The production process

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					   Ma                     Module 2 The production process

The production process
Introduction to Module 2
The manufacturing industry is dominated by processes and systems. These ensure that
products are produced efficiently, competitively and to the required quality. Many employees
will only be aware of their own job within the production process, however having an
overview of the whole process will help learners to understand their own contribution and the
impact that their role has on the work of others.

This module takes the learner through the process from goods inward to quality checks and
handover. The module can be delivered as a sequential package or teachers can select
individual themes that are relevant to particular learners’ needs, e.g. stores personnel may not
be concerned with machinery checks.

In this module learners have the opportunity to practise skills which underpin the production
process. The focus pages aim to help the learner to:
 understand the production process
 check in stores and perform stock control
 follow instructions
 use machinery
 work with time
 report and record problems and faults
 participate in team meetings.

It would not be possible to cover the wide range of manufacturing settings in these materials.
Teachers may need to support learners to apply the skills taught in this module to their own
area of work.

Ma   Module 2 The production process

   Ma                     Module 2 The production process

Skills checklist                                                                             2:0
The production process is very complicated. It begins with materials coming into the factory
and ends with products being despatched to customers.

Each person in the organisation plays a part in production and everyone needs to work
together to produce quality goods on time. It helps to know the part you play and how your
work affects others in the company.

The skills listed in the following table are all important to different parts of production. You
may need all of these skills or only some of them. Tick the skills you are confident about
already. Use the materials to work on skills that you have not ticked. Check the list again
later to see if you have improved.

Skills for the production process                                    Now             Later
Understanding the production process

Checking in goods

Managing stores and stock control

Following written instructions and job specifications

Following spoken instructions

Using machinery and recording downtime

Reporting problems and faults


Ma   Module 2 The production process

     Ma                         Module 2 The production process

PAGES 2:1–2:2
The production process
Occupational setting
Every learner’s experience of the production process will be different, depending on the area of manufacturing
in which he or she works. However, understanding their role in the process will help each learner to understand
their contribution and to recognise the importance of doing the job well. This focus page aims to take a look at
the production process and introduce some of the vocabulary associated with it. It provides an introduction to
the other themes in this module.

Examples from the workplace where the production process, or part of it, is exemplified, e.g. process sheets
Pre-prepared cards/sticky notes
The production process from the Source material (0:16)

Learning outcomes
1    To understand the production process and identify a role within it (focus page, Task 1)
2    To link specialist vocabulary with different parts of the process (focus page, Task 1)

Suggested teaching activities
    Identify with learners what ‘the production process’ means.
    Discuss with learners the process of production in the place where they work. List on a flip chart the
     different areas of work mentioned. How do they link together?
    Ask learners to identify the different areas of production at their workplace and to write each of them down
     on a piece of card or a sticky note. Get them to put the different areas into the order in which they occur.
    Discuss real scenarios where the process breaks down. What are the consequences of one person not doing
     their job properly?

Focus page
    Using the example of the ‘Makeitkwik Lemonade Company’ on the focus page, trace through the simplified
     process shown. Make sure learners understand and can use this graphical representation. Show learners
     other representations of production processes from the workplace, such as flow charts.
    Relate the lemonade production process to a process familiar to the learners and draw out similarities and
     differences. Use sticky notes to track each stage of the production process familiar to learners and arrange it
     in the correct sequence.
    Discuss the role of a machine operative within one of the production stages. What are the consequences of
     them not doing their job well?
    Relate the above to the job roles of learners and the consequences of them not doing a good job. It is
     important to point out at this stage that there may be many reasons for not doing a job well; this is not about
     putting blame on anyone but to see how each process links together.
    Discuss specialist words associated with manufacturing and list some from the experience of the learners.
     Look at some of the specialist words used on the focus page, such as ‘palletise’.

    Curric. refs            NOS/NVQ                   Key Skills
    Rw/L1.2                 219                       C1.1

Task 1
Make a diagram of the production process where you work
 Provide learners with copies of The production process diagram from the Source materials. This can be
   altered to suit the requirements of the learner.

    Ma                         Module 2 The production process

   Questions 1–2: Using the production processes that learners compiled on the focus page, assist learners in
    deciding on specialist vocabulary used in their own workplace. Help learners to write these words into the
    list on the task page. Some learners may have specific terms to describe generic processes. Encourage them
    to add these to the list.
   Questions 3–5: Help learners to transfer words from the list to The production process diagram. This
    diagram will not suit all processes. If necessary, provide learners with an alternative plan.
   Use the diagram on the focus page for practice in explaining a procedure, using sequencing words like
    ‘first’, ‘then’, ‘after you’ve …’.

If the learner has difficulty
 Assist the learner in spelling technical words.
 Use the cards/sticky notes from the focus page to assist the learner in deciding on the process before
     committing themselves to paper. Experiment with the sequence and talk through the plan to confirm that it
     is correct.
 Dyslexic learners may be able to see the ‘big picture’ clearly, but they will need help to break down the
     process into chunks or stages. Again, sticky notes or moveable cards will help.

Ask learners to think about their own part in the production process. They should think about the things that
could affect their stage of production and how this might impact on the whole process. Ask learners to present
the information as a table that identifies the problems, the causes, and the impact on production. They may also
be able to add a column with suggested solutions.

Theme assessment
Use a digital camera to photograph different aspects of the production process in the workplace. Label the
photos and use them for induction of new operatives.

 Ma                    Module 2 The production process

The production process                                        (Focus) 2:1

                                   Quality checks
                                 take place at every
                                    stage of the

 Deliver bottles,
 tops and                                                   Distribute

                                                            Palletise and
 Store                                                      store
 and materials

 Wash and
 rinse bottles


                                                            Label and
      Mix and blend            Fill bottles      Add caps   code

                      One job is to check
                      that all the bottle caps
                      are on properly.

   Ma                    Module 2 The production process

The production process                                                           (Task) 2:2

Task 1
You will need The production process diagram from the Source material.
1 Think about the things that happen in your workplace.
2 Cross off the words on the list below that are not relevant to what happens where you
  work. Add some extra words that are relevant.

   prepare           machine               shape          store          join
   mix and blend     assemble              mould          process        deliver
   fill              finish                intake         pick           distribute
   label             package                wrap          palletise      wash
   inspect           code                   drill          cut           press
   __________        __________            __________     __________     __________

3 Using The production process diagram, write in the name of the company you work for
  above the factory.
4 Write in what happens at each stage of the production process in the place where you
5 Mark on the diagram where you fit in.

    Ma                         Module 2 The production process

PAGES 2:3–2:4
Checking in and stores – goods inwards
Occupational setting
Taking goods and materials into storage is a frequent and essential part of manufacturing. The supply of
materials in the correct quantity and of suitable quality is vital to the whole production process and there is a
heavy reliance on delivery and stores to get this right. Understanding the layout and abbreviations on delivery
sheets is essential to the task. Accuracy must always be emphasised when dealing with codes and learners
should be encouraged to take their time when checking codes and to double-check them. The skills at this end of
the production process are similar to those required for dispatch.

Examples of delivery notes or dispatch sheets from the workplace

Learning outcomes
1   To understand and use the organisational features of a delivery note to locate information (focus page, Task
2   To recognise words written as abbreviations (focus page)

Suggested teaching activities
   Examine some delivery notes. Point out that delivery notes come in many different formats and that the
    word ‘manifest’ is another term used to describe delivery notes. Make sure the meaning of this word is
    understood and find out what similar documents are called in the workplace. Pick out some of the common
    features of these documents: tabular format, rows and columns, abbreviations, codes, etc.
   Discuss and identify the range of skills that are involved in the checking in and dispatch process. List these.
    Emphasise the need for total accuracy and checking when dealing with deliveries or dispatch.

Focus page
   Project the focus page using PowerPoint or an OHT. Look at it together and find all the features listed for
    the sample delivery manifest.
   Ask the learners what is being delivered. Discuss what the word ambient means and check if anyone knows
    what other raw materials could be coming in that require storage in an ambient temperature, e.g. sugar,
    flour. This need not be a very long discussion but it will help learners to understand where to look on the
    delivery note to see what is being delivered. They need to be made aware that not only will they have to
    check the codes for accuracy but they will have to store the goods appropriately, and they cannot do this
    without understanding the nature of the goods being delivered. If learners are from a range of settings
    discuss the different storage requirements of different materials.
   Extend the discussion by asking questions such as, ‘What time did the delivery arrive at the store?’
   Find the seal number. Discuss the fact that many delivery vehicles are fitted with a security seal on the
    trailer door to ensure that the consignment is not tampered with. When the vehicle arrives at the factory, the
    seal on the vehicle should be the same as on departure from the supplier. Ask, ‘What is the seal number of
    this consignment?’
   Point out the use of abbreviations for the words containers and pallets and stress that it is very common to
    make words shorter on forms. Ask learners why they think abbreviations are used (because of limited
    space). Write on the board five other abbreviations commonly used in manufacturing, and ask learners what
    they think the whole words are. Point out that there are lots of clues in an abbreviation, as it always uses
    letters from the whole word.
   Ask learners to find the product identifiers – the code numbers for the products.

    Ma                          Module 2 The production process

  Finally ask learners to find the codes for specific products, e.g. ‘What is the product identifier code for the
   raw product that arrived in 4 containers?’ (Note: codes are covered in more detail in the next theme.)
 Ask learners to work in pairs to talk each other through the checks that may need to be completed on this
   delivery sheet.
 Curric. refs             NOS/NVQ                    Key Skills
 Rt/E3.5                  107                        N/A
 Rt/E3.7                  203
 HD1/E3.1                 207

Task 1
Extract information from a delivery note
 Explain that all the information for this task can be found in the example on the focus page.
 Remind learners how to use the format and headings if required.

If the learner has difficulty
 Check that the learner is able to use the tabular format and can track across the rows. Suggest using a guide
     or ruler to assist with this. Some dyslexic learners have difficulty with tracking and may need additional
     support with this.
 Make sure the headings are understood and all language interpreted.
 Some learners may benefit from writing critical words such as ‘courgette’ on a sticky note or a small card
     and keeping a notebook of words and abbreviations that are important to them.

Investigate some of the terms used on the manifest sheet, such as ambient, preferred ambient, and other job-
specific terminology related to checking in loads. Encourage learners to keep a notebook of words and
abbreviations that are important to them.

Theme assessment
Ask learners to look at a dispatch note or loading sheet from their own workplace. What are the similarities and
differences? Talk through the process with a partner and create a checklist of jobs that must be completed when
dispatching goods.

   Ma                      Module 2 The production process

Checking in and stores –                                                                 (Focus) 2:3

goods inwards
Goods and materials that arrive at the factory are accompanied by a delivery note. This
contains lots of information, which is used for different purposes.

   Use the headings to           Find out the meaning of                   Make sure you know
   see what information          any abbreviations. For                    which pieces of
   is listed below.              example:                                  information you need
                                  Plts = pallets                          for the job you are
                                  Conts = containers                      doing.
                                  Qty = quantity

 DELIVERY MANIFEST                                  Ship to: SAL-TECH LTD Brassington Park
 Depot: 8549 / Fair Oak                             Shipment: 30285
 Trailer: 9549030285
 Product        Product      Description     Plts       Qty       Conts          Qty         Storage
 Identifier     Type
 835850         Non-proc     York            10         250 kg    0                          Priority
                             potatoes                                                        ambient
 835980        Non-proc      White onions    4          200 kg    0                          Priority
 849589        Non-proc      Plum            0                    22             15 kg       Preferred
                             tomatoes                                                        ambient
 849348        Non-proc      Courgettes      0                    10             25 kg       Preferred
 835809        Proc          Mushrooms       0                    4              10 kg       Priority
 835994        Non-proc      Carrots         5          225 kg                               Preferred
 TOTAL                                        19                  36
 Seal number on arrival:     Arrive store: 13:35                 Start unload: 13:55
                             Depart store: 14:30                 Finish unload: 14:25

  Reading information set out as a table                          Take extra care with
  Step 1: Look over the information quickly                       codes. Sometimes
  to get the general feel of it.                                  they all look similar.
  Step 2: Trace across the rows → and
  down the columns ↓ to locate specific
                                                        849960        Non-proc           Can you
  Step 3: Carefully read the information                849096        Non-proc           see any
  where the row and column meet.                        849590        Non-proc           matching
                                                        849960        Non-proc           codes here?

    Ma                    Module 2 The production process

Checking in and stores –                                                          (Task) 2:4

goods inwards
Refer to the delivery note on the focus page to complete this task.

Task 1
a   Which raw material was delivered on 4 pallets?           ___________________________
b   Which raw material was delivered in 4 containers?        ___________________________
c   Which raw material was delivered on 5 pallets?           ___________________________
d   Which raw material was delivered in 10 containers?       ___________________________

a   How much should each container of courgettes weigh?               _________________   kg
b   How much should each pallet of carrots weigh?                     _________________   kg
c   How much should each container of mushrooms weigh?                _________________   kg
d   How much should each pallet of onions weigh?                      _________________   kg

3 How should these raw materials be stored? Tick your answer.

                         Priority      Preferred      Preferred        Priority
                         chilled        chilled       ambient          ambient
    a   Tomatoes
    b   Potatoes
    c   Carrots
    d   Mushrooms

    Ma                         Module 2 The production process

PAGES 2:5–2:7
Checking in and stores – checking codes
Occupational setting
Codes are used extensively throughout the manufacturing process to track and monitor materials and products.
Most products can now be traced back to the raw materials that they are made from. This enables companies to
identify faulty batches that may need to be withdrawn and also to identify poor-quality suppliers. Codes are
complex; reading and recording codes requires good attention to detail and accuracy.

OHT with lists of different codes
Several slips of paper with small lists of codes (can be matched in pairs)
Audio equipment

Learning outcomes
To read and compare large numbers and codes (focus page, Tasks 1, 2, and 3)

Suggested teaching activities
   Using an OHT, flash up a series of codes one at a time and ask learners to write down how many digits
    and/or letters they think they see each time. Make codes composed of 4, 5, 6 and 7 digits and/or letters.
    Check learners’ responses and ask which codes they found easier to ‘read’ and which they found harder and
    why. (The longer the code, the harder it is to see at a glance how many parts it contains.) Note: the time that
    learners see each code for needs to be longer if learners are dyslexic.
   Continue with this exploration of the strategies we use to handle large numbers by asking learners how they
    put a new number into their mobile phone. (Do they divide the number up into threes, or into other
    manageable chunks?) Ask them how they would tell another person what their phone number is. Get one or
    two to demonstrate by telling you their phone number – write it down on the board as they tell you, putting
    the number into ‘chunks’ the way they say it. Try to establish that most of us use some sort of strategy (e.g.
    dividing the number into manageable chunks) when we handle large numbers.
   Link this introductory activity with checking codes on labels in various manufacturing scenarios by giving
    each learner a slip of paper with a list of six 7-digit codes. The object of the exercise is to get them to look
    very carefully at their set of numbers and then find the one other person in the group with exactly the same
   Discuss with learners the strategies they used to make sure that they had found the correct partner, e.g.
    checking off numbers by grouping them into chunks of three or two digits; matching each digit one to one;
    using a piece of card/paper as a line guide to help go through the numbers. This exercise could be
    particularly difficult for those dyslexic learners who have a tendency to reverse the order of digits, e.g. 12
    can become 21 quite easily. Some dyslexic learners invert/reverse the actual digit, e.g. 9 becomes 6. The
    dyslexic learner with directional difficulties may be heartened by the fact that with codes it does not matter
    which way you check them off, providing the digits retain the same order.

