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Evidence Guide: MSS405024 - Apply the theory of constraints

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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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MSS405024 - Apply the theory of constraints

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

Identify the system constraint and throughput

  1. Identify goals and objectives of the organisation.
  2. Identify systems, processes and products to be examined.
  3. Determine throughput of steps within the system.
  4. Identify the capacity constrained process.
  5. Determine optimum throughput of capacity constrained process (drum).
  6. Determine maximum system throughput based on the capacity constrained process.
Identify goals and objectives of the organisation.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify systems, processes and products to be examined.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine throughput of steps within the system.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify the capacity constrained process.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine optimum throughput of capacity constrained process (drum).

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine maximum system throughput based on the capacity constrained process.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Optimise constraint throughput

  1. Determine optimum accumulation (buffer) before capacity constrained process.
  2. Determine appropriate supply schedule and trigger (rope) for buffer.
  3. Implement buffer and rope to match drum.
  4. Monitor capacity constrained process and system to ensure optimum throughput.
  5. Take required actions to minimise non-productive rate at capacity constrained process.
Determine optimum accumulation (buffer) before capacity constrained process.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine appropriate supply schedule and trigger (rope) for buffer.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Implement buffer and rope to match drum.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor capacity constrained process and system to ensure optimum throughput.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Take required actions to minimise non-productive rate at capacity constrained process.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prioritise processes and resources to maximising output at the constraint

  1. Ensure operations and individuals in non-constrained locations protect buffers and prevent build-up of work in process except at buffer locations.
  2. Identify operations that conflict with maximising constraint performance and replace with measures that help maximise throughput.
Ensure operations and individuals in non-constrained locations protect buffers and prevent build-up of work in process except at buffer locations.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify operations that conflict with maximising constraint performance and replace with measures that help maximise throughput.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine strategy to reduce capacity constraint

  1. Examine causes of the constrained capacity.
  2. Develop possible ways of increasing system capacity.
  3. Analyse and rank possible alternatives for increasing capacity.
  4. Draft a strategy for increasing capacity of system.
  5. Obtain required approval for response strategy.
Examine causes of the constrained capacity.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Develop possible ways of increasing system capacity.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Analyse and rank possible alternatives for increasing capacity.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Draft a strategy for increasing capacity of system.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Obtain required approval for response strategy.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Implement a process of on-going improvement as appropriate

  1. Develop an implementation plan appropriate to the organisation.
  2. Implement plan, as appropriate.
  3. Monitor implementation.
  4. Modify implementation plan, as appropriate.
  5. Identify next capacity constrained process and take action.
Develop an implementation plan appropriate to the organisation.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Implement plan, as appropriate.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor implementation.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Modify implementation plan, as appropriate.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify next capacity constrained process and take action.

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

Identify the system constraint and throughput

1.1

Identify goals and objectives of the organisation.

1.2

Identify systems, processes and products to be examined.

1.3

Determine throughput of steps within the system.

1.4

Identify the capacity constrained process.

1.5

Determine optimum throughput of capacity constrained process (drum).

1.6

Determine maximum system throughput based on the capacity constrained process.

2

Optimise constraint throughput

2.1

Determine optimum accumulation (buffer) before capacity constrained process.

2.2

Determine appropriate supply schedule and trigger (rope) for buffer.

2.3

Implement buffer and rope to match drum.

2.4

Monitor capacity constrained process and system to ensure optimum throughput.

2.5

Take required actions to minimise non-productive rate at capacity constrained process.

3

Prioritise processes and resources to maximising output at the constraint

3.1

Ensure operations and individuals in non-constrained locations protect buffers and prevent build-up of work in process except at buffer locations.

3.2

Identify operations that conflict with maximising constraint performance and replace with measures that help maximise throughput.

4

Determine strategy to reduce capacity constraint

4.1

Examine causes of the constrained capacity.

4.2

Develop possible ways of increasing system capacity.

4.3

Analyse and rank possible alternatives for increasing capacity.

4.4

Draft a strategy for increasing capacity of system.

4.5

Obtain required approval for response strategy.

5

Implement a process of on-going improvement as appropriate

5.1

Develop an implementation plan appropriate to the organisation.

5.2

Implement plan, as appropriate.

5.3

Monitor implementation.

5.4

Modify implementation plan, as appropriate.

5.5

Identify next capacity constrained process and take action.

Required Skills and Knowledge

Elements describe the essential outcomes.

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

1

Identify the system constraint and throughput

1.1

Identify goals and objectives of the organisation.

1.2

Identify systems, processes and products to be examined.

1.3

Determine throughput of steps within the system.

1.4

Identify the capacity constrained process.

1.5

Determine optimum throughput of capacity constrained process (drum).

1.6

Determine maximum system throughput based on the capacity constrained process.

2

Optimise constraint throughput

2.1

Determine optimum accumulation (buffer) before capacity constrained process.

2.2

Determine appropriate supply schedule and trigger (rope) for buffer.

2.3

Implement buffer and rope to match drum.

2.4

Monitor capacity constrained process and system to ensure optimum throughput.

2.5

Take required actions to minimise non-productive rate at capacity constrained process.

3

Prioritise processes and resources to maximising output at the constraint

3.1

Ensure operations and individuals in non-constrained locations protect buffers and prevent build-up of work in process except at buffer locations.

3.2

Identify operations that conflict with maximising constraint performance and replace with measures that help maximise throughput.

4

Determine strategy to reduce capacity constraint

4.1

Examine causes of the constrained capacity.

4.2

Develop possible ways of increasing system capacity.

4.3

Analyse and rank possible alternatives for increasing capacity.

4.4

Draft a strategy for increasing capacity of system.

4.5

Obtain required approval for response strategy.

5

Implement a process of on-going improvement as appropriate

5.1

Develop an implementation plan appropriate to the organisation.

5.2

Implement plan, as appropriate.

5.3

Monitor implementation.

5.4

Modify implementation plan, as appropriate.

5.5

Identify next capacity constrained process and take action.

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 apply the theory of constraints to a one (1) or more processes and to:

identify the constraint

optimise constraint throughput/output

determine a strategy to reduce the constraint

implement an improvement plan.

Must provide evidence that demonstrates sufficient knowledge to interact with relevant personnel and be able to use the theory of constraints to improve process throughput, including knowledge of:

theory of constraints, including five focussing steps, types of constraint and methods of optimising process throughput

operations of the process and process steps

approaches to reducing the constraint

strategic plans for reducing the constraint.

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.

Constraint (something that prevents or makes it harder for the organisation to achieve improved performance) includes one or more of:

internal or external to the organisation

physical (e.g. equipment or material-based)

process-based (e.g. inefficient or wrong processes/policies/logistics)

people-based (e.g. poor training, communication)

market-based (e.g. lack of demand).

Non-productive time includes one or more of:

quality losses

downtime

other availability losses.