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CONSULTATION DRAFT OF PROPOSED DIPLOMA IN COMPETITIVE MANUFACTURING Background There are a series of existing qualifications on the NZ Qualifications Framework that recognise Competitive Manufacturing skills. These are the level 2 National Certificate in Competitive Manufacturing and the level 4 National Certificate in Competitive Manufacturing (with an optional strand in facilitation). Descriptions of these qualifications are attached as an appendix for your information. The full details are available on the NZQA website. The diagram below sets out the concepts developed by the Competitive Manufacturing consortium around linking qualification development to participants at different levels in an organisation. It is provided here to help illustrate the way in which the qualifications provide a possible staircase for development and the types of roles envisaged at the various levels of qualification. PROPOSED NATIONAL DIPLOMA IN COMPETITIVE MANUFACTURING Purpose: This qualification is for change agents and facilitators of competitive manufacturing who require a level of competence to interact between senior management and operational staff. The qualification develops knowledge and skills required to analyse and map a value stream, develop and set goals and measures to monitor and report on competitive manufacturing activities, and to facilitate holistic culture improvement. The remainder of the qualification allows development of specific supporting skills for the introduction of continuous improvement activities in an organisation. The optional strands allows those wishing to move into improve their Competitive Manufacturing technical skills or facilitation of competitive manufacturing teams to gain the skills and knowledge required. The qualification is designed to afford the maximum scope for career development within a range of processing industry disciplines that may include; administration, production, and value chain support areas. Content: The following skills would be common to all holders of the qualification: Skills required to analyse and map a value stream Develop and set goals and measures to monitor and report on competitive manufacturing activities To facilitate holistic culture improvement One of the following skills would be required: Lead a Competitive Manufacturing strategy Lead a Competitive Manufacturing strategy in a SME Lead a Competitive manufacturing strategy in a jobbing shop environment Five further skills are required from the following: Improve a value stream in a competitive manufacturing organisation Develop strategic plans for implementing competitive manufacturing in an organisation Manage relationships with non customer external organisations for a competitive manufacturing organisation Manage people relationships in a competitive manufacturing organisation Develop a communication strategy to support production in a competitive manufacturing environment Determine and improve process capability in a competitive manufacturing organisation Apply six sigma to process control and improvement in a competitive manufacturing organisation Develop a documentation control strategy in a competitive manufacturing organisation Develop and manage sustainable energy practices in a competitive manufacturing organisation Develop and manage sustainable environmental practices in a competitive manufacturing organisation Facilitate the development of new product in a competitive manufacturing organisation An optional strand in Technical Skills would require five of the following skills: Develop quick changeover procedures in a competitive manufacturing organisation Develop Just in Time system in a competitive manufacturing Design process layout in competitive manufacturing organisation Develop a levelled pull system for manufacturing in a competitive manufacturing organisation Optimise cost of product in a competitive manufacturing organisation Undertake value analysis of product costs in terms of customer requirements Analyse cost implications of maintenance strategy in a competitive manufacturing organisation Manage 5S system in a competitive manufacturing organisation Implement a special improvement event in a competitive manufacturing organisation Design an experiment in a competitive manufacturing organisation Manage the development of enterprise systems in a competitive manufacturing organisation Establish information collection requirements in a competitive manufacturing organisation Develop a proactive maintenance strategy in a competitive manufacturing organisation Adapt a proactive maintenance strategy to the process manufacturing sector in a competitive manufacturing organisation Adapt a proactive maintenance strategy for seasonal or cyclical manufacturing in a competitive manufacturing organisation Further Facilitation Strand A further facilitation strand has also been suggested that would allow upskilling in the management of people, the development of business processes and systems, the leading of people and organisational development skills. These skills would be selected from those already registered by other standards setting bodies on the national qualifications framework, and could be delivered by providers in generic management skills. APPENDIX ONE: CURRENT NATIONAL CERTIFICATES IN COMPETITIVE MANUFACTURING National Certificate in Competitive Manufacturing (Level 2) Purpose: This qualification is for employees new to competitive manufacturing. The qualification recognises the knowledge and skills of competitive manufacturing systems within either an introductory or technical application. The introductory application allows operators to become actively involved in the development and implementation of processes and systems that will improve reliability, availability and condition of equipment while also significantly improving production capacity and product quality. The technical application allows those moving directly to technical support and