Focus page
   Look together at the focus page and start by asking the learners what product is being delivered. Extend the
    discussion by asking questions such as, What is the ‘Best Before’ date? What is the week number? What is
    the time? Learners need to be made aware of the great importance of the correct identification of different
    aspects of the product.
   Ask the learners to identify some codes, e.g. What is the product identifier number? What is the SSC code?
    Discuss the importance of the accurate reading of codes.
   Ask learners if they have any strategies for reading/remembering/checking codes. Share strategies with the
    rest of the group.

    Ma                          Module 2 The production process

   Curric. refs              NOS/NVQ                   Key Skills
   N1/L1.1                   107                       N/A
   Rt/L1.4                   203
   Rw/L1.3                   207
Task 1
Read and compare large numbers on a ‘goods received’ note
 Remind learners of the strategies that can be used to check one number against another.
   – Counting how many digits there are in both numbers and seeing if they agree.
   – Splitting the number into manageable bits.
   – Saying the number aloud as you check it.
   – Noting if there are any parts of the code that are the same throughout a series.
 Guide learners to use helpful study skill strategies when doing a task like this, e.g. ticking off each number
   in the task and on the Finished Goods Report when it has been found and checked for match, so that there
   will be no doubt about which goods cannot been located.

If the learner has difficulty
 Cover up all the numbers in the task except the one the learner is working on. This will eliminate the visual
     distractions caused by numbers that look very similar. (Alternatively, cut out the codes. Cover and reveal
     one digit at a time.)
 Encourage the learner to ‘chunk’ the number in question and then to take just the first ‘chunk’ and to check
     it against those in the delivery note to find which one(s) are going to be a possible match. This process of
     elimination and reducing the load is what learners with good study skills do automatically.
 Support the learner to do the same with another number and then watch them do one on their own.
 If there are still difficulties, ask the learner to draw lines where they feel digits naturally ‘chunk’ together,
     e.g. 190/50/45. Get them to tick each ‘chunk’ if it matches.
 If difficulties persist, give the learner some 3- and 4-digit numbers to cross-check. If they can do these
     without difficulty then it is the size of number that is causing the difficulty and it is probably a visual
     problem. They will need a lot more practice at using the suggested strategies until they find a method that
     works for them.

Ask learners to look at code structures from their own workplace, or alternatively give them a range of product
labels. Identify the common features, such as the number of digits, common letters used, codes that have
meaning such as working week or product type.

Task 2
Match codes
Point out the tip that suggests using a ruler or some other straight edge to help track across data. Impress on
learners that line guides are used for speed reading and in offices where for example statistics are studied, where
the work involves studying many rows and columns of large numbers.

If the learner has difficulty
 Make sure that the learner ‘chunks’ each number to start with. Suggest they start with chunks of three, e.g.
     00232340 becomes 002 323 40. This is particularly important for dyslexic learners, due to the memory load
     and sequencing of numbers.
 Strongly insist on the use of a straight line to track across, or cover the rest of the list with paper to improve
     tracking and focus.
 Learners experiencing a lot of difficulty may benefit from being given just three codes to compare at a time.

Give the learner some pairs of large mixed codes (i.e. letters and numbers randomly presented on the page) and
ask the learner to sort and match.

    Ma                         Module 2 The production process

Task 3 (Audio 10)
Listen to some codes and check them off on a delivery sheet
 Make sure learners understand the task.
 Play/read codes one at a time.
 Point out the tip.

If the learner has difficulty
 Provide learners with a piece of card, to act as a straight edge and cover the codes not being dealt with, and
     get them to move the card down the list until they spot what they are looking for.
 In this type of activity, learners will be able to ask for codes to be repeated. Encourage learners to do so for
     this exercise.
 It may help learners to repeat the code that they hear to themselves before they mark it off on the delivery

Learners can read a list of codes to a partner who checks them off a list. Roles are then reversed.

Theme assessment
Ask the learner to track a product through the whole production process from when it arrives in the stores to
when it is dispatched. They need to identify the relevant product code on all the paperwork related to this
product and anywhere else it is displayed – for example, the code may appear on delivery sheets, the outer case,
scanners, racking, the dispatch note, etc. Each workplace will have its own system and use of codes, so the
teacher will need to adapt this assessment to suit the specific workplace.

   Ma                     Module 2 The production process

Checking in and stores –                                                         (Focus) 2:5

checking codes
Codes are used throughout the manufacturing process:
 to monitor incoming products
 to monitor outgoing products
 to track what is produced and packaged in-between.

Many jobs involve checking and recording codes. Look at this product label.
                                                         There is often more than one code
                                                         on a product label. Look for
                                                         descriptions that tell you what the
   Abbreviations                                         code refers to.
   are used to
   save space.

   PI No here

   UPC means
   product code.

 Some codes
 are used as
 parts of other

Reading, recording and checking codes requires great care, especially when the codes are
long. Here are some tips to help you.

 First look at the code to see how many letters or numbers it should have.
 Split the code into smaller chunks, e.g. 405382 can be checked as 405 382.
 Check the code a second time to make sure that you didn’t make any mistakes – be extra
  careful if a letter or digit is repeated.
 If you have a long list of codes, use a line guide such as a piece of paper or a ruler to help
  you keep your place.
 Say the digits aloud as you check.

   Ma                    Module 2 The production process

Checking in and stores –                                                         (Task) 2:6

checking codes
Task 1
The Finished goods report below shows that 12 batches
                                                               Read through the codes
have been manufactured and released for packing.                 slowly and carefully, a few
However, only 10 of these batches are in Goods Out.              digits/letters at a time.
                                                               Cross off the items on the
Check the Finished goods report against the batch                report sheet as you find
codes below. Which batches are missing?                          them.

Batches __________________________and ____________________________

 FINISHED GOODS REPORT            No 833002                         Page No: 1 of 1
 Goods released at 12:28 on 06/09/05
    ID      LOCN          BATCH        QTY                                  TOTAL
     01           S27102          YP048228              300                    300
     02           S27112          YP032174              300                    600
     03           S27210          YP033274              300                    900
     04           S27212          YP048828              300                   1200
     05           S27510          YP048832              300                   1500
     06           S27722          YP033274              300                   1800
     07           S27943          YP075482              300                   2100
     08           S29734          YP046432              300                   2400
     09           S29973          YP048882              300                   2700
     10           S29977          YP083875              300                   3000
     11           S29989          YP083894              300                   3300
     12           S29999          YP083857              300                   3600
 12 Pallets                                                               Total 3600

  YP048832                 YP046432                      Some codes have
                                                         ‘chunks’ of letters or
  YP083857                 YP048882                      numbers that are the
                                                         same (e.g. YP0). These
                                                         may relate to a particular
  YP033274                 YP032174                      product or batch. This
                                                         means that there are
                                                         fewer digits or letters to
  YP083894                 YP048228                      check.

  YP033274                 YP075482

   Ma                     Module 2 The production process

Checking in and stores –                                                          (Task) 2:7

checking codes
Task 2                                                            Use a ruler or piece
Which rows have codes that are all the same?                      of card to help you
Tick the rows where all the codes match.                        track across the
X Cross the rows where the codes do not match.                    rows of figures.

   00232340                      00232340                     00232340       
   66009123                      66009132                     66009132
   91005000                      91005000                     9100500
   44448765                      44448765                     44448765
   00000999                      0000999                      00000999
   50084329                      50084329                     50088329
   22044600                      22044600                     22044600
   01939220                      01939220                     01939220
   98765432                      98765432                     98765432
   42700025                      42700025                     42700052

Task 3 (Audio 10)
Chris is calling out codes from a delivery. Tick off the codes as you hear Chris call them out.
The first one has been done for you. Has anything been left out of the delivery?

               PXB528C        
               BPX 825C
               BPX 825Z
               BPX 825P
               BPX 825H
               BPX 825D

                          Tips                                               PXB528C
                          Chris does not call the codes out in the
                          order they appear on the delivery note.
                           Use a piece of card to cover the list.
                           Repeat the code you hear to yourself.            PXB 528 C
                           Break it up into smaller chunks.
                           Move the card down until you see the
                             code you want.

    Ma                          Module 2 The production process

PAGES 2:8–2:9
Checking in and stores – stock control
Occupational setting
Manufacturing revolves around the movement of stock. Particularly important to this process is the monitoring
and recording of stock levels in order that production can be fed with a continuous supply of materials without
running out. Likewise, stock levels of manufactured goods are monitored in order to ensure that levels are
sufficient to meet customer orders. Stock levels can be checked electronically or by a manual count. Weekly
manual stock-taking is still very common in many settings and may involve weighing and measuring as well as
accurate counting of batches. The findings need to be recorded correctly.

Several ‘bags’ of objects, some linked by a theme (see introductory activity)

Learning outcomes
1   To carry out a stock control by counting in batches (focus page, Task 1)
2   To recall multiplication facts for 2, 3, 4, 5 and 10 (focus page, Task 1)

Suggested teaching activities
   Divide the group up into small groups of three or four. Working in different areas of the room, ask each
    group to count the ‘things’ they are given. Ask them to think of at least two ways of doing it. (The ‘things’
    could be: a pile of coins; two sets of playing cards and a few odd ones; a box of random small objects; pens
    and pencils; a pile of receipts.)
   Ask each group to feedback their two methods used for counting. Ask why they used these methods, and
    which one they found the easiest. It should emerge that they had to establish some sort of criteria for
    counting ‘things’ in batches, e.g. coins by type and then into £1 piles; cards into tens, or into black and red
    cards, or into suits; blue pens/black pens/pencils in groups of ten, etc.
   Record all the different ways of counting used. Draw out the general point that if this was stock on shelves
    in the workplace, the stock would always be linked by type before counting took place. It requires careful
    reading of labels and stock lists to link goods not only by name but very often by code as well.
   Ask groups what they noticed about trying to count each item one by one. Were there any advantages?
    When it would be sensible to use this method? (e.g. when you have a small number of items; when you
    actually count how many batches/piles/rows you have formed) Ask the groups what they think the
    disadvantages of counting items singly may be (losing your place easily if distracted – have to start again).
   Note: the above activities can be completed with individuals working on a one-to-one basis with a teacher.
   Summarise the activity by linking it firmly with the activity of stock control in learners’ workplaces.
    Question learners about whether they have been involved in counting stock and explore the different
    methods and skills involved. Although some learners may be involved in weighing and recording stock,
    most will be counting stock items in boxes or on pallets. This will involve batch counting.

Focus page
   Talk generally around the page, picking up on the things highlighted during the introductory activity.
   Ask the learners to listen to you counting in multiples and to supply the missing number when you i)
    hesitate ii) deliberately miss out a number, e.g. 3, 6, 9, 12, 18, 21; 10, 20, 30, 50, 60. Do this as a bit of fun
    and as quickly as you can, so that no-one feels it is ‘childish’ to be counting.
   Try to get as many calculators as you can – at least one between two – and show learners how to do
    continuous counting by pressing a number on the keypad and then pressing the plus key, then the same
    number again followed by the equals sign: just pressing the equals sign as many times as you want will
    make the number grow by that amount (continuous adding), for example 4, press plus sign, press 4 again,
    press the equals sign, now you only have to keep pressing the equals sign to see the number 4 grow 4, 8, 12,
    16, 20, 24, etc. on the display.

    Ma                          Module 2 The production process

   Ask learners to use the calculator using this method to imagine counting stock on a shelf or in the
    warehouse, e.g. 6 crates with 8 items in a crate; 5 rows of 12 items. Compare answers.
   It should not take long before someone says that it would be a lot quicker if they just multiplied the two
    numbers together in a single operation. You will however have made the point that multiplying is a quicker
    way of doing continuous addition. Give learners several stock-counting scenarios, so that they can use their
    calculators to find the answers. Make sure that learners share the load if there is only one calculator between
   Point out that knowing about the continuous addition way of counting on the calculator is useful but the
    disadvantage may be the ease with which you can lose your place.
   Put emphasis on the strategies learners use and the words they say as they count aloud in batches. Here are
    some examples that learners may suggest:
    Counting in batches of 200:
    – two hundred, four hundred, six hundred, eight hundred, one thousand, one thousand two hundred, etc.
    – two, four, six, eight, ten, twelve hundred. (If this strategy is suggested, discuss what is meant by twelve
         hundred. Ask how learners would record this figure on the stock control sheet.)
    Some learners may use a tally system to record quantities. This can be shared with the group.
   If appropriate, demonstrate the mathematical method shown on the focus page and ensure learners know
    how to use a calculator to multiply. Care must be taken however with the multiplying method that the
    numbers are entered correctly and that the correct function button has been pressed. Learners may need to
    work out a method of remembering the order in which information should be entered.
    Curric. refs             NOS/NVQ                    Key Skills
    N1/E3.5                  107                        N/A
Task 1
Count stock in batches
 Remind learners that they need to identify the product name and code carefully before they start.
 Encourage learners to use the method that suits them best: this may be continuous addition or multiplication
   using a calculator.
 Learners should be encouraged to check their answers and to be wary of large numbers when there are a lot
   of zeros.

If the learner has difficulty
 It is important that learners understand the process that they are using. If this is not the case, return to first
     principles of counting items, grouping items and experimenting with different methods.
 Some learners may get lost in the middle of counting and be unable to hold numbers in their head. Use
     practical activities such as cards marked with the same number and ask the learner to count on as they
     physically move the cards from one pile to another. These learners may find it better to work in pairs or to
     keep a tally. Then complete the calculation using a calculator.

Give the learner some additional stock-counting scenarios with larger numbers involved, e.g. pallets of cans, 20
x 10 x 10 high. Add in the complications of incomplete boxes or containers.

Theme assessment
Ask learners to carry out a ‘mini stock-check’ at their place of work.

   Ma                    Module 2 The production process

Checking in and stores –                                                      (Focus) 2:8

stock control
Stock control involves making sure that there are enough:
 raw materials in storage to meet production needs
 manufactured goods to meet customer demand.

        GOODS IN                                                  GOODS OUT

           Storage –                                                Storage –
         raw materials                 Production               manufactured goods

                                     Quality checks


From time to time, a manual stock check is required.
                                                                    Point to the boxes as
                                                                    you say the numbers.

             Counting in batches may be quicker than multiplying.
             Example: There are 6 boxes with 50 items in each box.

                                                    Fifty ... one hundred … one hundred
                                                    and fifty … two hundred … two
             You could count in 50s like this:      hundred and fifty … three hundred
             or you could count in 50s like this:

                                                    Fifty … one hundred … fifty ... two
                                                    hundred … fifty ... three hundred

     How would you count in 200s? How would you
     count in 500s? How would you count in 1000s?                     Find this
                                                                      information on
     For the item that you are checking:                              the box label
                                                                      or count the
      Count the number of full boxes.
      Find how many items one full box contains.
      Multiply the number of full boxes by the
        number of items in one full box. This tells you
        how many items are in all the full boxes.
      Add on any items that do not make a full box.

   Ma                   Module 2 The production process

Checking in and stores –                                                     (Task) 2:9

stock control
Task 1
You have been asked to do a manual stock check. Fill in the stock sheet to show how many
of each item are in stock.

