to develop or improve a process layout in a jobbing or process manufacturing enterprise

What are the specific resource requirements for this unit?

Access to an organisation developing or redesigning its process layout.

What critical aspects of evidence is required to demonstrate competency in this unit?

Evidence of process layout or layouts undertaken should be available.

In what context should assessment occur?

Assessment will need to occur in an organisation developing or improving its process layout. Assessment could also be undertaken by project work or simulation provided adequate opportunity to test the practicality of the developed layouts exist.

Are there any other units which could or should be assessed with this unit or which relate directly to this unit?

What method of assessment should apply?

Assessors must be satisfied that the person can consistently perform the unit as a whole, as defined by the Elements, Performance Criteria, skills and knowledge. A holistic approach should be taken to the assessment.

Assessors should gather sufficient, fair, valid, reliable, authentic and current evidence from a range of sources. Sources of evidence may include direct observation, reports from supervisors, peers and colleagues, project work, samples, organisation records and questioning. Assessment should not require language, literacy or numeracy skills beyond those required for the unit.

The assessee will have access to all techniques, procedures, information, resources and aids which would normally be available in the workplace.

The method of assessment should be discussed and agreed with the assessee prior to the commencement of the assessment.

What evidence is required for demonstration of consistent performance?

Generally one significant process layout project should generate sufficient evidence

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.

Profiles

Profiles of products may include:

components/materials needed to manufacture

equipment/technology/processes required to manufacture

volume of activity to manufacture forecast amount

Compatible families

Compatible families are products/classes requiring identical or similar manufacturing equipment, technology or processes.

Required resource times

Required resource times may include:

set up time

equipment time

person time

process time

Lot size

Lot size may include:

external lot size

internal lot size

transfer batch size

kanban size

Viability

Viability includes:

appropriate calculated processing times

adequacy of equipment utilisation

acceptable maintenance implications

ability to meet OHS requirements

ability to meet environmental requirements

compliance with any legislative and regulatory requirements

acceptable to stakeholders

Competitive manufacturing strategy

Competitive manufacturing strategies may include one or more of:

Six sigma

Lean Manufacturing

Agile Manufacturing

Just in Time (JIT)

Supply chain management

Value Chain Management

Total Quality

Pro Active maintenance

Elimination of waste

Balanced Scorecard

Stakeholders

Stakeholders include:

employees

customers

equipment suppliers and contractors (especially if new equipment required)

Depending on the process and location stakeholders may also include:

regulatory authorities

local community representatives

utilities, eg water, power

Physical infrastructure

Physical infrastructure may include:

containers

material handling equipment

utilities supply (steam, air, gas, electricity, water)

Information and control infrastructure

Information and control infrastructure may include:

quality assurance

SPC/six sigma

planning systems/software

data collection and control systems/software

Work organisation

Work organisation includes:

number of personnel

skills mix of workforce

Unit Sector

CM Tools

This unit contains employability skills.