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

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

plan and design manufacturing facilities, services, plant, tooling and process, and process control system

interpret features of product and processing options and parameters to the brief or contract

advise client based on discipline knowledge and OHS and regulatory standards

establish budget and control measures and design schedule within design project control plan

research current manufacturing process design techniques, product manufacturability, process design, layout and automation options, lean systems and supply chain value analysis

determine sustainability, OHS, regulatory and risk management requirements

review software options, facilities, services, plant and tooling requirements of products, stock control, warehousing, buffer and emergency stock, material and product flow, transfer operations, information flow and manufacturing process control, process maintenance management, labour requirements and skills distribution

model and calculate using appropriate software and validation techniques

generate and evaluate a range of solutions for feasibility against design criteria

incorporate maintenance management, HR, information management and continuous improvement systems

implement systems thinking, continuous improvement, and constraint and contingency management options

communicate, negotiate and review with stakeholders and client throughout process to obtain agreement on proposal and sign-off on design

document design with required drawings, specifications and instructions.

Context of and specific resources for assessment

Full assessment of this unit would normally need to be undertaken on the job in the context of a commercial design project and software. Assessment of some elements of the manufacturing design process may be possible off the job providing full plant simulation facilities and software are available that reflect 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 its 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 able not only 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:

interpreting features of product performance objectives and specifications

planning and designing manufacturing facilities, services, plant, tooling and process, and process control systems

advising clients based on discipline knowledge and OHS and regulatory standards

preparing a product development flow chart

establishing budget and control measures and designing schedule within project control plan

determining sustainability, OHS, regulatory and risk management requirements

reviewing software options, facilities and logistics, services, labour, plant and tooling requirements

modelling and calculating using automated design tools and validation techniques

generating and evaluating a range of solutions for feasibility against design criteria

incorporating maintenance management, human resources, information management and continuous improvement systems requirements

implementing systems thinking, continuous improvement and constraint and contingency management options

calculating estimated and actual time to market

communicating, negotiating and reviewing with stakeholders and client throughout process to obtain agreement on proposal and sign-off on design

documenting design with drawings, specifications and instructions

investigating faults in existing manufacturing process designs and proposing solutions

Required knowledge

Required knowledge includes:

advanced and current manufacturing process design methodologies

standardisation techniques

economic, social and sustainability implications

market competitiveness factors

lean manufacturing principles

automated design tools

project planning, scheduling and control techniques, including budgeting and costing

characteristics of, and differences between, jobbing, flexible and mass production, and continuous process

implications of maintenance management and human resource systems for engineering-related planning processes

production information flow required for and from a manufacturing process

regulatory environment requirements, applicable standards and codes of practice

process design documentation, drawings, specifications and instructions

techniques for:

continuous improvement

problem solving and decision making

root cause analysis (RCA) or failure mode and effects analysis (FMEA) or design review based on failure mode (DRBFM), and Pareto analysis

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.

Client

Client may be:

internal or external to the designer’s organisation

Appropriate technical and professional assistance

Appropriate technical and professional assistance may include:

technical support and advice relating to elements which have intrinsic dangers, for example:

high pressure

energised fluid vessels

high temperatures and heat energy capacity

wiring or devices with high current or 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

professional services for:

finance, accounts and tax

insurance and legal

training and human resources (HR)

Parameters to the brief

The design brief may include the design of new manufacturing processes or fault analysis, rectification or modification to an existing design. Parameters to the design brief may include:

daily and seasonal production rates

requirements for shift work

provisions for increasing or reducing production rates

expected quality levels

other special features and limits in the design brief

OHS, regulatory, sustainability and environmental issues

OHS, regulatory, sustainability and environmental issues may include:

OHS Acts and regulations

relevant standards

industry codes of practice

risk assessments

registration requirements

safe work practices

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 OHS impact on employees, community and customer

state and territory regulatory requirements

Production systems

Production systems may include:

suppliers

materials handling systems

manufacturing processes

labour force capability

dstribution systems

Design methologies

Design methodologies may include:

design for assembly

design for automated assembly

design for manufacturability

design for qualify

design for maintainability

concurrent engineering

Automated design tools

Automated design tools may include:

computer-aided design (CAD)

computer-aided engineering (CAE)

solid modelling

finite element analysis

group technology (GT)

computer-aided process planning (CAPP)

expert system tools

cost analysis and financial modelling tools

Product manufacturability

Product manufacturability may be enhanced by concurrent product and process design. Product design for manufacturability includes:

consideration of manufacturing processes and plant in the product design process, such as the use of group technologies

Continuous improvement

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

Continuous improvement techniques may include:

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 system participation

technical training