Stock check
Product code       Item              Quantity
                                                            Point to the boxes as you
Z3570              Bearings                                 count out aloud, or count the
T2848              Grommets                                 boxes first, using your
R7382              Spindles                                 fingers to help you keep
S495               Labels                                   track.

    Ma                          Module 2 The production process

PAGES 2:10–2:11
Checking in and stores – rotating stock
Occupational setting
Checking date codes is an important aspect of managing stores where raw materials or products are perishable
or have a limited shelf life. This is particularly important in the food sector. It involves paying particular
attention to ‘sell by’ and ‘use by’ dates. Stock rotation, particularly in the fresh produce section, must adhere to
stringent Health and Safety regulations. Reading and understanding different date formats is therefore very
important for all concerned in storage.

Cards with a range of date code formats
Chart for months (see Introduction)
Blank card/labels
Products showing date codes

Learning outcomes
To read and understand date codes in a range of presentations (focus page, Tasks 1–3)

Suggested teaching activities
   This module looks at the importance of date order for stock control. It is essential that learners are aware of
    the significance of date codes. If possible look at a range of typical products showing different types of date
    codes (e.g. Sell By, Use By, Best Before).
   Prepare a pile of small cards (or food labels) with different dates in a variety of formats. Put them into the
    middle of a table. Ask learners – who can work in pairs – to take one card at a time and to lay them out on
    the table in date order, with the ‘oldest’ at the top (back). As the task progresses, encourage learners to
    confer with others. This could provide reinforcing opportunities for anyone who is uncertain to match dates
    that are the same.
    Question learners about the strategy they used to sort the dates:
    – Did they find that sorting by the day proved unhelpful?
    – Did they find that they had to sort by year if applicable and then by month and finally by day?
    – Did they have any difficulty knowing how many days are in each month?
    – Did they have any difficulty knowing the order and number of the months, e.g. 08 is the eighth month
         and is August?
    Note: this activity may cause difficulty for some dyslexic learners with sequencing difficulties.
   To support these activities, create a chart of the months of the year written in full, as first three letters and as
    numbers, and give the number of days in the month (e.g. August, Aug, 08, 31 days; November, Nov, 11, 30
    days. Draw attention to the positioning of a zero before numbers 1–9.
   ESOL learners may need additional work on the vocabulary of ordinal numbers, e.g. eighth month, second
    month, etc.
   Summarise the activity by asking for volunteers to come and put on the board one date – supplied verbally
    by you – in as many formats as possible.
   Write on the board ‘Use By’ and ‘Best Before’. Ask learners to explain the subtle differences between

Focus page
   The focus page reviews some of the activities in the introduction. It looks at stock control by date. Ask
    learners to consider where date codes might be found in the workplace, and to think of different date
   Refer learners back to the chart you created to support the activities on the focus page.
   Note: a person newly arrived in this country may be more familiar with a different date format, and you will
    need to spend extra time explaining the system used in the UK. Also, some companies use the American
    system of recording dates (month first). This should be checked before starting.

    Ma                         Module 2 The production process

  Curric. refs              NOS/NVQ                   Key Skills
  MSS1/E2.3                 107                       N/A
Task 1
Match ‘use by’ dates that have different date formats         MSS1/E2.3
 Remind learners to use the month chart if they are in any doubt about the order of months in the year.
 Do one example together to establish that learners are clear about drawing lines to the matching dates.

If the learner has difficulty
 Highlight each date as it is matched so the learner can see more easily what is left to be done.
 Write the dates onto individual pieces of card/paper so the learner can manually sort and match them,
     changing his or her mind until entirely satisfied. Ask the learner to put them into order by months and then
     by date. This ‘hands-on’ approach is very helpful for many learners who need a more kinaesthetic way to
 Dyslexic learners may have difficulties with dates: sequencing of numbers (04/06/06 looks very similar to
     06/04/06). Careful attention to checking will help.

Ask learners to go into the workplace and note the range of Use By/Best Before dates on products from goods in
storage and/or goods out of storage.

Task 2
Sort items into order using the oldest first       MSS1/E2.3
 Remind learners of the different date formats.
 Check with everyone that they are certain about which items are to be used first (the oldest stock).

If the learner has difficulty
Learners may have difficulty with the concept of ‘oldest first’. Relate this to everyday situations such as sorting
people by age, or sorting items in their own store cupboard or fridge. As above, use separate date cards or date
lines to reinforce the concept of time. Calendars can also be used, matching dated items to dates on the calendar.

Have a date-sorting race, using cards with dates in different formats.

Task 3
Write dates in a standard format               MSS1/E2.3
 Check that learners are familiar with the date format they need to use. Refer back to the focus page
    activities. Remind them of what each set of numbers represents.
 Ask learners to make sure to stick to a standard format which always uses two digits, and check that they
    are clear about the use of the zero (e.g. 01/02/04).

If the learner has difficulty
 Take the dates one at a time. Ask the learner to read each date in full to identify the day, month and year,
     and support them in transferring each into the standard date format. Withdraw support as they become more
 If learners are having difficulty understanding month order, refer them back to the focus page and
     encourage them to keep a little card with this information on it.
 Some learners may benefit from having all the dates except the one they are dealing with covered up, or
     each date transferred to a sticky note or small card.

 Make a table by recording the same dates in other formats.
 Give a quick-fire quiz on dates and date formats.

Theme assessment
Find out what date formats are used in the learners’ own workplace and what the date limits are. Some
companies in the food industry will have a storage limit that is given in hours (e.g. 72 hours).

   Ma                    Module 2 The production process

Checking in and stores –                                                (Focus) 2:10

rotating stock
Food products and many manufactured goods need to be controlled by date order. A system
called stock rotation is used to ensure that the oldest stock is used first.

  Different manufacturers write dates in different
   Sometimes the month is written out in full,
      e.g. 10 August 06.
   Sometimes the month is shortened to the
      first three letters, e.g. 10 Aug 06.
   Sometimes a number represents the
      month, e.g. 10-08-06.

                                                                      The energy
  If a date contains just numbers, the day of                         content of the
  the month is written first, then the month,                         batteries cannot
  then the year.                                                      be guaranteed
                     10/08/06                                         after the given

                Day Month Year
            The tenth of August 2006

  The months of the year are numbered in
  the order starting from January:

  01 January                    07 July
  02 February                   08 August
  03 March                      09 September
  04 April                      10 October
  05 May                        11 November
  06 June                       12 December

  If you are sorting stock into date order, put the          The quality of
  months in order first. Then look at the day of             the food cannot
  the month.                                                 be guaranteed
                                                             after the given
  For example, 02/07/06 comes before 01/08/06.               date.

   Ma                    Module 2 The production process

Checking in and stores –                                                            (Task) 2:11

rotating stock
Task 1
Draw lines to match the labels that have the same Use By dates.

  04/06/06           3 Aug                03-08-06          4th June              10 Jun

  06/04/06              10/04/06               04 Oct 06               10/06/07

  06 APR             10TH APR             30 October        30/10/06              04-10-06

Task 2
Compare the dates on these products. Write them in the boxes below in date order, starting
with the one that must be used first.
                                                           Use the oldest products first.

  21st Sept       06/02/06     19th          02         01/6/06        19th April      06/3/06
                               May 06        Nov                       2006

Use first                                                                             Use last

Task 3
Write the dates using the format shown.

  1st May 2008               01/05/08                Aug 6th 07

  22 October 08                                      4 SEP 06

  5th Jan 2006                                       20 MAR 07

  30th November 06                                   3rd FEB 2006

  March 2nd 2006                                     6 OCT 08

    Ma                         Module 2 The production process

PAGES 2:12–2:13
Getting the job done – spoken
Occupational setting
If operatives have team meetings on the factory floor, they have to listen under difficult circumstances. Many
instructions will be given verbally. Sometimes this means assimilating a lot of information and relying on
memory. It is important that learners practise ways of picking out and remembering the jobs they need to do or
the actions they need to follow by listening carefully, particularly to imperatives (both positive and negative),
such as ‘put’, ‘take’, ‘don’t put’ or ‘don’t take’.

Audio equipment
Work instructions

Learning outcomes
1   To use strategies for separating out relevant information from irrelevant details (focus page)
2   To listen for instruction words to identify what should and should not be done (focus page, Tasks 1 and 2)
3   To recognise sequence words in instructions (focus page, Task 1)
4   To know how to clarify and confirm understanding (focus page, Task 3)

Suggested teaching activities
   Introduce the theme by giving learners some muddled instructions about something relevant or interesting
    to them. These muddled instructions should include a lot of irrelevant information (‘By the way, did you see
    X last night?’); instructions in the wrong order (e.g. make your last instruction ‘And before you start any of
    this …’); and detail mixed in with specific instructions (e.g. ‘Even if there is nobody around to help you and
    you are in a hurry, you should still … ’).
   Ask learners what they picked up from the instructions. Elicit the fact that they weren’t ready for them,
    didn’t know who was to do what, had no opportunity to ask questions, etc.
   What is meant by an instruction? Who gives instructions? How are they given? (e.g. verbally, written) How
    can you tell when something is an instruction, as opposed to advice, a question or a comment on progress?
    Often, instructions can be identified by tone of voice and the use of instruction words.
   Write a set of simple instructions on the board (all beginning with an imperative, e.g. ‘take’, ‘leave’,
    ‘move,’ etc. Work with learners to underline the imperatives in each instruction on the board.
   Explain to learners that in the workplace, instructions will often be hidden in the other things people say.
    List instructions of this type on the board, for example:
    – I want you to get foils for each product.
    – You need to check there are enough for the day.
    – You’ll have to start the line again if it stops.
    Help learners to identify the instruction words that tell them what they need to do. Underline these words
    (as shown above) on the board.
   Explore learners’ experiences of receiving instructions in the workplace. Do they find them easy to follow?
    Are they sometimes given out in a hurry? What else can go wrong? (e.g. not hearing properly because of
    background noise, not paying attention) What is the impact if instructions are not followed in the right
    sequence? What might happen if you forget an instruction? Try to elicit examples of each of these.
   This might be a good opportunity to practise listening to instructions in poor conditions (i.e. not in the ideal
    conditions of a training room). This acknowledges the reality of work in factories, where noise and
    disturbance are inevitable.
   Remembering instructions is as important as understanding them. Use a memory game along the lines of
    ‘My grandmother went to market and bought …’, updated for manufacturing students to ‘The line manager
    told me to …’. Some useful memory techniques can be found on memory.html.

     Ma                          Module 2 The production process

Focus page (Audio 11)
    Work through the tactics for the listener in the boxes on the page. Apply them to the instructions on the
     page by asking, ‘How many instructions are there?’ Work as a group to count the instructions and list them
     on the board, underlining the instruction words.
     – Make sure the right foils are used for each product.
     – I want the seven of us to set up the line.
     – Afterwards I want Jim to check there are enough wires for the end of line.
     – Chris, you need to get the trays from Hygiene.
     – Make sure the white ones are used for waste and the black ones for scrap.
     – Don’t muddle them up.
    Discuss the negative instruction, ‘Don’t muddle them up’. Discuss other ways of introducing negative
     instructions such as ‘avoid’ and ‘never’.
    Explain that sometimes people do not give instructions in the order they want them carried out. Sequence
     words such as ‘before’, ‘next’, ‘first’, ‘finally’, help listeners to carry out instructions in the correct order.
    Ask learners to look for the two sequence words in the sample instructions on the focus page. Write these
     on the board (‘first of all’, ‘afterwards’).
    Look at the examples of self-questioning based on the instructions on the focus page. How will this help the
     worker to establish exactly what to do?
    Talk about what is meant by being an ‘active listener’ and why this is important. You may need to introduce
     the term ‘body language’ and demonstrate what this means. This is a useful focus for some role play on
     active listening: one person talks or asks questions, the other gives no feedback, either verbally or in body
    Play the audio clip of the instructions on the focus page, and ask learners to make a brief note of all the
     instructions in their own words – a way that helps to remember them. For example, learners might use
     numbers, bullet points or a mind map.
    In pairs, learners now use their notes to explain to a partner what to do. (This helps to confirm whether the
     instructions have been noted down clearly enough.)
    It might be useful to involve learners in role-plays based on everyday instructions, such as the following.
     – One person reads some instructions, the others focus on different aspects of listening for instructions,
          e.g. things you have to do, things you must not do, instructions for individuals, instructions for
          everyone, suggestions for questions to clarify understanding.
     – One person calls out orders; the others make a mental checklist and repeat back what they have heard.
    Dyslexic learners may benefit from highlighting key words in order to aid recall and understanding of the
    Curric. refs              NOS/NVQ                     Key Skills
    SLlr/L1.1                 204                         C1.1
    SLlr/L1.2                 219
Task 1 (Audio 12)
Listen to a set of instructions and pick out the things you must do in order
 Look at the ‘tips’ on the page and explain that learners are listening out for positive instructions, i.e. things
    you need to do.
 You may want to remind learners about the different ways that this type of instruction can be given (e.g.
    ‘make sure’, ‘do this’, ‘clear the …’, ‘you should/must …’, ‘I want you to’, ‘You need to’ and so on).
    Confirm that work instructions can be framed in a number of different ways and it is important to recognise
    these as instructions, i.e. telling you what to do.
 Play the audio clip once for gist. This is a complex set of instructions and learners will benefit from getting
    a good overview of what is happening. Allow them to discuss the clip if needed.
 Play the clip again for learners to listen out for the five instructions in the list.
 Explain to learners that they need to listen out for the sequence words to help them decide on the correct
 Point out that a good way of tackling this question is to listen and write a number 1 to 5 against each

    Ma                          Module 2 The production process

    instruction as they listen. They should write in pencil in case they change their minds.
   Play the clip again and let the learners number the instructions.
   Play the clip again for learners to check their order.
   Explain that they will be able to listen several times to check the order but that in real life they would have
    to ask questions if they didn’t understand first time. This may be an opportunity to practise framing

If the learner has difficulty
 Read the text of the audio script in smaller chunks, no more than one sentence at a time. Ask the learner:
     Does the person tell you to do something? What?
 Remind them they are listening for things that require action – what they must do (not what they must not
 Help the learner to relate the list of instructions to the audio clip by playing the clip and pausing at each
 List the sequence words and phrases on the board to help the learner. Play the clip, pausing at each word as
     follows: first, before, next, after that, finally.
 Help the learner to number the instructions using the list of sequence words.
 There may be some issues about language for ESOL learners. Some of the sentence constructions in the clip
     may be difficult to understand due to the spoken form.

 Using their own experience, learners should prepare a similar script containing instructions and sequence
 Ask learners to 1) list the instructions that appear within their script 2) put them in the correct order using
    the sequence words.

Task 2 (Audio 12)
Listen to the same instructions and pick out the things you must not do       SLlr/L1.2
 Replay the audio clip. Remind learners of some of the different ways speakers introduce negative
    instructions. Point out the ‘tip’ on the page.
 Replay the clip for learners to check their answers.

If the learner has difficulty
 Read the text of the audio clip in smaller chunks to allow the learner to take more time.
 Write down a short list of ways to introduce negative instructions for the learner. Include the word ‘avoid’
     as used in the task audio clip. Ask the learner to listen out for any of the words on the list. Pause the clip
     when the word ‘avoid’ is identified. Play this part of the clip again and allow the learner time to note down
     their answer.
 Note the language difficulties for ESOL learners, discussed above.

