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Evidence Guide: MSS405023 - Develop a levelled pull system for operations and processes

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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!

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MSS405023 - Develop a levelled pull system for operations and processes

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

Analyse production systems

  1. Acquire an 'as is' value map of the process for all major products.
  2. Separate repeated products from specials.
  3. Consult with production, maintenance, supervisory and management workforce on current production system and processes.
  4. Establish rate of flow required to meet customer demand.
  5. Identify process steps causing problems.
  6. Analyse inventories within process and determine causes of high inventories.
  7. Determine costs of problems and inventories.
  8. Develop improved flow sequence and future value map.
Acquire an 'as is' value map of the process for all major products.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Separate repeated products from specials.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Consult with production, maintenance, supervisory and management workforce on current production system and processes.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Establish rate of flow required to meet customer demand.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify process steps causing problems.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Analyse inventories within process and determine causes of high inventories.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine costs of problems and inventories.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Develop improved flow sequence and future value map.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Establish sequence

  1. Identify equipment and processes which can be sequenced by co-location.
  2. Identify equipment which is not suitable for co-location.
  3. Identify pacemaker process.
  4. Establish/review location of equipment for desired sequencing.
Identify equipment and processes which can be sequenced by co-location.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify equipment which is not suitable for co-location.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify pacemaker process.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Establish/review location of equipment for desired sequencing.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Initiate or develop flow system

  1. Determine rate and variability of demand for product.
  2. Compare capability of flow sequence to demand rate and variability.
  3. Set flow rate to level demand at pacemaker and handle variability.
  4. Identify trigger for pacemaker process.
  5. Establish kanban system for other process parts.
Determine rate and variability of demand for product.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Compare capability of flow sequence to demand rate and variability.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Set flow rate to level demand at pacemaker and handle variability.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify trigger for pacemaker process.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Establish kanban system for other process parts.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Balance the work

  1. Determine target time per product.
  2. Standardise work processes and operations and establish procedures to monitor variation.
  3. Adjust product/batch production to balance work.
  4. Arrange for any required competency development of workforce.
  5. Arrange for implementation of system.
  6. Monitor operation of system and take action according to procedures.
Determine target time per product.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Standardise work processes and operations and establish procedures to monitor variation.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Adjust product/batch production to balance work.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Arrange for any required competency development of workforce.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Arrange for implementation of system.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor operation of system and take action according to procedures.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

Elements describe the essential outcomes.

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

1

Analyse production systems

1.1

Acquire an 'as is' value map of the process for all major products.

1.2

Separate repeated products from specials.

1.3

Consult with production, maintenance, supervisory and management workforce on current production system and processes.

1.4

Establish rate of flow required to meet customer demand.

1.5

Identify process steps causing problems.

1.6

Analyse inventories within process and determine causes of high inventories.

1.7

Determine costs of problems and inventories.

1.8

Develop improved flow sequence and future value map.

2

Establish sequence

2.1

Identify equipment and processes which can be sequenced by co-location.

2.2

Identify equipment which is not suitable for co-location.

2.3

Identify pacemaker process.

2.4

Establish/review location of equipment for desired sequencing.

3

Initiate or develop flow system

3.1

Determine rate and variability of demand for product.

3.2

Compare capability of flow sequence to demand rate and variability.

3.3

Set flow rate to level demand at pacemaker and handle variability.

3.4

Identify trigger for pacemaker process.

3.5

Establish kanban system for other process parts.

4

Balance the work

4.1

Determine target time per product.

4.2

Standardise work processes and operations and establish procedures to monitor variation.

4.3

Adjust product/batch production to balance work.

4.4

Arrange for any required competency development of workforce.

4.5

Arrange for implementation of system.

4.6

Monitor operation of system and take action according to procedures.

Required Skills and Knowledge

Elements describe the essential outcomes.

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

1

Analyse production systems

1.1

Acquire an 'as is' value map of the process for all major products.

1.2

Separate repeated products from specials.

1.3

Consult with production, maintenance, supervisory and management workforce on current production system and processes.

1.4

Establish rate of flow required to meet customer demand.

1.5

Identify process steps causing problems.

1.6

Analyse inventories within process and determine causes of high inventories.

1.7

Determine costs of problems and inventories.

1.8

Develop improved flow sequence and future value map.

2

Establish sequence

2.1

Identify equipment and processes which can be sequenced by co-location.

2.2

Identify equipment which is not suitable for co-location.

2.3

Identify pacemaker process.

2.4

Establish/review location of equipment for desired sequencing.

3

Initiate or develop flow system

3.1

Determine rate and variability of demand for product.

3.2

Compare capability of flow sequence to demand rate and variability.

3.3

Set flow rate to level demand at pacemaker and handle variability.

3.4

Identify trigger for pacemaker process.

3.5

Establish kanban system for other process parts.

4

Balance the work

4.1

Determine target time per product.

4.2

Standardise work processes and operations and establish procedures to monitor variation.

4.3

Adjust product/batch production to balance work.

4.4

Arrange for any required competency development of workforce.

4.5

Arrange for implementation of system.

4.6

Monitor operation of system and take action according to procedures.

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, for one or more work area/product families, to:

acquire a value stream map for current products and processes

analyse process

perform required calculations to determine flow rate and variability

correctly identify pacemaker process

balance the work

monitor implementation of a levelled pull system and suggest improvements.

Must provide evidence that demonstrates sufficient knowledge to interact with relevant personnel and be able to develop or improve a pull system, including knowledge of:

technical and regulatory limits that must be adhered to in operations

processing requirements of products or services offered by the organisation

capabilities of equipment

capabilities and skills of the workforce

production planning techniques

methods of calculating rates of demand and flow of work (e.g. takt and pitch)

techniques for achieving a smooth and consistent flow of work

relationship of level of inventory to efficiency and muda (waste).

Range Statement

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.

Inventories within process include one or more of:

cycle stock which reflects the replenishment quantity and frequency

buffer stock to meet demand variability and forecast errors

safety stock required to guard against quality and delivery failures upstream.

Balance the work means balancing one or more of:

time of production

effort required by workforce and equipment

work organisation

job design

quality considerations

waste and other cost considerations between stations/ equipment/processes to achieve levelled pull within allowable time per product.