Course Title: Production Simulation (Part A)

Part A: Course Overview

Course ID: 014468

Course Title: Production Simulation (Part A)

Credit Points: 12

Course Code




Learning Mode

Teaching Period(s)


City Campus


135H Applied Sciences


Sem 1 2006

Course Coordinator: Elisabeth Gorczyca

Course Coordinator Phone: +61 3 9925 2624

Course Coordinator Email: l.gorczyca

Course Coordinator Location: Room 13D6a City Campus

Course Coordinator Availability: Monday mornings, Friday with appointment

Pre-requisite Courses and Assumed Knowledge and Capabilities

Students should be in the final year of program BP093

Course Description

This course is undertaken over 2 semesters.

This course will provide an opportunity to document a process including writing specifications (microbiological, chemical and physical for raw materials and final products), identification of critical control points (including creating a Food Safety program), deciding on appropriate control points, monitoring and recording procedures as well as organising, managing and evaluating (with justification) the acceptance/ rejection of the product produced.

Food Quality Assurance combines the application of statistical data to monitor the performance of a production line with documentation and the participatory style required nowadays in the workplace where the workers are encouraged to think and participate.

Objectives/Learning Outcomes/Capability Development

This course contributes to the student’s capabilities in the following ways:

(I) TEAM and LEADERSHIP skills

Team skills are the key capability for this course. Students work in groups of about 3 under their chosen leader (role can be floated) on an assigned product.

There will be some formal instruction on teamwork. In addition, the students will be expected to actively learn to work, communicate findings and cooperate with one another so as to acheive the best possible manual, product and production run.


As the students have to undertake 2 very involved tasks, namely, preparation of a manual and production, they have an oppportunity to assess their planning , organisational and time management skills.


As the students are required to identify problems before, and during production and suggest  both short term and long term practical solutions, they have an opportunity to evaluate their problem solving skills in circumstances where time is of the essences (during production).


Both written and verbal skills are developed. For example, the standard operating procedures require clarity of language to avoid errors in production.

When the course is completed and passed, a student should be able to do the following:

(i) Overall, be able to set up a Quality assurance Plan (Procedure, Manual including a Food Safety Plan and a testing manual) for an assigned food product - frozen, chilled, dried, and heat processed.

(ii) Develop a fFod Safety Plan for an assigned product based on HACCP principles & include Hazard Analysis, Risk Assessment, CCP decision and HACCP Audit documentation with Corrective Action recording (CAR).

(iii) Set Specifications for raw materials, an associated final product and appropriate packaging specifications for primary packaging.

(iv) Set up and use Acceptance sampling procedures (Attribute and Variable) for raw materials and final products for testing against single and double specifications.

(v) Document instructions for production - Standard Operating Procedures

(vi) Construct and interpret Process Control Charts for attribute and variable inspection.

(vii) Determine the sensitivitu of process control charts

(viii) Understand the significance of Process Capability Studies and be able to calculate  process capabilituy ratios and associated fallouts.

(ix) Be familiar with reporting techniques used to liaise with and assess suppliers - including vendor appraisal systems.

(x)  Be familiar with key aspects of Customer Complaint documentation, Recall systems and Audit systems

(xi) Understand and use the concepts associated with  Quality management systems including the ISO 9000 series.

Overview of Learning Activities

The participatory format of both the lectures ( for Quality Management systems and Production control statistics and Product acceptance sampling) and the workshops for introducing documents required to create product, Food safety and test plans are designed to encourage students to feel safe and comfortable in asking difficult questions.

The interviews are designed to help students identify their key production problems and focus on finding a solution as welll as coming to an understandin as to mho the production runs will be assessed.

Overview of Learning Resources

Students will be provided with lists of relevant text books for various sections of the course, library resources,  relevant journals and internet sites as well as access to past manuals.

Overview of Assessment

The assessment is divided between

(A) Individual assessment - (i) written examination and (ii) assessment of product, production and communications and

(B) Team assessment  - (i) manual (Product, Food Safety plan and testing) and (ii) Production and problem report.