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

A person who demonstrates competency in this unit must be able to evaluate jigs, fixtures, templates and gauges and their applications within manufacturing processes for safety, economy and fitness for purpose.

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

Assessors must be satisfied that the candidate can competently and consistently:

determine parameters and context of jigs, fixtures, templates and gauges in manufacturing processes

review design and construction features, functions, applications and limitations of jigs, fixtures, templates and gauges

identify principles, design, analysis techniques and software required to evaluate and optimise jigs, fixtures, templates and gauges and related manufacturing processes

evaluate WHS, regulatory and risk management compliance

report and document results.

Context of and specific resources for assessment

This unit may be assessed on the job, off the job or a combination of both on and off the job. Where assessment occurs off the job, then a simulated working environment must be used where the range of conditions reflects realistic workplace situations.

The competencies covered by this unit would be demonstrated by an individual working alone or as part of a team.

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. Where applicable, physical resources should include equipment modified for people with disabilities.

Method of assessment

Assessment must satisfy the endorsed Assessment Guidelines of the MEM05 Metal and Engineering Training Package.

Assessment methods must confirm consistency and accuracy of performance (over time and in a range of workplace relevant contexts) together with application of underpinning knowledge.

Assessment methods must be by direct observation of tasks and include questioning on underpinning knowledge to ensure correct interpretation and application.

Assessment may be applied under project-related conditions (real or simulated) and require evidence of process.

Assessment must confirm a reasonable inference that competency is not only able to be satisfied under the particular circumstance, but is able to be transferred to other circumstances.

Assessment may be in conjunction with assessment of other units of competency where required.

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.

Required skills

Required skills include:

determining role and benefit of jigs, fixtures, templates and gauges in a manufacturing process

reviewing materials, treatments, finishing and assembly, and installation of jigs, fixtures, templates and gauges

investigating sustainability implications of jigs, fixtures, templates and gauges

selecting and using appropriate analysis techniques and software for evaluation of jigs, fixtures, templates and gauges

identifying relevant WHS, regulatory and risk management compliance requirements

relating use of jigs, fixtures, templates and gauges to:

lean manufacturing systems and techniques

requirements of manufacturing control software, such as system control and data acquisition software (SCADA)

applying systems thinking, continuous improvement, and constraint and contingency management to evaluation of jigs, fixtures, templates and gauges

reporting and documenting scoping, principles and techniques identification and evaluation of jigs, fixtures, templates and gauges and related manufacturing processes, graphics and models

Required knowledge

Required knowledge includes:

WHS and regulatory compliance requirements, and risk management practices relevant to jigs, fixtures, templates and gauges and related manufacturing and maintenance processes

typical range of jigs, fixtures, templates and gauge applications, including effects on:

repeatability of processes

accuracy and other quality requirements

labour and skill requirements for operations

integration with or facilitation of jigs, fixtures, templates and gauges with lean manufacturing techniques, including:

standardisation

reduction of waste (also often called muda)

takt time

just in time (JIT)

typical construction methods for jigs, fixtures, templates and gauges

graphical representations and developments of jigs, fixtures, templates and gauges, including assemblies, component parts, operational overlays and user instructions

dimensioning systems, including tolerances, limits and fits, and affect on manufacturing method

materials and their applications in jigs, fixtures, templates and gauges

positioning, locating and clamping methods

design and simulation techniques, including use of CAD software for design and animations

jig, fixture, template and gauge manufacturing techniques, such as:

fabrication and joining processes

machining (e.g. milling, turning and grinding)

post-processing of CAD files

computer numeric control (CNC) machining

electro-discharge machining (EDM)

‘rapid’ (additive) processes

heat treatment,

surface treatments

finish grinding and polishing

SCADA and other manufacturing control software and implications for jigs, fixtures, templates and gauges

systems thinking, continuous improvement, constraint and contingency management, and comparative supply chain performance

sustainability implications of jigs, fixtures, templates and gauges

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.

