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Evidence Guide: MSS403051 - Mistake proof an operational process

Student: __________________________________________________

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!

From the Wiki University

 

MSS403051 - Mistake proof an operational process

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

Analyse process

  1. Identify sources of variability/non-conformance in the process.
  2. Identify critical control points in process.
  3. Analyse causes of variability/non-conformance.
Identify sources of variability/non-conformance in the process.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify critical control points in process.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Analyse causes of variability/non-conformance.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Develop preventative techniques/systems

  1. Liaise with team members and other people to develop mistake proof options for performing operation.
  2. Test and validate mistake proofing options.
Liaise with team members and other people to develop mistake proof options for performing operation.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Test and validate mistake proofing options.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Implement permanent fix

  1. Liaise with relevant people to have systems/procedures changed to implement solution.
  2. Liaise with relevant people to implement the solution.
  3. Liaise with relevant people to ensure self and others in the team or work area have an appropriate skills set.
  4. Follow through to ensure implementation occurs.
Liaise with relevant people to have systems/procedures changed to implement solution.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Liaise with relevant people to implement the solution.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Liaise with relevant people to ensure self and others in the team or work area have an appropriate skills set.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Follow through to ensure implementation occurs.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor implementation

  1. Critically observe the implementation.
  2. Compare the results of the implementation against the expected outcomes.
  3. Modify solution to improve outcomes.
  4. Ensure procedures reflect change.
  5. Ensure training/assessment reflects change.
  6. Audit change at agreed period/cycle.
  7. Take action on any observed deviation.
Critically observe the implementation.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Compare the results of the implementation against the expected outcomes.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Modify solution to improve outcomes.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure procedures reflect change.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure training/assessment reflects change.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Audit change at agreed period/cycle.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Take action on any observed deviation.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Seek improvements

  1. Observe changes.
  2. Analyse process again, if required, to ensure improvements are sustained.
Observe changes.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Analyse process again, if required, to ensure improvements are sustained.

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 process

1.1

Identify sources of variability/non-conformance in the process.

1.2

Identify critical control points in process.

1.3

Analyse causes of variability/non-conformance.

2

Develop preventative techniques/systems

2.1

Liaise with team members and other people to develop mistake proof options for performing operation.

2.2

Test and validate mistake proofing options.

3

Implement permanent fix

3.1

Liaise with relevant people to have systems/procedures changed to implement solution.

3.2

Liaise with relevant people to implement the solution.

3.3

Liaise with relevant people to ensure self and others in the team or work area have an appropriate skills set.

3.4

Follow through to ensure implementation occurs.

4

Monitor implementation

4.1

Critically observe the implementation.

4.2

Compare the results of the implementation against the expected outcomes.

4.3

Modify solution to improve outcomes.

4.4

Ensure procedures reflect change.

4.5

Ensure training/assessment reflects change.

4.6

Audit change at agreed period/cycle.

4.7

Take action on any observed deviation.

5

Seek improvements

5.1

Observe changes.

5.2

Analyse process again, if required, to ensure improvements are sustained.

Required Skills and Knowledge

Elements describe the essential outcomes.

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

1

Analyse process

1.1

Identify sources of variability/non-conformance in the process.

1.2

Identify critical control points in process.

1.3

Analyse causes of variability/non-conformance.

2

Develop preventative techniques/systems

2.1

Liaise with team members and other people to develop mistake proof options for performing operation.

2.2

Test and validate mistake proofing options.

3

Implement permanent fix

3.1

Liaise with relevant people to have systems/procedures changed to implement solution.

3.2

Liaise with relevant people to implement the solution.

3.3

Liaise with relevant people to ensure self and others in the team or work area have an appropriate skills set.

3.4

Follow through to ensure implementation occurs.

4

Monitor implementation

4.1

Critically observe the implementation.

4.2

Compare the results of the implementation against the expected outcomes.

4.3

Modify solution to improve outcomes.

4.4

Ensure procedures reflect change.

4.5

Ensure training/assessment reflects change.

4.6

Audit change at agreed period/cycle.

4.7

Take action on any observed deviation.

5

Seek improvements

5.1

Observe changes.

5.2

Analyse process again, if required, to ensure improvements are sustained.

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 to mistake proof (apply baka yoke or poka yoke) on one (1) or more occasions and to:

analyse causes of variability and non-conformity

develop and validate baka yoke or poka yoke options

implement most appropriate option

monitor the change and seek further improvements.

Must provide evidence that demonstrates knowledge relevant to their job role sufficient to fulfil their job role independently, including:

baka yoke and poka yoke approaches

factors causing variability in the process and methods of controlling it

analyse error causes and determine control options

analyse benefit/cost, feasibility, regulatory compliance and perceived value to the customer

validation of baka yoke and poka yoke proposals.

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.

Mistake proofing (baka-yoke or poka-yoke) includes one or more of:

eliminating the possibility of an error occurring

reducing the occurrence of errors and/or to minimise their impact

eliminating the possibility of the error via changes to the process

preventing the error from occurring via physical or virtual barriers

reducing likelihood of the error by encouraging correct action (e.g. through warning systems)

mitigating the impact of the error if it does occur.

Prioritising options for mistake proofing includes one or more of:

success rate in eliminating errors

feasibility

skills required by employees

cost

capacity to reduce waste.

Procedures (written, verbal, visual, computer based, etc.) include one or any combination of:

work instructions

standard operating procedures (SOPs)

safe work method statements

formulas/recipes

batch sheets

temporary instructions

any similar instructions provided for the smooth running of the plant.