- MSACMT622A - Design a process layout
MSACMT622A
Design a process layout
Application
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. |
Elements and Performance Criteria
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
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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 |
Evidence Required
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 |
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. | ||
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 |
Sectors
Unit Sector | CM Tools |
Employability Skills
This unit contains employability skills. |
Licensing Information
Not applicable.