Elements and Performance Criteria

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. It may sometimes be referred to as

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.

While the term die is the traditional term, competitive manufacturers who 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/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 development of changeover procedures between campaigns or similar changeovers.


Critical analysis of the existing changeover involves a detailed examination to observe all actions and delays and the times taken.


The principles of quick changeover include the principles of efficient movement as well as an understanding of jigs, fixtures, locating devices and mechanical aids which will reduce human effort and time required.


Activities which should be improved/eliminated include not only those which take time or are unreliable in terms of outcome, but also those which are difficult to do or have adverse OHS implications (eg repetitive strain injury, back injury, finger injuries).


An acceptable risk profile is one which at the minimum meets regulatory and organisation requirements and does not increase the current risk profile.


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.

Overview of assessment requirements
The person will be able to critically examine existing changeover procedures and develop and implement improved procedures which will steadily move the organisation to greater uptime/lower changeover caused downtime.

What are the specific resource requirements for this unit?
Access to an organisation using quick changeover.

What critical aspects of evidence are required to demonstrate competency in this unit?
Evidence of changeover procedures modified and improved in accordance with the above criteria should be available.

In what context should assessment occur?
Assessment will need to occur in an organisation following quick changeover or by a suitable project.

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 other improvement units.
This unit is related to:

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?
Where evidence is from a continuous improvement to changeover then a range of improvements will be required to generate sufficient evidence. Where evidence is from the initial introduction of quick changeovers or a complex improvement, then the single project may generate sufficient evidence.