Google Links

Follow the links below to find material targeted to the unit's elements, performance criteria, required skills and knowledge

Elements and Performance Criteria

  1. Prepare for changeover
  2. Make quick changeover
  3. Improve work health and safety (WHS)

Range Statement

This field allows for different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.

Competitive systems and practices include one or more of:

lean operations

agile operations

preventative and predictive maintenance approaches

monitoring and data gathering systems, such as Systems Control and Data Acquisition (SCADA) software, Enterprise Resource Planning (ERP) systems, Materials Resource Planning (MRP) and proprietary systems

statistical process control systems, including six sigma and three sigma

Just in Time (JIT), kanban and other pull-related operations control systems

supply, value, and demand chain monitoring and analysis

5S

continuous improvement (kaizen)

breakthrough improvement (kaizen blitz)

cause/effect diagrams

overall equipment effectiveness (OEE)

takt time

process mapping

problem solving

run charts

standard procedures

current reality tree.

Changeover may include one or more of:

an exchange of equipment (often dies or tools (traditional))

a change between products/batches or between campaigns or processes. It may be any quantum change to produce a different product or undertake a different process.

Set-up can be divided into two types:

internal set-up (requires work to stop, work that can be done only when the machine or process is not actively engaged in production, computers etc. need to be reset and restarted)

external set-up (work can continue during the changeover, work can be done concurrently with the machine or process performing production duties).

Set-up time includes:

the work time required to change over a machine or process from one item or operation to the next item or operation.

Procedures (written, verbal, visual, computer based, etc.) include one or more of:

work instructions

standard operating procedures (SOPs)

safe work method statements

formulas/recipes

batch sheets

temporary instructions

any similar instructions provided for the smooth running of the plant.

Knowledge Evidence

Must provide evidence that demonstrates knowledge relevant to their job role sufficient to fulfil their job role under routine only supervision and to solve routine problems, including knowledge of:

principles of quick changeover, including:

setting of target time for changeover

conversion of internal set-up time to external set-up time, where appropriate

simplification of changeover steps

monitoring and continuous improvement of changeovers

purpose and requirements of changeover

minimisation of changeover waste (e.g. scrap and energy)

quality requirements for products and purposes

relevant operational procedures

health, safety and environment (HSE) principles relevant to own job.