Practise listening skills in workplace situations where instructions are given. Learners should practise making
notes of instructions, perhaps in columns of ‘dos’ and ‘don’ts’.

Task 3
Answer some questions about what you have heard                SLlr/L1.1
Ask learners to try the questions from memory, but replay the audio clip if necessary.

If the learner has difficulty
Read the relevant parts of the audio script again and question learners about what they have heard.

Listen to the audio clip again and ask learners to consider the way the instructions were given. Which aspects
were helpful, and which were not so good?

Theme assessment
Ask learners to give a set of instructions to a partner verbally, putting the instructions in order and emphasising
the instruction words and sequence words. You will need to give learners a list of possible sequence words to
include in their instructions. The partner makes notes from the instructions and can ask questions to confirm
information or check understanding.

   Ma                       Module 2 The production process

Getting the job done –                                                        (Focus) 2:12

spoken instructions
Factories are noisy places! You have to listen carefully to make sure you know what you
have to do.

 Get ready to listen.       (Audio 11)                             Listen for your name.

 Look as if you are                                                  Keep a notepad to jot
 listening:                                                          down what you have
  nod                                                               to do …… or keep a
  look at the                                                       mental note of what
      speaker                                                        applies to you.
  look keen!

 Ask questions to              Right, team. This is Peter. I’m going          have I got
 check you have                to be showing him what goes on on              to do?
 understood.                   our line. We’re starting with the
                               vegetarian pie today and if we finish
                               that, going on to the chicken, so
    Did you say                make sure the right foils are used for
    we’re setting up           each product. First of all I want the          Is there
    for vegetarian             seven of us to set up the line – you           anything
    pie to start with?         know what you usually do.                      I must
                               Afterwards I want Jim to check there           not do?
                               are enough wires for the end of line.
   Listen for the              Chris, you need to get the trays from
   sequence words,             Hygiene. We’ll need five black and
                                                                           Tick off each
   such as ‘first’,            four white to start with. Make sure the
                                                                           thing as you do
   ‘second,’ ‘then’,           white ones are used for waste and
   ‘afterwards’, ‘before       the black ones for scrap. Don’t
   that’, ‘later’, ‘next’      muddle them up.
   and ‘finally’. These
   tell you what order
   to do things in.
                                  Is there any
                                  particular order to            I’ve got to go to
                                  do this in?                    Hygiene and get
                                                                 four white trays and
        We’ll only do                                            five black ones.
        chicken if we finish
        the vegetarian.

   Sometimes you only             Repeat instructions                Make sure you
   need to follow the             in your own words                  reply clearly to be
   order if something             to check you                       heard above the
   else happens.                  understand.                        factory noise.

    Ma                     Module 2 The production process

Getting the job done –                                                            (Task) 2:13

spoken instructions
Task 1 (Audio 12)
Listen to instructions for setting up the foiler. Write numbers next to the five instructions
below to show the correct order.

   Secure the foil feeder with two bolts.            __

   Secure the sucker plate with two bolts.           __

   Blow out the three suckers with the air pipe.     __

   Fit the foil feeder onto the locating pins.       __

   Assemble the sucker plate.                        __

Task 2 (Audio 12)
Listen to the instructions again. Write down the thing that must not be done.

DO NOT:                                                       Tips
                                                               Listen out for the sequence
                                                                 words and phrases.
____________________________________________                   Count off on your fingers
                                                                 every time a new job is
                                                               Try to make a picture in your
                                                                 head of what needs to be

Task 3

Answer these questions without listening to the audio again. Choose an answer from the box.
1 What can be dangerous stuff?
2 What is debris?
3 How many bolts does the operator have to fix?

Bits of leftover rubbish
Compressed air
Health and Safety
Two bolts
Four bolts

    Ma                         Module 2 The production process

PAGES 2:14–2:16
Getting the job done – written
Occupational setting
Instructions in a manufacturing setting are written to ensure that all workers are working efficiently and
effectively to accomplish tasks to the same standard. Some instructions are only referred to when certain
circumstances arise, e.g. when someone is new to a machine or uses a machine after a time gap.

Job instructions sheet from the Source material (0:17–0:18)

Learning outcomes
1   To read and understand the language of instructions (focus page, Task 1)
2   To recognise and use organisational structure to aid understanding (focus page, Task 1)
3   To recognise instructional language, e.g. imperatives and ‘must do’ words (e.g. ‘always’) (focus page, Task
4   To know that some instructions are conditional, (e.g. ‘if’, ‘in the case of’) and they are only carried out if
    the circumstance or ‘condition’ exists (focus page, Task 1)

Suggested teaching activities
   Discuss with learners what is meant by an instruction. Instructions are directions, commands or orders that
    they follow on a day-to-day basis.
   Use a flipchart to record what the group feels are the advantages and disadvantages of following
    instructions in their job. Safety issues, maintaining standards, knowing how to do something, may all
    emerge as advantages. Restricting responsiveness and creativity may emerge as the disadvantages.
    Hopefully the advantages will outweigh the disadvantages – but you may have to add to the list.
   Ask learners to identify any good or bad points they have found when trying to read and/or follow written
    instructions. Can they all quote one set of instructions in particular? Can they say what it is about the
    procedures that they don’t like or can’t understand?
   List the good and bad points in two separate columns as they are identified.

Focus pages
   Look at the focus pages and identify any comments made on the page that come close to what the learners
    have said about difficulties they have found when reading and understanding instructions (e.g. use of formal
   Point out that each of the numbered points on the form is an instruction. Each point begins with an
    instruction or ‘command’ word.
   Ask learners to highlight all the instruction words in the numbered points. This will be particularly helpful
    to ESOL learners, who need to aware of imperatives as ‘markers’ to help them in reading and understanding
   Read through the first tip box on the second focus page. Point out the word ‘and’ and the commas
    highlighted in yellow. Make sure that learners have highlighted the imperatives following the use of ‘and’
    in points 3 and 8 and the ones following the commas in point 13.
   Look at the second tip box and relate the information to instruction 14 in the list.
   Look at positive and negative commands. How can you spot each kind? Relate the information in the third
    tip box to instruction 15.

    Ma                         Module 2 The production process

  Curric. refs              NOS/NVQ                  Key Skills
  Rw/L1.2                   204                      C1.2
  Rs/L1.2                   219

Task 1
Read and show understanding of written instructions by answering questions.
 Remind learners that it is a good idea to read through the whole set of procedures before beginning.
 Ensure learners understand the format of the instructions.
 Remind learners that they can use scanning for key words to find the answers for the questions. For
    example, for question 7 learners could scan for the key words ‘damaged pies’.

If the learner has difficulty
 Reduce the workload by giving the learner a more straightforward (in language terms) set of instructions
     and asking them some questions.
 Go back to the current task sheet and talk through each point with the learner. Ask the learner to highlight
     the questions/words causing the greatest difficulty. Work though these questions individually with the

Ask learners to rewrite a set of spoken instructions as clearly as possible. Point out that simplifying is not
always about creating shorter text. A simpler text may be longer, because instructions are broken down into
even smaller steps. Check that the written instructions ‘work’ by trying them out with a partner.

Theme assessment
Choose written instructions from the learner’s own workplace and use the strategies outlined to read and
understand them. Make up a quiz about the instructions for other learners.

    Ma                    Module 2 The production process

Getting the job done –                                                       (Focus) 2:14

written instructions
You may need to read written instructions when:
 you are learning to use a new piece of machinery
 you haven’t worked with a machine for a while.

Before you start working through the
instructions, check that:

   you have the correct instructions for the job
   you understand the format and the different
    headings                                                Who is it for?
   you can find and understand the health and
    safety information.

                                                       Check the heading.

      Ma                 Module 2 The production process

   Getting the job done –                                           (Focus) 2:15

   written instructions

Tip                    Tip                       Tip
Look out for phrases   Sometimes there is more   Think about the things that
such as ‘do not’ and   than one thing to do in   must be done. Look out for
‘must not’ to spot     one instruction. Watch    words such as must, always
things you must not    out for the word and as   and ensure.
do.                    well as commas.

    Ma                   Module 2 The production process

Getting the job done –                                                       (Task) 2:16

written instructions
Task 1
Find the Job instructions from the Source material. Answer these questions about them.

1 How many instructions are there in the Method for stage 1? Circle your answer.
  1 2       3        4       5
2 How many points in the Health and Safety column are things you must not do? Circle
  your answer.
  1 2       3        4       5
   What colour is the start button        ______________________________________
    for the conveyor?

    How many pies go in a net?               ______________________________________

    At what stage are damaged
    pies put in the waste bins?              ______________________________________

    Look at stage 3. What should             ______________________________________
    you always do at this stage?             ______________________________________

    Could you remind me where                ______________________________________
    the damaged pies go?                     ______________________________________

8 Whose job is it to bring in empty wires?


9 Are blue gloves always worn when dealing with the scrap bins?


10 Who should you look out for when moving racks?


    Ma                         Module 2 The production process

PAGES 2:17–2:18
Machinery – checks
Occupational setting
Machinery is used extensively in manufacturing. It is important that anyone using machinery carries out a series
of checks before they use a machine. This is particularly important in situations where a number of people may
be using the same machine. Larger companies and organisations may have a system of checks and a
maintenance department that will deal with reported defects. Individuals working alone or in small teams may
be entirely responsible for checking and maintaining their machines. Learners should be able to follow a
checklist in order to ensure that they complete all the necessary checks. This may mean using either a preset
format like the one shown on the focus page, or the list from an operator manual. An example of a forklift truck
checklist is used, but the teaching points should be applied to any pre-start checks used by the learners on
machinery from the workplace.
This theme may be used to support learners who are working towards their forklift certificate (NPTC Certificate
of Competence in Forklift Operations Unit 1 Pre-use Safety). Note: where forklifts are not a suitable focus for
this activity, adapt the content to suit the target audience. This can be done using the Word version of the

Daily pre-shift checklist from the Source material (0:19)
Operator manuals
Audio equipment
Machinery if available

Learning outcomes
1   To understand and locate information presented in a table (focus page, Tasks 1 and 2)
2   To complete a form in table format (focus page, Task 2)

Suggested teaching activities
   Give the learners the scenario of using a machine with which they are not familiar without checking it first.
    The brakes are faulty and there is an accident. No-one is hurt but a load is spilt and work held up while it is
    cleared up. Whose responsibility is it?
   Learners must be aware that they are responsible for their own health and safety and for the health and
    safety of others, including colleagues and the public. They cannot assume that machines are in good order.
    They have to complete pre-start checks.
   Discuss the experiences of learners when completing such checks. What are the difficulties? Cite using the
    manual/check sheet, need to be methodical, etc.
   Ask learners to find the pre-start checks in their own manuals or bring examples in from the workplace.
    These may vary from very simple checks for smaller machinery to more extensive checks, depending on the
    size and complexity of the equipment.

Focus page
   Go through the example shown on the focus page. Ask learners to read through the notice entitled ‘Electric
    forklift truck pre-shift checks’ and ask some direct questions about the instructions given here. How many
    things are in the folder? What are they? Who should complete this form? How often should it be
    completed? What do you think the DO NOT USE notice is for? Why shouldn’t it be removed from the
    vehicle? What type of vehicles may this be applicable to?
   Ask learners if they have come across similar checklists or forms at work. Go through the format, making
    sure learners are confident with the tabular layout. It is most important that learners understand the need to
    complete all checks. Tracking down the left-hand column and completing each check in order is the key to
    this. They must also track across to the correct day to fill in the box. It is important that they always make
    an entry. Check the Day column at the end to make sure each box is filled in.

    Ma                         Module 2 The production process

   Discuss how to use scanning skills to locate information quickly. This relies on looking for key words, for
    example if you need to find out if there have recently been problems with the brakes, you need to search for
    the word ‘brakes’ to locate the correct row.
   As you go through the table discuss with learners what might be involved with each check. What will they
    be looking for?
   Check that learners are familiar with all the abbreviations and technical language on the form.
   Give the learners examples with a blank copy of the Daily pre-shift checklist from the Source material in
    front of them. For example, ‘It’s Thursday. Clock hours are … Left hand indicator is faulty … Monitor is
    OK.’ Apply this to the form, showing learners where the information should be written, or getting them to
    decide where it should be written. (A copy of the form can be shown on an OHP.)
   You may need to discuss what is meant by ‘clock hours’ and how this is used to calculate how long the
    machine has been in use. Note: for one of the tasks learners need to calculate from the clock hours how long
    the machine worked for.
   Discuss with learners what action they should take if they find defects. How should these be recorded? With
    so little space on a form they need to be brief and to the point.
   Discuss clarification questions that may be asked as the form is completed.
   Note: a labelled diagram from a manual could be used to support all learners. This would help them to
    picture the sort of equipment being checked as well as helping them to understand some of the language
   As the checks are a practical activity, the session could be extended to include a practical session where the
    actual pre-start checks are demonstrated and the methods described above are put into practice.
    Curric. refs            NOS/NVQ                   Key Skills
    HD1/L1.1                204                       C1.1

Task 1
Extract information from the pre-shift checklist on the focus page
 Direct learners towards the partially completed form on the focus page and the discussion that you have had
    around this.
 Remind them how to find the correct box for information by moving down the checks and across to the
    correct day.
 Check that they understand the True/False style of question. They could do this work in pairs, then discuss
    how they arrived at the answers.

If the learner has difficulty
 Assist learners who are having difficulty by supporting them to use the tabular format.
 Learners who have problems with visual tracking skills will have difficulty keeping their place in rows and
     columns on a table. Use a ruler or piece of paper to help with this. A card shaped like an ‘L’ or a reversed
     ‘L’ can help with tracking on a table.
 Some learners may have problems with the scanning skills required to answer these questions and may need
     support to decide what key words to look for.
 Make sure learners understand the abbreviations for the days of the week.
 Make sure learners understand what they have to do to find the ‘clock hours’.
 Put statements on cards for learners to work through and put into a pile for true statements and a pile for
     false statements.

 Ask learners to use some manuals to look up the faults highlighted in this task.
 What is the most common cause for the problem of juddering on the lift operation?

    Ma                         Module 2 The production process

Task 2 (Audio 13)
Listen to a person completing the checklist and use the form to record the findings
 Remind learners that the best way to ensure they complete all the checks is to complete the sheet in a
    systematic way, marking each part of the form as they go.
 Explain the task. Point out that this person is checking through each item on the list as if working with a
    partner (the learner) who is filling in the form.
 Play the audio clip for gist, then explain the key technical vocabulary such as ‘masts’, ‘chains’, ‘tension’,
    ‘crank it up’, and colloquial language such as ‘a bit of a judder’.
 Ask learners to listen through the whole clip again, following down the form and ticking off each section
    that is referred to as it is mentioned. Is anything missed out?
 Play the clip a third time. Encourage learners to tick off the things that are OK.
 Play the clip once more and ask learners to complete the items that need more information. Spelling is not
    important for this task.

