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Evidence Guide: ICPSU486C - Mistake proof a production process

Student: __________________________________________________

Signature: _________________________________________________

Tips for gathering evidence to demonstrate your skills

The important thing to remember when gathering evidence is that the more evidence the better - that is, the more evidence you gather to demonstrate your skills, the more confident an assessor can be that you have learned the skills not just at one point in time, but are continuing to apply and develop those skills (as opposed to just learning for the test!). Furthermore, one piece of evidence that you collect will not usualy demonstrate all the required criteria for a unit of competency, whereas multiple overlapping pieces of evidence will usually do the trick!

From the Wiki University

 

ICPSU486C - Mistake proof a production process

What evidence can you provide to prove your understanding of each of the following citeria?

Analyse the process

  1. Identify sources of variability/non-conformance in the process
  2. Identify critical control points in the process
  3. Analyse causes of variability/non-conformance
Identify sources of variability/non-conformance in the process

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify critical control points in the process

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Analyse causes of variability/non-conformance

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Develop preventive techniques/systems

  1. Liaise with team members and other people to develop mistake proof method of performing operation
  2. Test and validate mistake proofing
Liaise with team members and other people to develop mistake proof method of performing operation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Test and validate mistake proofing

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Implement permanent fix

  1. Liaise with relevant people to have systems/procedures changed to implement solution
  2. Liaise with relevant people to implement the solution
  3. Liaise with relevant people to ensure the workforce has an appropriate skills set
  4. Follow through to ensure implementation occurs
Liaise with relevant people to have systems/procedures changed to implement solution

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Liaise with relevant people to implement the solution

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Liaise with relevant people to ensure the workforce has an appropriate skills set

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Follow through to ensure implementation occurs

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor implementation

  1. Critically observe the implementation
  2. Compare the results of the implementation against the expected outcomes
  3. Modify solution to improve outcomes
  4. Ensure procedures reflect change
  5. Ensure training and assessment reflect change
  6. Audit change at agreed period/cycle
  7. Take action on any observed deviation
Critically observe the implementation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Compare the results of the implementation against the expected outcomes

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Modify solution to improve outcomes

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure procedures reflect change

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure training and assessment reflect change

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Audit change at agreed period/cycle

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Take action on any observed deviation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Seek improvements

  1. Observe changes against enterprise expectations for production
  2. Analyse process against enterprise expectations for production
Observe changes against enterprise expectations for production

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Analyse process against enterprise expectations for production

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

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:

the competent team leader will be able to analyse their process and implement systems to ensure the process is mistake proof and the operators work in a predictable way with little or no chance of mistake. Evidence of actions taken to mistake proof the process should be available

one complex project on standardisation of a process or several simpler projects will be needed to gain sufficient evidence.

Context of and specific resources for assessment

Assessment must ensure:

assessment needs to occur in a workplace implementing competitive manufacturing or by using a suitable project

access to an organisation using a competitive manufacturing approach.

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:

ICPSU684C Determine and improve process capability.

Required Skills and Knowledge

Required skills

OHS in relation to operating machinery such as safely switching off machinery before cleaning is started

communication of ideas and information by liaising with relevant people to have systems/procedures changed to implement solution

collecting, analysing and organising information by liaising with team members and other people to develop mistake proof method of performing operation

planning and organising activities by implementing a permanent fix

teamwork when liaising with team members and other people to develop mistake proof method of performing operation

mathematical ideas and techniques by implementing a permanent fix

problem-solving skills by modifying solution to improve outcomes

use of technology by seeking improvements

Required knowledge

communication ability to discuss items with both operators and technical support personnel

problem solving

analysis

teamwork

design conceptualisation

understanding of their process

factors in the process which may cause variability

methods of controlling the variability in the process

mistake proofing methods relevant to the process/product

Range Statement

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.

Mistake proofing may include:

sometimes known as baka-yoke/poka-yoke - a manufacturing technique of preventing mistakes by designing the manufacturing process, equipment, tools and components/subassemblies so that an operation literally cannot be performed incorrectly; an attempt to perform incorrectly, as well as being prevented, is usually met with a warning signal of some sort.

Procedures may include:

procedures includes all work instructions, standard operating procedures, formulas/recipes, batch sheets, temporary instructions and similar instructions provided for the smooth running of the plant. They may be written, oral, computer-based or in some other form

for the purposes of this Training Package, procedures also includes good operating practice as may be defined by industry codes of practice (eg Good Manufacturing Practice (GMP), Responsible Care) and government regulations.