Jigs and fixtures

Jigs and fixtures are used to position, hold and support components for assembly, fabrication or machining operations. Jigs also guide operations, such as drilling. Jigs and fixtures are specially designed so that large numbers of components can be machined or assembled identically while maintaining the correct relationship and alignment between the tool and the work piece, and to ensure interchangeability of components. A jig or fixture is designed and built to hold, support and locate a component (part) to ensure that it is drilled, machined or fabricated within the specified limits

Templates

Templates are production tools used to accurately manufacture duplicate and interchangeable parts and may perform positioning and guidance functions as well as profile checking for machining and fabrication operations

Gauges

Gauges are used to check dimensions of components, machining operations or assemblies. For this unit gauges refers to:

specifically manufactured items to allow quick dimensional or other checks, for example, go/no-go gauges with references or use of graduated devices or instruments

Features and functions, of jigs, fixtures, templates and gauges

Features and functions of jigs, fixtures, templates and gauges include:

materials used in their construction

method of fabrication (e.g. welding and machining)

dimensions and tolerances

method of holding or locating work pieces or production items

method of installation and any capacity for operator adjustment during use

method of adjustment for production changeover

where the jig, fixture, template or gauge is being used by someone other than the designer or manufacturer, the degree of training required for its correct use

any limitations on the use of the jig, fixture, template and gauge

cost

degree of saving generated by the jig, fixture, template or gauge over alternatives. The saving may be in:

quality

error rate

production capacity

labour requirement

WHS, regulatory requirements and enterprise procedures

WHS, regulatory requirements and enterprise procedures may include:

WHS Acts and regulations

relevant standards

codes of practice from Australian and overseas engineering and technical associations and societies

risk assessments

safe work practices

state and territory regulatory requirements

Standards and codes

Standards and codes refer to all relevant Australian and international standards and codes applicable to evaluation of jigs and fixtures

Appropriate technical and professional assistance

Appropriate technical and professional assistance may include:

technical support and advice relating to elements which have intrinsic dangers, such as:

high pressure

energised fluid vessels

high temperatures and heat energy capacity

wiring with high current control voltages above extra low voltage

professional support for technologies, such as:

specialist electric motor drives and controllers

specialist materials, plastics, metal alloys and nano materials

special processes, foundry, alloy welding, heat treatment, sealing and fastening

Sustainability

Sustainability is used to mean the entire sustainable performance of the organisation/plant, including:

meeting all regulatory requirements

conforming to all industry covenants, protocols and best practice guides

minimising ecological and environmental footprint of process, plant and product

maximising economic benefit of process plant and product to the organisation and the community

minimising the negative WHS impact on employees, community and customer

Systems thinking

Systems thinking refers to the conduct of engineering work in a manner that demonstrates knowledge of how the interaction of different technical systems on equipment, machinery or structures, as well as the skills and techniques of personnel, combine to perform or support engineering-related operations, processes or projects. It embraces determining or establishing how the function of each technical system or component, as well as the skills and techniques of personnel, effects or potentially may effect, outcomes. Systems should be interpreted broadly within the context of the organisation and depending on the project or operation can include equipment, related facilities, material, software, internal services and personnel, and other organisations in the value chain

Continuous improvement implementation

Continuous improvement implementation may relate to plant, products, processes, systems or services, including design, development, implementation or manufacture, commissioning, operation or delivery and maintenance.

Improvement processes may include techniques, such as:

balanced scorecard

current and future state mapping

measuring performance against benchmarks

process improvement, problem solving and decision making

data management, generation, recording, analysing, storing and use of software

training for improvement systems participation

technical training

Constraints and contingencies

Constraints and contingencies may be:

financial

organisational, procedural or cultural

physical constraints, such as limits to resources, limits to site access or logistical limitations

Lean principles

Lean principles affecting tooling and related processes include:

tooling and processing costs

capacity and responsiveness to product demand

quality of product

reliability of tooling, process and supply

waste minimisation which includes ease of tool change