If the learner has difficulty
 Some learners will have difficulty listening and completing the form at the same time. Advise them to just
     listen the first time. Discuss what has been found on the machine, what was OK and what was wrong.
 Ask different groups of learners to listen out for different things and each complete one section of the form.
 Provide partially completed forms for some learners to complete.
 Support learners the second time through to tick each item with a pencil. It may be easier at this stage to
     work their way down the left-hand column. They can then transfer the information into the column for
 As they listen a third time, ask them to just mark the checks where something was wrong. The details can be
     completed afterwards.
 Audio scripts can be read out more slowly if this is more appropriate to the learner.
 Check any difficulties that ESOL and other learners may have with understanding technical words or
     colloquial expressions. These may need to be explained in context.
 Use highlighter pen to indicate the correct row/column for specific pieces of information. Some learners
     may benefit from using an L-shaped card to track across rows and columns.

 Discuss ways in which learners can ensure all checks are completed if they have no checklist, e.g. working
    from top to bottom or front to back of the vehicle. It is important to establish a routine for checks.
 Discuss in pairs other common faults or defects that they may encounter with each of these checks. Draw
    upon their own experience with machinery and equipment. It would be useful to make a list of the most
    common faults (the Top Three) found under each heading.

Theme assessment
Observe learners completing a pre-start check on a machine in the training setting. Practical application of this
task is critical. When assessing learners in the workplace, check that they complete pre-start checks in a
systematic way.

   Ma                     Module 2 The production process

Machinery – checks                                                            (Focus) 2:17

Operator manuals for machinery include a list of pre-start or daily checks. Some employers
will also have a checklist that you must complete each time you use the machine.

  Make sure you know what you have                Electric forklift truck pre-shift checks
  to do.                                          Every forklift truck will have a folder in
                                                  the cab. This contains pre-shift
  Use a systematic approach.                      checklists, a DO NOT USE sign and an
  The best way to tackle a checklist like         instruction sheet.
  this is to start at the top and work your       It is the responsibility of the driver to
  way down.                                       complete a pre-shift checklist daily. Each
                                                  vehicle will also be checked weekly by
                                                  the Maintenance Department.
                                                  The folder MUST NOT be removed from
                                                  the vehicle.
                                                  Failure to complete pre-shift checks
                                                  will be considered a breach of Health
                                                  and Safety Regulations.

                                      Daily pre-shift checklist
  Vehicle no: 34                                                 Week no: 15
  Item to be checked                            Sat    Sun Mon Tues Wed Thu Fri
                                                                  Track down the
  1. Clock hours                                1543 1551 1556
                                                                  checklist, stopping to
  2. Mast and chains, links, anchoring                       complete each check.
       points                                                     Track across to the
  3. Wheels and wheel nuts                                  right day to complete
  4. Forks                                                  the box. For example,
  5. Back rest for cracks, etc.                             you are now on Check
  6. Orange flashing light                                   9 for Monday and
  7. Brakes and handbrake – check for                       there’s a problem.
       efficient operation, excessive
                                                                  You haven’t got room
  8. Hydraulics – control levers,                           here to describe the
       hydraulic fluid leaks                                      fault. Use the space at
  9. Lift operations – raise, lower and tilt   X              the bottom of the form.
  10. Foot controls – accelerator, clutch                     Keep writing clear
       and brake                                                  and simple. Put full
  11. Check all instruments – indicators,                     details in a defect
       brake lights, horn, headlights,                            form.
       reversing alarm
  12. Monitor – OK is displayed                               Make sure you are
  Initials                                      JKL TG            familiar with any
  = satisfactory       X = fault (please specify below)          technical words or
                                                                  abbreviations on the
  9. judders on lowering from height - check oil levels?          checklist.
  Do not drive a vehicle if you have any concerns about its safety.

  Use scanning skills to find            You will be trained to carry out these checks.
  information in the checklist.          Look in the operator manual for more information.

    Ma                    Module 2 The production process

Machinery – checks                                                              (Task) 2:18

Task 1
Use the Pre-shift checklist on the focus page to see what has been checked.

1   The machine was used on Saturday, Sunday and Monday.                    True / False
2   The operator on Sunday completed all the checks.                        True / False
3   The machine worked for 7 hours on Saturday.                             True / False
4   The lift operation was faulty on Monday.                                True / False
5   The lift mechanism was juddering when raised.                           True / False

Task 2 (Audio 13)
You will need the Daily pre-shift checklist from the Source material. Listen to this operator
working his way through the checklist on Saturday morning. On the checklist tick off
everything that is OK and record any faults he finds.
                                                                Check each item on the
                                                                list. Tick the items that
                                                                are OK. Make a note of
                                                                any defects or any
                                                                action taken.

    Ma                         Module 2 The production process

PAGES 2:19–2:21
Machinery – using diagrams
Occupational setting
Many manufacturing companies present instructions in a more graphical format. This makes them more
accessible and reduces the amount of reading required. A lot of information is also displayed on VDUs. Work
instructions on screen often show labelled photographs and diagrams that are referred to in the text. This theme
aims to demonstrate how these materials might be used effectively. It is important that all teaching in this theme
is related to learners’ experience in the workplace.

Work instructions that include labelled diagrams
Instructions from other sources, for example car manuals, kitchen machinery instructions
Access to the machinery the diagrams relate to
Working instructions panel layout from the Source material (0:20)
Colour copies of Task page 2:21

Learning outcomes
To understand the format of labelled diagrams (focus page, Tasks 1–3)

Suggested teaching activities
   Show learners a variety of work related instructions which include diagrams, and one or two from outside of
    work, for example car manuals, instructions for machinery in the home, DIY manuals, etc. Hold a
    discussion about the materials, covering the following:
    – How do learners feel about using diagrams for instructions – worried, confident, anxious, thankful,
         tense, relaxed?
    – Which of the materials look easiest to follow, and why? Is it familiarity with the machine, or familiarity
         with the instructions? Is one more clearly laid out than the others? Is there more or less writing? Does it
         use photographs or illustrations? Does it relate clearly to the real world (as opposed to being too
    – Compare instructions with text to those without. Some people will feel more comfortable following
         written instructions with diagrams to back them up. Others will struggle to read or understand the text,
         and will only use the pictures.
   Explain to learners that how they feel about following instructions like these will have an effect on how
    easy they find them to use. Feeling anxious and tense when using diagrams and instructions is very
    common, but takes brainpower away from the task. Instructions that are familiar in some way are much
    easier to use.
   Ask learners to look at the labelled instructions for a particular piece of machinery. Ask them to look at the
    whole picture first, taking in what is familiar and what isn’t.
   Ask learners to find particular parts of a machine using the labelled diagram. If possible they should do this
    on the machine itself. Discuss and note any difficulties that arise, for example not understanding technical
    language or having difficulty in relating the diagram to the actual machine.

Focus page
   Take learners through the thought processes of the operative on the page.
   Using the diagram of a control panel on the page, ask learners to identify which button/ switch activates
    each item.
   Ask learners to trace with a finger the order in which the buttons/switches should be activated.
   Talk about the names of the processes, and whether they mean anything to the learners. Talk about how
    becoming familiar with the names makes reading easier, and makes the sequence easier to follow.
   Ask for suggestions as to how this sequence could be remembered. Ask learners what strategies they use for
    remembering other things, and how they could be applied here.

    Ma                         Module 2 The production process

  Curric. refs              NOS/NVQ                  Key Skills
  Rt/E3.9                   204                      C1.2

Task 1
Find buttons on a control panel using a labelled diagram and a key               Rt/E3.9
 Remind learners of the teaching on the focus page. Stress that this task is based on a real machine, but it
    should NOT be followed in reality as several steps have been omitted and some added.
 Check learners understand left/right/bottom/ top, etc.

If the learner has difficulty
 Read each statement slowly together and check that the learner can understand the gist of it.
 Ask them what they are going to look for on the diagram. For each statement, learners need to look for two
     things, for example the bottom right-hand corner of the control panel first and then the emergency stop
     button. It can help a learner with visual tracking difficulties to be explicitly aware of this.
 It may be appropriate to help an ESOL learner with the vocabulary by looking at actual machinery and
     labelling a blank diagram of a control panel.

Ask the learner to sketch a basic diagram of the control panel and label all the parts, using a key. Number the
parts in the expected order of use.

Task 2
Use a key to find information                 Rt/E3.9
Tell learners they are going to identify some buttons on the panel using the key and vice versa.

If the learner has difficulty
 Direct learners to the number 4 on the panel diagram and then to the number 4 on the key and assist them to
     read the name of the part. Repeat for other questions.
 Provide further examples as extra practice.

Ask learners to set a quiz for other learners based on this panel layout or one from the workplace.

Task 3
Use a key to recognise buttons on a control panel and follow instructions for start up            Rt/E3.9
 Go through the layout of the key with learners, discussing the numbering system and the different sections,
    pointing out the section with the information needed to complete the task.
 Ask learners to use the words in red to find the correct number on the diagram, and to write this number into
    the boxes.

If the learner has difficulty
 Give the learner slips of paper to write the names of the parts they are looking for on, and use each slip of
     paper individually to search for the correct part and part number.
 Refer back to Task 1 for help with vocabulary and meaning.

Draw a flow chart of the start-up procedure, using symbols to represent each button and arrows to connect them
in the correct order. Use cards or sticky notes to write down each stage, then sort the cards or notes into the
correct order.

Task 4
Use job instructions, labelled diagrams and a key to get work instructions in the right order
Remember the sequence for starting a machine                     Rt/E3.9
 Learners could work in pairs for this task, checking that each partner can follow the correct sequence.
 Reiterate the part of the question that says the battery is fine and the fault light is off.
 Ask learners to refer to the Working instructions panel layout in the Source material to answer Task 4a, and
    not to answer it from memory. For Task 4b, learners should try to answer from memory only.

    Ma                         Module 2 The production process

If the learner has difficulty
 Write each step of the process as given in the Start-up procedure on separate slips of paper. Ask the learner
     to put them in order; then remove the steps which refer to the battery and the fault light (make sure the
     learner understands why). Finally, use the sequence on the slips of paper to follow the start-up sequence on
     the diagram.
 Ask the learner what they are good at remembering. What strategies do they use to memorise something?
     Which of those strategies could be applied here? Use a different set of instructions and an actual machine to
     check whether the learner is comfortable memorising a sequence using actual physical material.

Tell a partner or an instructor what the start-up sequence is from memory, without referring to any written

Theme assessment
Give learners new labelled instructions for using a piece of machinery and ask them to show you or a partner
what to do on the actual machine.

   Ma                     Module 2 The production process

Machinery – using diagrams                                                   (Focus) 2:19

You often need to refer to photographs and diagrams in the operating instructions for
machinery. These often have a key to help you find the correct part.

                                  I haven’t worked on this
                                  line for a while.
                                  Better check I can
                                  remember what to
                                  do. Let’s see …              There’s a diagram
                                                               with numbers on it
                                                               and a list to tell me
                                                               what part of the
                                                               control panel each
                                                               number stands for …
                                 So I use the
                                 diagram to find
                                 the parts on the
                                 panel …

                                                     The instructions tell you to
                                                     switch the parts on in order
        The numbers on the                           as the product goes down
        instructions match the                       the line, so I’d better check
        order to start up in …                       which bit is which – why
                                                     don’t they give them names
                                                     we can recognise?

                        I’ve got it now,
                        so off we go …

  Section 4 – PRODUCTION RUN
   1    From the main control panel,
        switch the following on in sequence
        as product proceeds down the line:
        1. Foiler
        2. Strip feeder
        3. Blocker dies
        4. Depositor/fill
        5. Water sprayer
        6. Tampers
        7. Lidder dies
            (Refer to diagram)
   2    Also check that the:
        Lid pastry
        Auto take off

   Ma                     Module 2 The production process

Machinery – using diagrams                                                    (Task) 2:20

You will need the Working instructions panel layout from the Source material for these tasks.

Task 1
Decide if these statements are true or false. Circle your answer.

1 The EMERGENCY STOP button is in the bottom right-hand
  corner of the control panel.                                            True / False

2 The MAIN BREAKER is in the bottom left-hand corner of the
  control panel.                                                           True / False

3 The BATTERY ALARM is next to the FAULT LIGHT.                            True / False

4 The MAIN BREAKER switch has three positions.                             True / False

5 The POWER-ON BUTTON is above the POWER-OFF BUTTON.                      True / False

Task 2

1 What is labelled as number 4 in the key?


2 What number is the FAULT RESET BUTTON in the key?


3 What is labelled as number 12 in the key?


4 What number is the CYCLE START BUTTON in the key?


    Ma                       Module 2 The production process

Machinery – using diagrams                                                        (Task) 2:21

Task 3
For each step of the start-up procedure below, write in the number from the diagram that goes
with the red parts of the control panel.

    Work Station Process Book – 1st Manufacturing                ID               0-DP-06
    Working Instructions Section
                              Issue date
                                                                 Page no.
                                                                 Issued by
     Start-up procedure Date                                     TEC approval
                              Date                               MFT approval

    6.4      Start-up procedure
    6.4      Start-up procedure
    6.4.1    Turn the main breaker ____ to on position.
    6.4.2    Turn on the power-on button.____
    6.4.3    If the fault light ____ is lit, press the fault reset button ____.
    6.4.4    If the fault light ____ continues to be lit, call an engineer.
    6.4.5    If the battery alarm ____ lamp is lit, call an engineer.
    6.4.6    Turn on the remote key switch ____.
    6.4.7    Turn to auto mode using the auto key ____.
    6.4.8    Press the cycle start button ____.
    6.4.9    At end of run, press the power-off button ____.
    6.4.10   Set main breaker ____ to off.

Task 4
a Your job is to start up this machine. List the five actions that you should take. Include the
  numbers on the control panel. Make sure they are in the right order.
  The battery is OK and the fault light doesn’t come on.

1 _______________________________________________________________________

2    _______________________________________________________________________

3    _______________________________________________________________________

4    _______________________________________________________________________

5    _______________________________________________________________________

b Trace the order of the actions for start-up on the diagram.

    Ma                        Module 2 The production process

PAGES 2:22–2:23
Machinery – recording downtime
Occupational setting
Time is critical in manufacturing and all processes are carefully organised to ensure the most effective use of
time. Processes are costed on a time basis and most monitoring sheets will involve recording time. Machine
downtime is something that all operatives will be familiar with and it is normally carefully recorded. Downtime
can have an impact on bonuses and piece work payments so operatives are usually very aware of the importance
and impact of downtime. Operatives recording downtime or monitoring time spent on jobs need to be aware of
how to record time (12-hour or 24-hour) and how to calculate time. Again, there may be specific conventions
used within a particular company and learners will need support to apply the skills taught here to their own

An analogue clock
Machine downtime sheet and Clock times from the Source material (0:21 and 0:22)

Learning outcomes
1   To read and record time in 12-hour and 24-hour clock format (focus page, Tasks 1 and 2)
2   To convert between the 12-hour clock and 24-hour clock (focus page, Task 2)

Suggested teaching activities
   Ask learners to say the present time shown on a room clock in as many different ways as they can, for
    example 9.35 am, twenty five to ten, 09:35, thirty five minutes past nine. Ask them to also write down the
    time in numbers only. The only options are actually 12-hour format or 24-hour format despite the fact that
    we verbally express time in many different ways. Point out that the correct way to record time is using a
   Go round the group and ask what sort of watch they are each wearing. Discuss the difference between
    analogue and digital. Why have you chosen to wear a digital watch? If you have to catch a train/bus or have
    to be somewhere by a certain time which watch would you find the easiest to use to help in planning your
   Ask those learners who have a digital watch to identify whether it is a 24-hour or 12-hour clock. Ask those
    with 24-hour watches to explain how they work out what time they must leave if they are to get to an
   Ask those with an analogue watch to do the same. It may emerge that it is quite difficult to calculate time
    with a 24-hour clock digital display because you cannot see the ‘passage of time’ as you can on an analogue
    clock. It may however be easier to read the time instantly using a digital display.
   Discuss the frequency of reading and recording time in the workplace. How is time recorded in different
    places in the workplace? What are the consequences of this being done inaccurately?
   Ask learners to share with the group any methods they already use to convert between 12- and 24-hour
    clock times. Acknowledge validity if successful. Some learners would benefit from having a card of 12-
    hour times and their 24-hour equivalents for reference.

