This unit applies to individuals in an organisation which is implementing competitive systems and practices and is pursuing quick changeover as one of its competitive operations tools. The unit can apply to quick changeovers of equipment, processes, batches or product type.
This unit covers the carrying out of these quick changeovers and also recommending improvements within the scope and authority of the individual’s job.
Particular technical skills may also be required in some operations sectors and for some jobs. These skills should be gained from the Training Package relevant to the individual’s industry and occupation.
This unit requires the application of skills associated with applying quick changeover procedures, including the planning and organising of own work, identifying problems and making suggestions for improvement of procedures.
This unit may not be applicable to a totally continuous operation producing only the one product, or simultaneous range of products. The unit is also not applicable to a maintenance/PVI shutdown as experienced by the continuous process manufacturers. However, where there is continuous operation on a campaign basis, it may be applied to the changeover between campaigns or similar changeovers.
Elements and Performance Criteria
Prepare for changeover
Determine when changeover will be required
Review plans and instructions for quick changeover
Identify role of others in quick changeover
Obtain all required tools/parts/materials for changeover
Organise process and tools/parts/materials ready for changeover
Make quick changeover
Plan changeover according to quick changeover principles
Liaise and work with relevant people in quick changeover
Complete changeover according to procedures
Check output meets specification
Debrief with all relevant stakeholders
Note any steps which cause a problem
Recommend changes to problematic steps
Improve occupational health and safety (OHS)
Identify hazards to self or others in all steps/actions
Determine risks from each hazard
Identify actions which may be performed in a more ergonomic manner
Recommend changes to improve OHS
Required skills include:
determining/predicting when a changeover will occur through knowledge of products and processes in own work area
communicating with others to clarify scope and procedures for quick changeover and contributing suggestions for improvement
planning own tasks in quick changeover
identifying and working to target changeover time
working as part of a team
setting up quick changeover using appropriate tools, process skills and procedures
following OHS procedures and regulatory requirements and notifying risks
Required knowledge includes:
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
relevant operational procedures
target time for changeover
relevant OHS regulations and requirements
purposes/requirements of changeover
methods of recommending changes
quality requirements for products and processes
minimisation of changeover waste (e.g. scrap and energy )
The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.
Critical aspects for assessment and evidence required to demonstrate competency in this unit
A person who demonstrates competency in this unit must be able to provide evidence of the ability to:
identify the scope and equipment to be used in a quick changeover implemented in their work area
identify the target time
understand the difference between internal and external changeover steps
identify own tasks and responsibilities in a quick changeover
identify problems in quick changeovers
contribute suggestions for improvement.
Context of and specific resources for assessment
Assessment of performance must be undertaken in a workplace using or implementing one or more competitive systems and practices.
Access may be required to:
workplace procedures and plans relevant to work area
specifications and documentation relating to planned, currently being implemented, or implemented changes to work processes and procedures relevant to the assessee
documentation and information in relation to production, waste, overheads and hazard control/management
reports from supervisors/managers
case studies and scenarios to assess response to contingencies.
Method of assessment
A holistic approach should be taken to the assessment.
Competence in this unit may be assessed by using a combination of the following to generate evidence:
demonstration in the workplace
case studies/scenarios (particularly for assessment of contingencies, improvement scenarios, and so on)
reports from supervisors, peers and colleagues (third-party reports)
portfolio of evidence.
In all cases it is expected that practical assessment will be combined with targeted questioning to assess underpinning knowledge.
Where applicable, reasonable adjustment must be made to work environments and training situations to accommodate ethnicity, age, gender, demographics and disability.
Guidance information for assessment
Assessment processes and techniques must be culturally appropriate and appropriate to the oracy, language and literacy capacity of the candidate and the work being performed.
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, if used in the performance criteria, is detailed below. 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) may also be included.
Competitive systems and practices
Competitive systems and practices may include, but are not limited to:
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
continuous improvement (kaizen)
breakthrough improvement (kaizen blitz)
overall equipment effectiveness (OEE)
current reality tree
Competitive systems and practices should be interpreted so as to take into account:
the stage of implementation of competitive systems and practices
the size of the enterprise
the work organisation, culture, regulatory environment and the industry sector
Changeover may refer to:
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
In competitive systems and practices equipment-based quick changeover techniques in manufacturing can often be referred to under different names, for example:
single minute exchange of die (SMED) – The term originated with die changeovers but now often refers to the ability to perform any set-up activity in a minute or less of machine or process downtime
single-digit set-up – performing a set-up activity in a single-digit number of minutes (i.e. fewer than ten)
one touch exchange of die (OTED) – 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 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)
external set-up (work that can be done concurrently with the machine or process performing production duties)
The same distinction can be applied to non-production equipment-based work areas where changeovers of processes or operations can be:
internal (requires work to stop, be reset, computers restarted, and so on)
external (where work can continue during the changeover)
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 may include:
standard operating procedures
temporary instructions and similar instructions provided for the smooth running of operations, processes, plant and equipment
good operating practice as may be defined by industry codes of practice (e.g. good manufacturing practice (GMP) and responsible care) and government regulations
Procedures may be:
written, verbal, computer-based or in some other format
Competitive systems and practices
This unit contains employability skills.