leadership roles to develop skills to support the implementation of competitive manufacturing. The qualification is designed to afford the maximum scope for career development within a range of processing industry disciplines that may include administration, production, and value chain support areas. Content: The following skills are common to all holding the National Certificate Apply competitive manufacturing practices in a competitive manufacturing organisation Sustain process improvements in a competitive manufacturing organisation Manage the impact of change on own work in a competitive manufacturing organisation Interpret product costs in a competitive manufacturing organisation Undertake root cause analysis in a competitive manufacturing organisation To complete the qualification a trainee needs to have four of these skills: Use core quality management tools Basic knowledge of establishing improvements in a manufacturing environment Basic knowledge of workflow management in a manufacturing environment Apply quick changeover procedures in a competitive manufacturing organisation Apply Just in Time (JIT) procedures in a competitive manufacturing organisation Apply cost factors to work practices in a competitive manufacturing organisation Apply 5S procedures in a competitive manufacturing organisation Monitor process capability in a competitive manufacturing organisation Complete quality control tests and report results in a competitive manufacturing organisation Use planning software systems in a competitive manufacturing organisation Use System Control and Data Acquisition (SCADA) systems in a competitive manufacturing organisation Use sustainable energy practices in a competitive manufacturing organisation Use sustainable environmental practices in a competitive manufacturing organisation Contribute to a proactive maintenance strategy in a competitive manufacturing organisation The technical strand is optional and requires a minimum of four skills: Facilitate a Just in Time (JIT) system in a competitive manufacturing organisation Improve cost factors in work practices in a competitive manufacturing organisation Analyse manual handling processes in a competitive manufacturing organisation Lead 5S in a competitive manufacturing organisation Undertake process capability improvements in a competitive manufacturing organisation Mistake proof a production process in a competitive manufacturing organisation Facilitate use of planning software systems in a competitive manufacturing organisation Facilitate System Control and Data Acquisition systems in a competitive manufacturing organisation Assist in implementing a proactive maintenance strategy in a competitive manufacturing organisation And further six skills are required from the first or second list above or the following list: Implement a competitive manufacturing system in a competitive manufacturing organisation Ensure process improvements are sustained in a competitive manufacturing organisation Lead change in a competitive manufacturing organisation National Certificate in Competitive Manufacturing (Level 4) Purpose: This qualification is for leaders in competitive manufacturing who require a level of competence to interact between members of their team and management. The qualification develops knowledge and skills required to lead change, implement a competitive manufacturing system and ensure process improvements are sustained. The optional strand allows those wishing to move into facilitation of competitive manufacturing teams to gain the skills and knowledge required. The qualification is designed to afford the maximum scope for career development within a range of processing industry disciplines that may include; administration, production, and value chain support areas. Content: The following skills are common to all holding the National Certificate Implement a competitive manufacturing system in a competitive manufacturing organisation Ensure process improvements are sustained in a competitive manufacturing organisation Lead change in a competitive manufacturing organisation Two of the following skills are required: Facilitate a Just in Time (JIT) system in a competitive manufacturing organisation Improve cost factors in work practices in a competitive manufacturing organisation Analyse manual handling processes in a competitive manufacturing organisation Lead 5S in a competitive manufacturing organisation Undertake process capability improvements in a competitive manufacturing organisation Mistake proof a production process in a competitive manufacturing organisation Facilitate use of planning software systems in a competitive manufacturing organisation Facilitate System Control and Data Acquisition systems in a competitive manufacturing organisation Assist in implementing a proactive maintenance strategy in a competitive manufacturing organisation Five further skills are required from the list above and /or the following: Collect data for a specified purpose Basic knowledge of workflow management in a manufacturing environment Undertake proactive maintenance analyses in a competitive manufacturing organisation Assist in implementing a proactive maintenance strategy in a competitive manufacturing organisation Analyse and map a value chain in a competitive manufacturing organisation Manage a value chain in a competitive manufacturing organisation Manage people relationships in a competitive manufacturing organisation Develop quick changeover procedures in a competitive manufacturing organisation Develop a Just in Time (JIT) system in a competitive manufacturing organisation Optimise cost of a product in a competitive manufacturing organisation Undertake value analysis of product costs in a competitive manufacturing organisation Manage a 5S system in a competitive manufacturing organisation Develop the application of enterprise systems in a competitive manufacturing organisation Establish information collection requirements in a competitive manufacturing organisation Top