Focus page
   Look first at the section of the downtime sheet shown on the page and ask learners to find the recorded
    times. Ask them why they know that they are looking at time and not just other codes. (Try to elicit from
    them that it is the language of time that gives them the clues, e.g. start, end. These time markers are
    particularly important for ESOL learners to understand.)
   Point out that the 24-hour clock always uses four digits when talking about and recording time.
    – Explain the use of zero, as in 02:45 (said as ‘oh-two-four-five’ or ‘zero-two-four-five’). Give learners
         some 24-hour clock times to say aloud.
    – Give learners some oral 24-hour clock times to write down and say that it is correct to separate the
         hours from the minutes using a colon, but learners may also see it written using a full stop or with
         nothing between the numbers for the minutes and the numbers for the hours.

     Ma                         Module 2 The production process

    Using the clock graphic on the left-hand side of the page, read and discuss the points made. Write a mixture
     of times (24-hour and 12-hour) on the board, and ask learners to convert between the two, either by adding
     12 on or taking 12 off or just by using the clock.
    Ask learners to look at the right-hand side of the page and get them to record the time shown on the clock in
     both 12-hour and 24-hour clock formats. Ask for volunteers to come up and write the different ways they
     say what the time is using the 12-hour format. Do the same for the 24-hour clock. What should emerge is
     how standardised the 24-hour clock is compared with the 12-hour. There are fewer reasons therefore for 24-
     hour time to be misunderstood – hence its use in work situations.
    Curric. refs            NOS/NVQ                  Key Skills
    MSS1/E3.3               219                      N1.1

Task 1
Read and record time using the 12-hour clock format                    MSS1/E3.3
 Remind learners of work done on the focus page.
 Ensure that learners are familiar with the section of the form necessary to complete the task.

If the learner has difficulty
 Support the learner to read the time from the clock, verbalise it and transfer the numbers onto the sheet.
 Provide lots of extra practice.
 Refer learners to Skills for Life materials, Entry 3 Unit 3.

Read back times from an actual downtime sheet.

Task 2
Read and record time in 12-hour and 24-hour clock formats              MSS1/L1.2
 Remind learners of work done on the focus page.
 Ensure learners are familiar with the section of the form necessary to complete the task.

If the learner has difficulty
 Provide lots of extra practice.
 Bear in mind that dyslexic learners may have particular difficulty with telling and recording time.
     Additional help may be required.

Read back times from an actual downtime sheet.

Task 3
Transfer times onto a Machine downtime sheet                MSS1/L1.2
 Remind learners of work done on the focus page.
 Ensure learners have the Machine downtime sheet and the Clock times sheet from the Source material.
 Ensure learners know how to complete the task. The letters beside the clock faces match the letters on the
    downtime sheet where times need to be filled in.

If the learner has difficulty
 Cover the form so that only the parts being dealt with are visible.
 Use a straight edge to help align the rows.
 Assist learners to verbalise the times on the clock before transferring them to paper.

Make a table of 12-hour times and their 24-hour equivalents to assist other learners.

Theme assessment
    Identify other situations at work when time may be shown or recorded in different formats.
    Observe learners entering times into a workplace downtime sheet as evidence for NOS 219.

   Ma                    Module 2 The production process

Machinery – recording                                                                (Focus) 2:22

Downtime is the length of time that a machine is out of action or unavailable. Recording
downtime enables the management to:
 identify the cause, to prevent it from happening again                            Midday is
 calculate how much money was lost, because of lost production.                     recorded as
Look at the section of a downtime sheet.                                            Midnight is
                                                                                     recorded as

    Date    03.02.06                                Machine        Metal detector

                                                    Actual downtime
    Start downtime        End downtime                                      Reason/comments
    0712                  0923                      131                     Calibration alarm
    1315                  1327                      12                      Manual stop

 You know when it is the morning                24-hour times are written with four digits. The
 (am) using a 24-hour clock,                    first and second digits represent the hour.
 because the first two digits are from          The third and fourth digits represent the
 1 to 12. Quarter past one in the               minutes.
 morning is 01:15.                              Usually a colon (:) is used to separate the
                                                hours and minutes. You may also see 24-hour
 The hours for afternoon and                    times written as 0712 or 07.12.
 evening times (pm) have 12 added
 onto each number of the clock
 face. Quarter past one in the                  The minute hand shows how many minutes
 afternoon is 13:15.                            there are after the hour. For example, 23
                                                minutes past 9 is written as 09:23.

                                                Words like ‘quarter’, ‘half’, ‘past’ and ‘to’ are not
                                                used in the 24-hour clock.

                                          A quick way to change ‘pm’ times to 24-hour
                                               clock times is to add on 12 hours.
                                          Midnight is written as 0:00.

   Ma                    Module 2 The production process

Machinery – recording                                                        (Task) 2:23

Task 1
You are working on the screw conveyor, when it stops unexpectedly. Use the clocks to
complete the section of the downtime sheet below.

 Start downtime            End downtime

                                               Record each of the downtimes using the
                                               24-hour clock format.
Task 2
You are on the night shift when the hopper stops working. Use the clocks to complete the
section of the downtime sheet below.

 Start downtime            End downtime

Task 3
Look at the Machine downtime sheet and the Clock times sheet from the Source material. Fill
in the missing times a–l on the downtime sheet. The Clock times sheet shows the missing
times. Use 24-hour clock times.
                                          clock times is to add on 12 hours.

     Ma                         Module 2 The production process

PAGES 2:24–2:25
Machinery – calculating downtime
Occupational setting
See previous setting

Completed Machine downtime sheet from previous theme
Blank machine downtime sheet from Source material (0:23)

Learning outcomes
To calculate an amount of time that has elapsed (focus page, Tasks 1 and 2)

Suggested teaching activities
    Review learners’ understanding of the 24-hour clock and complete a conversion table on the board or a flip
     chart. If learners need to reinforce conversions, use cards with 12-hour times and match to a set with 24-
     hour times.
    Give learners some examples of conversions to check their understanding. Confirm the time system used in
     their work settings.
    Ask learners to list the routine jobs they do every day. Ask them to estimate how long one of the jobs takes.
     Then ask them to calculate the time taken from the start and end times. During this activity observe methods
     used by learners to calculate time periods. These may include:
     – Estimating and rounding to the nearest ¼ hour or ½ hour.
     – Counting on – hours first and then minutes.
     – Counting on – minutes first and then hours.
     – Adding the minutes and then converting to hours (thinking in 60s).
    Encourage learners to share with others their strategies for making time calculations. Identify any areas of
     difficulty such as counting past the hour. Establish strategies that will suit individual learners. Learners that
     need a lot of underpinning work to help them understand time and calculation should be directed to the
     Skills for Life materials, Entry 2 Unit 3, Entry 3 Unit 3 and Level 1 Unit 3.

Focus page
    Look at the different ways of working out downtime given on the focus page. Discuss the use of ‘counting
     back’ time to calculate when you should start a task. There are additional materials for practising time
     calculations in Skills for Life Numeracy Level 1, Unit 3. Point out where each of the calculations is recorded
     on the section from the downtime sheet.
    Give additional practice items to confirm learner confidence.
    Check that all learners are familiar with the terminology used for different tasks and jobs that may be
     unfamiliar to them. Ask learners to explain tasks to other members of the group if they have job tasks that
     are uncommon.
    Curric. refs             NOS/NVQ                   Key Skills
Task 1
Complete the calculations on a Machine downtime sheet
 Ensure answers to Task 3 in the previous theme are correct.
 Remind learners how to convert times from 12-hour to 24-hour clock times.

If the learner has difficulty
 The learner may be having difficulty with either reading or interpreting time OR be unable to convert into
     24-hour clock times. Check which of these issues is most problematic to the learner.

    Ma                         Module 2 The production process

   Return to the focus page and remind the learner that time can be calculated in different ways. Go through
    each of the ways shown on the page to identify where the learner is confused. Read out the times and ask
    the learner to show you or say the time in their own way. Learners who are used to digital displays may not
    be familiar with times ‘to’ the hour, such as quarter to eight. There may also be issues with the fraction
    format for some learners.
   Learners with serious difficulties in reading and interpreting time will need some additional support to give
    them confidence with these skills. Cards with 12-hour and 24-hour times can be made and used to practise
    with. Also refer learners to Skills for Life materials, Level 1 Unit 3.
   Working in pairs/groups promotes discussion and enhances understanding.
   A time line or a clock may be useful for calculating the passage of time.
   Use a ruler or other straight edge to help learners keep their place on the form.
   It may help some learners to use their fingers to mark off each chunk of time.

Have a quick-fire quiz asking learners to calculate elapsed times.

Task 2
Read, record and calculate with time
 Ensure learners have the Blank machine downtime sheet from the Source material.
 Go through the tip on the page.

If the learner has difficulty
 Cover parts of the form not in use.
 Use a guide to assist alignment of rows.
 Check the learner’s strategies by asking them to talk through the process or method they are using. This will
     enable you to see whether it is the method or the calculation that is incorrect. Suggest the use of fingers to
     keep count when counting on in hours. Remind them not to forget the additional minutes.
 Show passage of time using the hands of an analogue clock and count minutes/hours as they pass.
 Learners that need a lot of underpinning work to help them understand time and calculation should be
     directed to the Skills for Life materials, Entry 2 Unit 3, Entry 3 Unit 3 and Level 1 Unit 3.

Ask learners to record activities that they complete during the working day and calculate rest periods, set-up
time and production time. Complete further time calculations over a period of a week.

Theme assessment
Observe learners calculating times into a workplace downtime sheet as evidence for NOS 219.

   Ma                      Module 2 The production process

Machinery – calculating                                                    (Focus) 2:24

Once you’ve recorded the start downtime and end downtime of the machine, you need to
calculate and record the actual downtime.
  To calculate the actual downtime
                                          The screw conveyor went down at 05:21
  you need to find the difference
                                          because of an electrical fault and came back
  between the start downtime and
                                          up at 05:52.
  the end downtime.
                                          In this example the start downtime and the
  The actual downtime is normally
                                          end downtime occurred in the same hour (5
  recorded in minutes (min).
                                          o’clock in the morning) so you can:

                                             subtract the minutes
  Remember!                                   52 min – 21 min = 31 min
  There are 60 minutes in 1 hour.            count on in 10s from 21 to 52
                                              21, 31, 41, 51 = 30 minutes. And another 1
                                              makes 31 min
                                             count back from 05:52 to 05:21
                                              52, 42, 32, 22 = 30 min and 1 more makes
                                              31 min.

    Date    15.02.06                          Machine    Screw conveyor

                                              Actual downtime
    Start downtime         End downtime                           Reason/comments
    0521                   0552               31                  Electrical fault
    1240                   1450               130                 Manual stop

  The screw conveyor went down again at 12:40           Actual downtime needs to be
  because of a manual stop and came back up at          recorded in minutes. If you
  14:50.                                                calculate in hours and minutes,
  In this example the start downtime and end            you need to convert the time into
  downtime occurred in different hours so you can:      minutes.
   Count on in hours then minutes:
      12:40, 13:40, 14:40 is 2 hours. And 10 more       To convert hours and minutes
      minutes to 14:50 gives 2 hours 10 min.            into minutes, multiply the hours
   Subtract the hours first and then the minutes:      by 60 and then add on the
      14 hours – 12 hours = 2 hours                     minutes.
      50 min – 40 min = 10 min
      So the downtime is 2 hours 10 min.                For 2 hours and 10 minutes:
   Count back from 14:50 to 12:40:                      Multiply the hours by 60 to
      14:50, 13:50, 12:50, 12:40 = 2 hours 10 min.         change them into minutes:
                                                           2 x 60 = 120 min.
           1hour   1hour   10 min                        Add this to the minutes:
                                                           10 + 120 = 130 min.

   Ma                    Module 2 The production process

Machinery – calculating                                                     (Task) 2:25

Task 1
You will need the Downtime sheet from the Source material that you used in Task 3 on page
Complete the form to show how many minutes the machine was down.

Task 2
The table below contains details about the downtimes of the hopper on 7th March 2006.
Use the table to complete the Blank machine downtime sheet from the Source material.

         Reason: Electrical fault                              Tips
             Start downtime               End downtime         Take the task a step
                    am                         am              at a time.
                                                               1 Read the start
                                                                   downtime on the
                                                               2 Convert the time
                                                                   to 24-hour time.
                                                               3 Write the 24-hour
         Reason: Manual stop                                       time on the
             Start downtime               End downtime             Downtime sheet.
                   pm                          pm              4 Do the same with
                                                                   the end downtime.
                                                               5 Calculate the
                                                                   downtime in

         Reason: Electrical fault
             Start downtime               End downtime
                   pm                          pm

    Ma                         Module 2 The production process

PAGES 2:26–2:27
Reporting and recording faults – using
the phone
Occupational setting
When working on the production line, workers often have to report faults to the technical department by phone.
It is essential, particularly in a noisy environment, that the speaker gets the message across clearly and
accurately. It is equally important to listen carefully. This theme aims to exemplify the skills needed for
effective verbal communication.

Role-play cards
Audio equipment

Learning outcomes
1   To identify some good practice techniques for speaking and listening on the phone (focus page, Task 1)
2   To practise listening for essential information on the phone (Tasks 2 and 3)

Suggested teaching activities
   Discuss with the group the differences between speaking to someone face to face and on the telephone.
    What makes one harder or easier than the other? The key issue here is body language or the lack of it when
    on the phone.
   Ask the group to think about reasons why they might speak to somebody by phone. Responses to this will
    vary according to the type of business they work for and their own job role. Reasons can be listed on a
    board or flipchart.
   Give learners role-play cards to complete a short role-play in pairs. The role-plays should be conducted on
    internal phones where possible, or back to back so that body language is not visible.
   Two sample role-play cards:

     You are working on the number 3 line. The                    You are working in the maintenance
     machine that puts the lids on – the lidder – has             department. It is a busy day! You have
     stopped for the fifth time today. Phone the                  several jobs already lined up. Some of
     maintenance department and ask for somebody                  them are urgent.
     to come and look at it.

   The greater the variety of role-play cards, the greater the number of different combinations that can be
    played out in the group. This activity can also be conducted in threes, with one person acting as an impartial
   Obtain feedback from each pair about the role-play and identify what works and what doesn’t work on the

Focus page
   On the focus page, establish that items in green boxes are examples of good practice and those in red boxes
    are examples of bad practice. Go through these examples first, asking for comments about why one example
    is better than another. Ask learners to give other good alternatives and procedures that they are advised to
    use in their own workplace.
    Note: read out an item without word spaces so that learners can see how difficult it is to listen when people
    speak very fast without pauses or punctuation.
    Note: the blank red box indicates that the listener is making no response to the speaker to show that they are
   As a group go through the bulleted list of points for speaking and for listening on the phone. Learners can
    tick off items that they have already identified on their own lists and add extra items to the focus page if
    they have them.

