Unit of competency Outline

Date retreived
23/07/2026 8:50 PM AWST

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Mistake proof a production process

Mistake proof a production process

Unit of competency
National Code
ICPSU486C
State Code
D3281
TGA Status
Replaced
DTWD Status
Replaced
Current Release Number
1.00
Current Release Date
05/07/2010
View on TGA
State Implementation and Classification
Approved Date
09/09/2014
Field of Education
080317 - Quality Management
Original Release Date
09/09/2014
Nominal Hours
60
Description
This unit describes the performance outcomes, skills and knowledge required to focus on preventing errors/backsliding to a previous behaviour.
Notes
Elements and Performance Criteria
1. Analyse the process
  • 1.1. Identify sources of variability/non-conformance in the process
  • 1.2. Identify critical control points in the process
  • 1.3. Analyse causes of variability/non-conformance
2. Develop preventive techniques/systems
  • 2.1. Liaise with team members and other people to develop mistake proof method of performing operation
  • 2.2. Test and validate mistake proofing
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 the workforce has 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 and assessment reflect change
  • 4.6. Audit change at agreed period/cycle
  • 4.7. Take action on any observed deviation
5. Seek improvements
  • 5.1. Observe changes against enterprise expectations for production
  • 5.2. Analyse process against enterprise expectations for production
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.
Mistake proofing may include:
sometimes known as baka-yoke/poka-yoke - a manufacturing technique of preventing mistakes by designing the manufacturing process, equipment, tools and components/subassemblies so that an operation literally cannot be performed incorrectly; an attempt to perform incorrectly, as well as being prevented, is usually met with a warning signal of some sort.
Procedures may include:
procedures includes all work instructions, standard operating procedures, formulas/recipes, batch sheets, temporary instructions and similar instructions provided for the smooth running of the plant. They may be written, oral, computer-based or in some other form
for the purposes of this Training Package, procedures also includes good operating practice as may be defined by industry codes of practice (eg Good Manufacturing Practice (GMP), Responsible Care) and government regulations.
EVIDENCE GUIDE
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

Critical aspects for assessment and evidence required to demonstrate competency in this unit
Evidence of the ability to:
the competent team leader will be able to analyse their process and implement systems to ensure the process is mistake proof and the operators work in a predictable way with little or no chance of mistake. Evidence of actions taken to mistake proof the process should be available
one complex project on standardisation of a process or several simpler projects will be needed to gain sufficient evidence.

Context of and specific resources for assessment
Assessment must ensure:
assessment needs to occur in a workplace implementing competitive manufacturing or by using a suitable project
access to an organisation using a competitive manufacturing approach.

Method of assessment
A range of assessment methods should be used to assess practical skills and knowledge. The following examples are appropriate for this unit:
direct questioning combined with review of portfolios of evidence and third party workplace reports of on-the-job performance by the candidate.

Guidance information for assessment
Holistic assessment with other units relevant to the industry sector, workplace and job role is recommended, for example:
ICPSU684C Determine and improve process capability.
Replaces
State Code National Code Title Type
D0531 ICPSU486B Mistake proof a production process Unit of competency
Replaced By
State Code National Code Title Type
AUP14 ICPSUP486 Mistake proof a production process Unit of competency