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Elements and Performance Criteria

  1. Prepare for changeover
  2. Make quick changeover
  3. Improve Occupational Health and Safety (OHS)

Evidence Required

The Evidence Guide provides advice on assessment and must be read in conjunction with the performance criteria required skills and knowledge the range statement and the assessment guidelines for this training package

Overview of assessment requirements

The person will effectively and routinely carry out quick changeovers in liaison with other relevant personnel and will make recommendations for improving the changeover

What are the specific resource requirements for this unit

Access to an organisation using quick changeovers

What critical aspects of evidence are required to demonstrate competency in this unit

Evidence of routine positive participation in quick changeover

In what context should assessment occur

Assessment will need to occur in an organisation using quick changeover or a suitable simulation for example in a workshop

Are there any other units which could or should be assessed with this unit or which relate directly to this unit

This unit may be assessed concurrently with relevant technical process units

This unit is related to

MSACMTA Develop quick changeover procedures which covers the managerdesign area for quick changeover

MSACMT620A Develop quick changeover procedures which covers the manager/design area for quick changeover.

What method of assessment should apply

Assessors must be satisfied that the person can consistently perform the unit as a whole as defined by the Elements Performance Criteria skills and knowledge A holistic approach should be taken to the assessment

Assessors should gather sufficient fair valid reliable authentic and current evidence from a range of sources Sources of evidence may include direct observation reports from supervisors peers and colleagues project work samples organisation records and questioning Assessment should not require language literacy or numeracy skills beyond those required for the unit

The assessee will have access to all techniques procedures information resources and aids which would normally be available in the workplace

The method of assessment should be discussed and agreed with the assessee prior to the commencement of the assessment

What evidence is required for demonstration of consistent performance

Evidence should be available of routinely participating in quick changeovers


Range Statement

The Range Statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording in the Performance Criteria is detailed below. Add any essential operating conditions that may be present with training and assessment depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts.

Changeover

Changeover may refer to an exchange of dies/tools (traditional), or a change between batches, or between campaigns. It may be any quantum equipment/process change to produce a different product.

Changeover is sometimes referred to as SMED which is a more extreme form where SMED is an abbreviation for Single Minute Exchange of Die; literally, changing a die on a forming or stamping machine in a minute or less; broadly, the ability to perform any set-up activity in a minute or less of machine or process downtime; the key to doing this is frequently the capability to convert internal set-up time to external set-up time; variations on SMED include:

Single-digit set-up: performing a set-up activity in a single-digit number of minutes, i.e. fewer than ten.

OTED: One Touch Exchange of Die; literally, changing a die with one physical motion such as pushing a button; broadly, an extremely simple procedure for performing a set-up activity.

Set-up time - work required to change over a machine or process from one item or operation to the next item or operation ; can be divided into two types:

internal set-up work that can be done only when the machine or process is not actively engaged in production; OR

external set-up work that can be done concurrently with the machine or process performing production duties.

While the term die is the traditional term, competitive manufacturers who require changeover, but where dies are not used or are less significant, have applied this to a range of other changeovers.

This unit may not be applicable to a totally continuous operation producing only the one product, or simultaneous range of products. This is not applicable to a maintenance/ PVI shutdown as experienced by the continuous process manufacturers. However, where there is continuous manufacturing on a campaign basis, it may be applied to the changeover between campaigns or similar changeovers.

Procedures

Procedures include all work instructions, standard operating procedures, formulas/recipes, batch sheets, temporary instructions and similar instructions provided for the smooth running of the plant. They may be written, verbal, computer based or in some other form.

For the purposes of this Training Package, 'procedures' also includes good operating practice as may be defined by industry codes of practice (eg Good Manufacturing Practice (GMP), Responsible Care) and government regulations.