    Ma                          Module 2 The production process

   Curric. refs              NOS/NVQ                   Key Skills
   SLlr/L1.1                 223                       C1.1

Task 1 (Audio 14)
Listen to a telephone conversation and identify good practice
 Direct learners to the lists on the focus page that describe good speaking and listening skills when using the
 Explain that they will be listening to a lengthy conversation between an operative and the technical
    department. Initially they should just listen carefully and think about the general impression given.
 Ask learners to discuss any general issues about the conversation. Refer them to the lists on the focus page
    as issues come up. Encourage learners to think about the good points as well as criticisms they have.
 Play the audio clip again and ask learners to tick items on the list if the operative is doing them correctly
    and cross items on the list that the operative is not doing correctly. Allow discussion about this within the
    group or in pairs.
 Listen to the clip once more to confirm any items learners are not sure about.

If the learner has difficulty
This is a substantial amount for learners to listen to and absorb. Learners having difficulty will benefit from
having the task broken down. Play the audio clip a bit at a time and assist the learner to go through the list on
the focus page. Ask direct questions such as, Does the operative use an appropriate greeting? Does she confirm
the time the technical department will be down to do the repair?

Learners compose their own scripts using the lists on the focus page as a guide. Learners could then read out
their scripts to the rest of the group.

Task 2 (Audio 15)
Pick out essential information
 Point out that speakers often give a lot of irrelevant or unnecessary information when they report problems
    in the workplace. The skill is to be able to listen out for the relevant detail or details. Learners are going to
    practise this skill in this task.
 Play/read the audio clip to learners and ensure that they understand how to complete the task.

If the learner has difficulty
 Pause the audio clip after every one or two sentences. Ask the learner, Is this information about a fault? Is
     the speaker reporting a fault in this sentence?
 Pause when the learner has identified the correct part of the clip and allow them time to complete the task.

Compose a similar script for learners reporting a fault or problem at work and containing irrelevant detail. Ask
learners to pick out the relevant information, i.e. the reporting of the problem or fault.

Task 3 (Audio 16)
Pick out key information to complete a message.
 Remind learners of the tips on the focus page and point out that this task practises listening skills.
 Play the audio clip. Ask learners to listen to the clip and complete the partially completed message given on
    the page.

If the learner has difficulty
 Check that the learner understands the task.
 Provide the learner with the list of words that are missing from the clip, to make the task easier:

    Ma                         Module 2 The production process

    oil level
    TC1 CNC
   Pause the clip when each word occurs and allow the learner time to look at this list, find the correct answer
    and write it into the space.

Give learners a range of scenarios relevant to their own workplace and ask them to work in pairs to record
suitable messages using an answering machine or mobile phone. Play back to evaluate. Check that learners use
the list of good practice for their speaking skills.

Theme assessment
Ask learners to evaluate their performance the next time they need to speak on the phone at work.

   Ma                    Module 2 The production process

Reporting and recording                                                        (Focus) 2:26

faults – using the phone
Factories are noisy places! If you need to phone the Maintenance Department, for example,
you have to speak clearly and listen carefully.

                                                     GO                          STOP
        When speaking on the phone:
      Introduce yourself.
      Speak plainly and distinctly. 
      Give any information or directions       Is that Fred in the
                                                 Maintenance                  Are you Fred?
        clearly and in the right order. 
      Ask questions to confirm that the        Department?
        listener has understood what you
        have said. 
      Offer any extra information that        This is Gary           You’re … er …
        may be useful to the listener.         on the number          speaking ... er … to
                                                2 line.                … oops … are you
  Is that all OK or                                                    still there?
  do you need more
  information?             Bye then.
                                             The feeder keeps            There’s something
                                             jamming.                    wrong down here.
  Mm …
  Right …
  Oh …

                                                            When listening on the phone:

                                                           Listen carefully. 
                                                          Concentrate on what the other
                                                            person is saying. 
                                                           Let the other person know that
    So you need                                             you are listening. 
    to get a part                                          Repeat back important
                          OK.                               information to check you have
    from stock?
                                                            heard correctly. 
                                                           Ask questions to be sure you
                                                            have got the message. 
     Could you repeat
     the bit about how
     long you think          Say that again.
     you’ll be before
     you get down

   Ma                      Module 2 The production process

Reporting and recording                                                            (Task) 2:27

faults – using the phone

Task 1 (Audio 14)
1 Listen to an operative reporting a problem to the technical department.
2 Using the lists on the focus page, highlight all of the things that the operative does.
3 Compare your list with a partner’s. Discuss ways in which the operative could improve
  his telephone technique.
                                                 I’m fed up with this. Over and over
                                                 again. We phone you, you repair it, it
Task 2 (Audio 15)                                goes again. Have you ever known
Listen to the operative reporting a fault.       anything like it? I thought these new
What fault is being reported?                    machines were supposed to make our
Highlight the answer.                            lives easier. The vacuum transfer won’t
                                                 go to origin again. I bet you’ll be able to
                                                 fix it in your sleep soon. Come down as
                                                 quick as you like, we’re wasting time

Task 3 (Audio 16)
Listen to an operative reporting a problem.
Fill in the spaces in this part of the conversation.

    Hello, this is ____________________________
    I’m on the TC1 CNC machine.
    There seems to be a _____________________
    Could you come down and take a look, please?
    I’ve checked the _______________________
    and taken off the swarf conveyer and cleaned
    out the _______________________________
    but it still won’t go. It’s the _________________
    machine. OK?
    Do you need any more information?

    Ma                         Module 2 The production process

PAGES 2:28–2:29
Reporting and recording faults
– filling in a form
Occupational setting
Manufacturing operatives have to report many of their workplace activities on forms of different descriptions.
This theme develops the skills required for accurate completion of forms.

Audio equipment
Machine breakdown report from Source material (0:24)

Learning outcomes
1   To know how to read a form, using the format to locate and place particular information (focus page, Task
    1, Task 2 question 1, Task 3)
2   To check that information has been entered accurately (focus page, Task 2 questions 2 and 3, Task 3)

Suggested teaching activities
   Give the group some examples using your vocational knowledge about when they may need to report faults
    or damage to a machine. Include one fault that is found at pre-start check and another that is damage
    occurring while working. In both cases they need to make a decision about the safety and usability of the
   Discuss with learners the different systems they have in their own workplace for faults or damage that that
    needs to be dealt with by the maintenance department. These will probably range from none at all to formal
    reporting systems, depending on the employer.
   Discuss with learners why it is important to report faults and what is important when recording any
   Identify with the group key points, such as being clear, giving the facts and details, sticking to the relevant
    information, and following the system.
   Ask learners what sorts of forms are difficult to complete, e.g. forms with specialist vocabulary, long forms,
    forms with unclear or unfamiliar instructions. Discuss practical advice – use headings, look up meanings,
    ask for help. Ask learners how they do it. Exemplify the types of instructions found on reports (delete,
    circle, etc.) and the conventions (bold type, capital letters, etc.).

Focus page
   Make sure learners have a copy of the Machine breakdown report form from the Source material. Introduce
    the form. Check learners are clear what is meant by a defect. Ask learners to think about the reasons for
    having a system like this.
Section 1: Before you start
 Refer learners to the tip box on the focus page with this heading. Relate the points in the tip box to the
    instructions for completing the form.
 Explain to learners that they should read a form first before they begin to fill it in. This includes being clear
    about how to complete it and looking at the information required under each heading.
 Point out that headings are often written in bold or capitals to draw attention to them. Ask learners to find
    examples of headings, titles etc. on the focus page.

Section 2: When you are writing
 Suggest and practise tactics with learners for writing technical information, such as remembering a few
    letters at a time.
 Explain the need to check for accuracy. Is the information in the correct place on the form? Is all the
    information provided? Is the handwriting readable?

      Ma                         Module 2 The production process

     Pay particular attention to the section where learners need to describe the defect or damage. Discuss the
      amount and type of information required here. Why is it not enough to say ‘It doesn’t work’? Introduce
      vocabulary to describe non-functioning machinery.
     Provide examples for practice. Do learners have any other tactics they find useful?
     Stress that filling in a form is a way of communicating with someone else and therefore legibility is
     Use capital letters if handwriting is untidy.

Section 3: After you have filled in the report sheet
 Proof-read the form for accuracy of spelling and of content.
    Curric. refs            NOS/NVQ                  Key Skills
    Rw/E3.2                 C1.2
    Ww/E3.1                 C1.3

Task 1
Read a defect report form, including the small print
 Check that learners have the Machine breakdown report form from the Source material.
 Remind learners of the general necessity of preparing and keeping written reports.
 Remind learners of the importance of reading through a form first.
 Point out to learners they must read the form carefully to check that they understand it and know what to do
   with it when completed.

If the learner has difficulty
 Read through the form with the learner and check that all the language is understood. The answer to
     question 1 cannot be found on the form. Where would be a good place to look?
 Help the learner to find the information they need to answer the remaining questions by scanning for words
     to link the question to the form, and then reading carefully for details.

Look at defect report forms from the workplace and answer similar questions based on these.

Task 2
Complete part of a defect report form
 Explain that only part of the form needs to be completed for this task.

If the learner has difficulty
 Check that the learner knows what information needs to be added for each heading.
 Dyslexic and weaker learners may benefit from being given a master copy showing the headings and then
     writing these headings on a memory card for future reference.

 In pairs, list some common problems for certain types of machines.
 Identify in pairs the faults and defects that they can safely deal with themselves, and those that need to be
    referred to the workshop.

Task 3 (Audio 17)
Use a scenario to write a brief but accurate description of a defect or fault
 The audio clip should be used to reduce the amount of reading needed to complete the task.
 Remind learners of the need to be accurate but brief in their comments on the form.

    Ma                         Module 2 The production process

   Explain the need to include only facts and relevant information. Opinions will not be relevant or useful to
    the person(s) reading the form. Learners should think about the type of information that the person reading
    the form may need to know. The reader(s) will be staff in the maintenance department who need to fix the
    machine. What type of information will help them do this?

If the learner has difficulty
 Read through or listen to the scenario more than once and discuss with the learner what has happened. Build
     the big picture. Make sure learners understand the overall process. Make sure they realise the purpose of the
     form and who will be reading it, i.e. who the information is being provided for.
 Play the audio clip and pause after each sentence. Ask the learner, Will this information be useful for the

Working in pairs, learners give each other scenarios that their partner must interpret and write down. Learners
may need to use workshop manuals for this, in order to find common faults or part names.

Theme assessment
The skills of reporting problems practised here can be applied to writing evidence statements for learner
portfolios, where learners need to be accurate and to the point, to include detail but not irrelevant information.
Ask learners to describe in writing any problem they have dealt with at work. Use headings to structure this:
Date, Location, Problem, How I dealt with it. Learners need to be able to complete forms such as these in a way
that is clear and easy to understand.

      Ma                    Module 2 The production process

Reporting and recording                                                                               (Focus) 2:28

faults – filling in a form
As well as reporting a fault face to face or on the phone, you may have to fill in a fault form.
  Before you start:                                Find out the
   Read the whole form,                            meaning of anything
     including the ‘small                           you don’t
     print’. There may be                           understand.                            Look at the title.
     instructions about                            Check that you                         Are you filling in the
     filling in the form and                        have all the                           correct form?
     other important                                information you
     information.                                   need.
                                                                 MACHINE BREAKDOWN REPORT
  Look at the                              To be completed by operator and given to Manager/Supervisor immediately.
                                       Machines with identified defects should NOT be used until they have been inspected by
  headings carefully                       maintenance staff or permission has been given by the Manager/Supervisor.
  to decide what                    Only to be filled in using ink                                             No 0251
  information goes                  Department:
                                    Date:                                                       Time:
  where.                            Operator:                                        No:                  Supervisor:

                                    Reason for breakdown:
      Think carefully              Machine no:
                                    Operator’s comments:
       about the spaces
       where extra
       information is
       needed.                                               PASS TO QUALITY ASSURANCE OFFICE
      Keep to the facts.           Recipient:
                                    Action taken to rectify breakdown:

  When you are writing:             Number of personnel carrying out                               Total
   Complete                        repair                                                         number
                                                                                                   of hours
    straightforward                 Further action required to prevent re-         Classification:
                                    occurrence: (i.e. changes to                   1.              Operator
    information accurately          process/machine/tooling/further training)      2.              Tooling
    and clearly.                                                                   3.              Faulty part
   Be clear and precise.                                                          4.
   Include details but             Repaired by:                           Name:            Signature:         Date:
    keep to the point.                                            RETURN TO THE QA OFFICE

   Make sure details are
                                     Must be signed before detaching top copy. Top copy to be given to workshop supervisor.
                                                                   Bottom copy to be kept in file.
                                                  After you have filled
                                                  in the report sheet:
      Make sure that you are                      read what you
       following the instructions on                  have written.                        Check that all the
       the report sheet.                                                                   information is in the
      Make sure your handwriting                                                          proper places.
                                                  If you want to, write in
       can be understood by
                                                  pencil first, check it                    Check that the
       anybody reading it.                                                                     information is
                                                  through, making any
      Make sure you copy unusual                                                              accurate.
                                                  changes, then
       words, such as the names of
                                                  complete the form in                      Check that words
       machine parts, accurately.                                                              are spelt
      Is the meaning clear?                                                                   correctly.

   Ma                    Module 2 The production process

Reporting and recording                                                      (Task) 2:29

faults – filling in a form
You will need the Machine breakdown report form the Source material.

Task 1
Answer these questions on a separate sheet of paper.
1 What is another word for ‘defect’?
2 Who do you give the form to when you have completed it?
3 What happens to the top copy of this form?
4 What happens to the bottom copy of this form?
5 When can you use the machine again?
6 What should you use to complete the form?

Task 2
1 Use the information on the notebook to fill in the form as if you were David Williams.
2 Read through the form to check for errors.
3 Check your completed form against the one in the Answers to be sure that you have put
  the information in the correct places.

Task 3 (Audio 17)
Listen to the operator talking about something that has gone wrong with the machine he
Use the information to complete the ‘Operator’s comments’ part of the form.

    The machine was working as usual and I was thinking my
    own thoughts, when suddenly I heard a juddering noise
    and the blade came to a standstill. It gave me quite a
    shock, I can tell you. The techs said it was because there
    was a coupling loose on the gearing or something.

    Ma                         Module 2 The production process

PAGES 2:30–2:31
Handover – meetings
Occupational setting
Handover from one shift to another may be a formalised process in some factories; in others it will be a very
informal exchange between line leaders. Its purpose is to check the progress of a particular batch or run and to
catch up on any problems or issues such as machinery faults, staffing or supply deficiencies. During handover
meetings and any other situations where information is given, manufacturing workers have to listen for
information that may not always be explicit. They may also be required to give factual accounts of what has
occurred during their shift. This theme seeks to exemplify how to impart information and to give pointers to
what to listen for. It helps to develop the skills required for Unit 206 and other aspects of optional units.

