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 measure and analyse production or service performance data and apply techniques for process control to maintain efficient and effective production or supply or service to customers and to provide data for improvements to enhance competitiveness. This includes working individually and as part of a team in accordance with organisational procedures

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 measurable and controllable parameters of product or service,

determine acceptable variation of production or service parameters

use manual and automatic methods for measurement, data gathering and analysis

apply software and control chart techniques for SPC, performance analysis and graphical representations, including generating histograms, Pareto diagrams, flowcharts, tally charts, scatter plots and/or run charts from production or measurable service data

review production and service functions in order to recommend or make process improvements that are based on statistical analyses

identify WHS and regulatory requirements, risk management and related organisational procedures

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:

identifying production control task parameters and context within organisation strategic objectives and markets

confirming stakeholder and support functional group interdependencies and communications, reporting and information flow

determining controllable parameters of product or service and acceptable variation

using manual and automatic methods for measurement, data gathering and analysis

production of different charts used in production and service control, including:

histograms

Pareto diagrams

flowcharts

tallycharts

scatter plots

run charts

applying a range of sampling plans to products or measurable aspects of services and justifying the choice of sampling plan

analysing data for trends and correlations

setting of KPIs capable of measurement and ongoing monitoring

determining appropriate corrective actions based on analysis of measurable production or service performance parameters

Required knowledge

Required knowledge includes:

process capability, including:

capable processes definition

upper, lower and target specification limits

in-control

out-of-control, assignable causes and trends

corrective action plans, such as Western Electric, Wheeler or Nelson rules

capability indices

sample estimators

confidence intervals for indices and Chi square distribution

role of production or process control in supporting lean processes, for example:

value stream management

standardised work

demand pull

just-in-time (JIT)

process levelling

cycle time

quick changeover

preventative maintenance

waste minimisation

efficient process layout

role of production control in quality maintenance:

mistake proofing process

defect detection, production halt and correction procedures

total quality management (TQM), quality assurance (QA) procedures and quality control (QC), and SPC processes

role of SPC and process capability

production control performance indicators/indices

applications where role of probability in sampling and SPC is important

SPC, including:

data types and frequency distributions

population mean and standard deviation

sample mean and standard deviation

upper and lower specification limits and target

upper and lower process control limits and centre line

data mean and process control centre line offset

3 sigma s and 6 sigma s

sigma shift to account for long-term drift of data

types and functions of control charts

attributes and varaiables of sampling plans

features and functions of graphical methods for display of data:

Ishikawa ‘Fishbone’ diagrams

histograms

Pareto analysis diagrams

flowcharts

tallycharts

scatter plots

run charts, including control charts

types of manual and automated data collection and information flow

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.

Production control related tasks

Production control related tasks covered by this unit may include:

measuring and recording data either manually or using automated data collection

determining process capability indices for a large sample of a product with a particular dimension normally distributed within upper and lower specification limits

applying a range of sampling plans to products or measurable aspects of services and justify the choice of sampling plan based on the properties required of the plan

applying control charts to a sample from a product or service to determine acceptability of the product or service within set limits (e.g.3s and 6s limits)

analysing data for trends and taking corrective action in accordance with procedures

selecting and employing appropriate control charts from c-chart, p-chart and X-bar and R or np control charts

employing a Pareto analysis to determine priority issues for solutions related to a specific problem

Process control

Process control includes the qualitative and quantitative analysis of the process and production data necessary to ensure customer requirement

Required performance indicators for production or service operations

Required performance indicators for production or service operations will vary according to the nature of the product or service and may include:

design features, such as dimensional and weight specifications and tolerances

production schedules

organisation or customer specified target error rates and waste, including those set under lean systems, such as 6s

equipment availability indices

mass balancing targets

WHS related indicators (e.g. lost time injury)

takt time compliance

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

registration requirements

safe work practices

state and territory regulatory requirements

Lean principles

Lean principles and techniques use cost, capacity and responsiveness, quality, reliability and waste minimisation as drivers of the process and measures for process improvement.