Elements and Performance Criteria

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:
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
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
Changeover may refer to:
equipment exchanges, such as an exchange of dies/tools (traditional)
change between batches
change between campaigns (process manufacturing)
quantum equipment/process change to produce a different product
Quick changeover
Quick changeovers may be known by a number of alternative titles depending on the industry sector. In manufacturing quick changeovers may be referred to as:
single minute exchange of die (SMED)
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
While the term die is the traditional term, organisations that require changeovers using other equipment are also covered by this unit.
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/pressure vessel inspection (PVI) shutdown as experienced by the continuous process manufacturers. However, where there are continuous operations on a campaign basis, it may be applied to the development of changeover procedures between campaigns or similar changeovers
Set-up work
Set-up time is the work required to change over a machine or process from one item or operation to the next item or operation. It can be divided into two types:
internal set-up work that can be done only when the machine or process is not actively engaged
external set-up work that can be done concurrently with the machine or process performing productive duties
Principles
The principles of quick changeover include:
the principles of efficient movement as well as an understanding of equipment features and aids, including jigs, fixtures, locating devices and mechanical aids which will reduce human effort and time required
Improved/eliminated
Activities which should be improved/eliminated include:
those which take time or are unreliable in terms of outcome
those which are difficult to do or have adverse OHS implications (e.g. repetitive strain injury, back injury and finger injuries)
Hazards and risks
Hazards and risks include those related to:
OHS
regulatory compliance
environment
commercial and contractual obligations
An acceptable risk profile for changeovers is one which, at the minimum, meets regulatory and organisation requirements and does not increase the current risk profile
Procedures
Procedures may include:
work instructions
standard operating procedures
formulas/recipes
batch sheets
temporary instructions and similar instructions provided for the smooth running of the plan
good operating practice as may be defined by industry codes of practice (e.g. good manufacturing practice (GMP) and responsible care)
government regulations
Procedures may be:
written, verbal, computer-based or in some other format

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 their ability to:
observe and analyse steps in an existing changeover
manage risks in adjusting changeover procedures
develop changeover adjustments that deliver the greatest overall benefit
supervise changeover procedure trials.
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 responses 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
workplace projects
suitable simulation
case studies/scenarios (particularly for assessment of contingencies, improvement scenario, and so on)
targeted questioning
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.