Handover information for modelling good and bad practice (see below)
Audio equipment
Explain this! cards from the Source material (0:25)

Learning outcomes
1   To understand the need to provide relevant information (focus page, Tasks 1 and 2)
2   To understand appropriate tone and register (focus page, Tasks 1 and 2)

Suggested teaching activities
   Check learners’ understanding of ‘handover’. Ask learners to give some of their own experiences and elicit
    from the group the purpose of handover.
   Present (role-play) a model of handover information in a bad way, i.e. not sequenced, extraneous detail, too
    much personal opinion. You may want to add in something on poor use of language in relation to diversity.
   Discuss reasons why this is not a good way to report back information. Elicit the need for precision and a
    professional approach. Discuss what can go wrong when giving information at work. Talk about what can
    happen when people get the wrong message, get confused about what is meant, or can’t remember the
    important bits of information.
   Model the same information presented in the correct way.
   Discuss the roles of speaker and listener and the difficulties that may arise (noisy environment,
    muddled/hurried speech, listening while doing something else). Ask learners, and list, the qualities of a
    model speaker and a model listener in the handover situation. Body language, eye contact, etc. may be
    mentioned here.
   Note that ESOL learners may need extra help. This is an opportunity to raise issues such as using slang or
    colloquialisms such as ‘It’s been a nightmare’, ‘The machine’s been a bitch’, ‘She’s running smooth as
    custard’, ‘Tell me about it!’, ‘You wouldn’t believe it!’

Focus page
   Cover the points on the focus page, giving further examples if necessary.
   For the speaker, include:
    – Ways of being ready to speak, with all the information at hand (using notes or forms)
    – Ways to ask confirmation questions (Got that? OK with all that? Did you get the bit about …?)
    – Ways to rephrase the same information (we’re nearly out of foil/don’t forget you’ll soon need more
   For the listener, include:
    – Discussion of ways to ask questions (Can I just check that …? Can you tell me what you meant by …?
         Please could you repeat the part about …?)
    – Ways to repeat back information in their own words (So the machine has been down nearly all day?
         Did you say that … ?).
    – Strategies for remembering information.
   This is a useful opportunity to discuss appropriate ways to behave in other interactions at work (keeping to
    the facts, strategies to make a point effectively, making sure you are listening carefully, being clear). This
    could be the focus of a role-play.

    Ma                          Module 2 The production process

   Curric. refs                            NOS/NVQ                  Key Skills
   SLc/E3.1          SLc/E3.2              206                      C1.1
   SLc/E3.3          SLc/E3.4
Task 1
Question 1 (Audio 18)
Select the important details to suit the purpose                  SLc/E3.3
 Make sure learners understand what they are listening for before they begin the task.
 Play the audio clip three or more times. Remind learners that the shift leader needs to tell the person taking
    over from them relevant information about what has happened during the shift and that they need to cross
    out all information that is not relevant to this even though in reality pleasantries will be exchanged.

If the learner has difficulty
Ask the learner to imagine you are the next shift leader and agree what information items should be given.
Listen to the audio clip a bit at a time and ask the learner to make decisions about each item that they hear. Ask
questions until you have got the important information, then locate this information in the script.

Provide a more intricate scenario for learners to repeat the exercise or to list the facts from. Allow only one
attempt at listening (to emulate real life).

Question 2 (Audio 19)
Provide confirmation that information has been heard          SLc/E3.2
 Play the audio clip or read the script three times or more.
 Ask learners to choose the speech bubble that confirms the main point.

If the learner has difficulty
After listening once through, go through each speech bubble and audio clip in turn. Discuss which speech
bubble would give the most useful information. Make sure the language of each is understood.

Ask learners to role-play a handover conversation with you.

Tasks 2 and 3
Pass on information and check the listener understands.         SLc/E3.1         SLc/E3.2          SLc/E3.3
 Explain to learners that they need to work in pairs for this task and check that they understand the
 It may be helpful to invent another scenario and go though it with learners to demonstrate the procedure.
    When giving your explanation draw attention to when you repeat the important information by using
    emphasis and when you check understanding by questions.
 It may be better to invent scenarios familiar to the learner and write them out on blank cards.
 Make sure learners know that they need to keep swapping roles from speaker to listener.

If the learner has difficulty
 Turn back to the focus page. Go through the chosen card with the learner using the ideas on the page. Model
     some phrases and sentences that will be useful to the learner.
 Ask the learner to choose another card and first explain to you what the purpose is; then give the
     information; then check that you have understood it.
 Take the final card, and give the explanation yourself. Ask the learner to echo your words and the way you

Ask learners to role-play giving information to a group of people, e.g. explaining to a group of new workers
where to find materials or how to order new supplies. Ask learners to point out the differences between giving
information to one person and to a small group of people.

Theme assessment
Think of a situation relevant to learners where they need to give information. Develop a role-play around it,
and/or check their competence on the factory floor.

   Ma                       Module 2 The production process

Handover – meetings                                                          (Focus) 2:30

If you are a team leader, you will need to pass information on to the next shift to let them
know how things have gone and if there have been any problems. You will probably be
speaking to another team leader. If you’re taking over from another shift, you need to know
about any problems or issues that have occurred. You will need to listen to the other team

If you are the speaker …                                           If you are the listener …

      Prepare what you                                                        Prepare
      want to say.                                                            to listen.

      Speak clearly,                                                          carefully to
      giving just the                                                         what is said.

                                                                          Do not interrupt
      Check that the                                                      unless you have
      listener                                                            something
      understands.                                                        important to say.

   Tips                                                              Tips
    Take your time.           Make a note of important               Look at the
    Keep to the               details you need to remember.            speaker and
      point. Don’t                                                      concentrate on
      waste time giving                                                 what the speaker
      unnecessary                                                       is saying.
      details that will        Remember who you are talking           Make a mental
      confuse the              to and use language that suits           note of how many
      listener.                the situation.                           things you are told.
    Give information                                                 Repeat back what
      in the right order.                                               you hear to check
    Repeat the key                                                     you have heard
      details in a                                                      correctly.
      different way.                                                  Ask questions if
    Ask the listener                                                   you need to know
      questions to                                                      something or want
      check that they                                                   something made
      understand.                                                       clearer.

   Ma                     Module 2 The production process

Handover – meetings                                                          (Task) 2:31

Task 1 (Audio 18)
1 Listen to a shift leader handing over to the next shift leader. Cross out all the things he
  didn’t need to say.
                                      Hiya. How’s things with you today? You’re looking
                                      better than when I last saw you. Not much has
                                      happened here tonight – nothing has gone wrong,
                                      would you believe? We should hit production
                                      targets for tonight if nothing else. The ink is nearly
                                      out on the printer, though, so you’ll have to change
                                      that soon. Other than that … Oh! Did you get the
                                      fantasy football results? How did we do?

                                          Look for the sentences that give the
                                          information the new shift leader needs.

(Audio 19)
2 Listen to five possible sentences to let the shift leader know that you have heard what he
   said about the ink. Tick the most appropriate response.
                                                                  5 Those printers are
   1 You are so lazy. If          2 Right. I’ll keep                forever running out
     you know the ink’s             an eye on the                   of ink. They should
     running out why                ink. __                         get new printers.
     ever don’t you                                                 They moan soon
     change it before my                                            enough if the date
     shift starts? __                                               stamps aren’t
                                  3 I hearby notify you
                                                                    clear. __
                                    that I have heard
                                    what you said about
                                    the ink. __                       4 OK. __

Task 2                                                                   Remember!
Now it’s your turn to try giving information to others. Work in pairs.    Give only the
1 Choose an ‘Explain this!’ card from the Source material.                 details that are
2 Give the explanation on the card to your partner.                        necessary.
3 Repeat the things you want him or her to do or remember.                Use suitable
4 Check that your partner has understood by asking questions.              language for
5 Swop roles and repeat steps 1–4 with a new card.                         the person you
                                                                           are speaking to.

Task 3                                              Discuss whether you:
Discuss the role-play with your partner.             passed on just the details
1 What did you do well when passing on information?  spoke clearly
2 What aspects do you think you need to improve on?  repeated the key information
                                                     checked the other person

     Ma                         Module 2 The production process

PAGES 2:32–2:33
Handover – forms
Occupational setting
Many forms are filled in during the production process, often in tabular format. This theme aims to exemplify
filling in such forms.

As many forms in tabular format as are available in the workplace
Daily pre-start-up check sheet from the Source material (0:26)
Audio equipment

Learning outcomes
1    To understand the format of tabular forms
2    To enter information into forms that have a tabular format

Suggested teaching activities
    Explore the forms from the workplace. Why do they need to be filled in? How do they need to be filled in?
     What have they got in common? What are the implications of filling them in incorrectly?
    Discuss the problems encountered when filling in a table, e.g. lack of space to write, finding the correct
     place to write. List the problems. Revisit the list at the end of the focus page to see if there are any
     outstanding issues.

Focus page
    Go through the ‘thoughts’ on the focus page. Ask learners to provide answers to the questions. (They are
     numbered to match the answers on the answer page.) Find examples on the page to match the answers.
     Make sure all learners have some strategies that will help them to complete these forms. There is a larger
     copy of the form in the Source material. This can be projected with an OHP or you can use PowerPoint.
    Go through the other points on the page. Stress the need to read the form thoroughly, follow any
     instructions, be methodical and proof-read.
    Curric. refs            NOS/NVQ                  Key Skills
    Rt/E3.2                 206                      N1.1

Task 1 (Audio 20)
Fill in a check sheet using information from an audio clip
 Make sure learners have the Daily pre-start-up check sheet from the Source Material.
 Prepare learners for listening by explaining the task and setting the scene. Check learners are familiar with
     the check sheet. Get them to read it through and ask questions about anything they do not understand.
 Play the audio clip once so that learners get the gist. Discuss any points arising.
 Play the clip again and tell learners to fill in the second column of the check sheet using the correct symbols
     or words.
 Play the clip again as learners check the sheet.

If the learner has difficulty
 Check that learners are able to read and understand the sheet. Make sure they know how to complete it
     using the correct symbols or words.
 Learners may find that listening and completing the check sheet is too much. Split up the task by pausing
     the audio clip, or read the audio script step by step, questioning the learner as you go.

    Ma                         Module 2 The production process

   Provide a copy of the information in the speech bubble broken down point by point with bullet points.
   Dyslexic learners may prefer to highlight the key words as they read, before filling in the form.
   Learners having difficulty with tracking on the form may benefit from using a ruler or guide.

Make an audio clip (with missing items) to go with a workplace checklist for other learners to use.

Task 2
List jobs to be completed
 Check that learners have correct answers to Task 1.
 Remind them that the information can be obtained by scanning down the checklist and also looking at the
     audio script.

If the learner has difficulty
Assist the learner to look in the table for missing information. Use a highlighter pen or coloured pen to identify
missing checks.

Complete the missing items from the learner-made audio clip.

Task 3
Write additional information onto the form
 Look at the existing checks completed on the form. Ask learners where they think action would need to be
    taken and what this may be. Direct them towards the instructions on the form.
 Read through the speech bubble to identify action that may be taken and direct learners to comments
    already on the form.
 Ask learners to add the details clearly.

If the learner has difficulty
 Take the learner through the check sheet and assist them to identify where there may need to be action taken
     as the result of the check. Talk through the action to be taken and support learners to decide what to write.
     Emphasise that writing needs to be concise and clear.
 Model changing what is said to what is written.
 Give support with any spelling problems. Emphasise that spelling usually does not need to be absolutely
     precise, but must be as close to the original as possible. Maintaining the right beginnings and ends of words
     is important.

 Present learners with other scenarios and assist them to formulate short phrases to describe what happened.
 Ask learners to discuss their own work situations and to describe areas where action needs to be taken and
    recorded. Discuss and formulate phrases and words that will simply and clearly describe these problems.

Theme assessment
Observe learners completing checks in the workplace and use their completed documentation for evidence.

   Ma                                   Module 2 The production process

Handover – forms                                                                                                      (Focus) 2:32

Most production lines have end-of-shift checks as well as pre-shift checks. You can use the
forms to help remind you what to say to the next shift leader.

         How do I know                                    Should I write                                    Do the rows have
         which column                                     ticks, a date, my                                 headings too?
         to write in?                                     initials or what?

                                                                                                                  How do I find
                                                                                                                  the right row
        How do I know                                                                                             to write in?
        I’ve got the
        right form?
                                                                                                                  How do I find
                                                                                                                  the right box
                                                                                                                  to write in?

                                                                                                           The spaces are
                                                                                                           very small. How do
                                                                                                           I fit everything in?

                                  DAILY PRE-START-UP CHECK SHEET
 MACHINE/LINE: MIXANDBAKE                                 DATE: 01/02/06
 DEPARTMENT: Production                                   SHIFT A CHECKED BY: LH Richards
                                                          SHIFT B CHECKED BY:
                                                          NIGHT SHIFT CHECKED BY:
 All checks to be carried out on machines in motion.
 All checks to be carried out at the start of each shift or when a different operator runs the line.            Everything was OK
 Health and safety
                          Shift A
                                       Shift B
                                                            Night shift
                                                                              Action taken        Reported to   when I took over –
 Panels in position?                                                                                           except for the floor
 Safety guards            
                                                                                                                which needed
 On/off buttons                                                                                                mopping. They
 Checked                  
                                                                                                                came down and
 compressed-air                                                                                                 did that as soon as
 Emergency stop           
                                                                                                                I phoned them.
 Glass: ovens ok?         
 Fire exits and           
 extinguishers ok?
 Gantry and floor         X                                                   Reported at         Cleaning
 area clean?                                                                  0605                services
 Tray wash                
 Microwave leakage        
 test performed?

                                                                                                                     When you have
  Start by reading the                                                              Be methodical –                  finished, check
  form through so that                             Pay special
                                                                                    do everything                    through your
  you know what to                                 attention to
                                                                                    on the list in the               writing to check
  expect when you                                  any
                                                                                    order it is                      that it makes
  come to fill it in.                              instructions.
                                                                                    written.                         sense.

   Ma                     Module 2 The production process

Handover – forms                                                               (Task) 2:33

Task 1 (Audio 20)
You will need the Daily pre-start-up check sheet from the Source material. Listen to an
operative on Shift B checking through the checklist. Fill in the form as if you were the

    Let’s see, where shall I start? Are the panels in
    position? Yes. What about the safety guards? Yes. On
    button working? Yes. Off button? Yes. Compressed air
    check. I’ll do that later. Emergency stop button
    working? Yep. I’ll do the glass check after. The fire
    extinguisher's in position? OK. Oh dear, there’s a pile
    of boxes in front of the fire door. I’d better get them
    moved. I’ll phone housekeeping later. Back to the list.
    Is the floor clean? It'll do. What about the gantry? Yes,
    that’s OK. The tray wash is working. Microwave
    leakage test next. Yes, that’s good. On to product
    safety checks. Mine is the only foreign body I can see
    near this machine, so a tick in that box. The machine
    looks clean and I can't see any cracks in the glass or
    Perspex. Nearly there. Just metal inspection to go now.
    Any new scratches on the blades? There’s a bit of
    wear there – I’ll report that. These blades look a bit
    dodgy. I’d better change the blade set. Good. That’s
    about all. We’ll soon be ready to roll.

Task 2
The operative has forgotten some checks. Make a list of what needs to be done on the

Task 3
Fill in any more details you can
on the form.

  Hello, is that housekeeping?
  It’s 2:15. Could you come
  down to Mix and bake and
  move some empty boxes that
  are blocking the fire exit?