Employability skills (a)

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Employability skills (a)

Employers value people who:

• fit well into their team and workplace

• use initiative to solve routine problems

• work productively

• have good time-management skills

• are committed to continuous learningand improvement.

Slide 1: MCMT220A Apply quick changeover procedures

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Employability skills (b)

Employability skills can:

• help you gain employment

• make you a productive and valuable worker

• increase your chances of promotion.


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Employability skills (c)

Employability skills developed inMSACMT220A Apply quick changeover procedures:• Communication• Teamwork• Problem-solving• Self-management• Planning & organising• Technology• Lifelong learning• Initiative & enterprise


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Competitive (lean) manufacturing

To be competitive companies must:

• keep customers satisfied

• increase efficiency

• reduce costs

• reduce waste

• respond quickly

• continuously improve

• have enthusiastic and skilled staff.


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Seven types of waste in manufacturing

1. Overproduction

2. Defects

3. Inventory

4. Motion

5. Processing

6. Transportation

7. Waiting


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Lean manufacturing tools (Kaizens)

• 5S

• Pull systems (kanban)

• Value stream mapping

• Just-in-time production

• Total productive maintenance


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Lean manufacturing tools (Kaizens) cont …

• Takt time

• Heijunka

• Jidoka

• Visual process control

• Error-proofing (poka-yoke)

• Waste (muda) elimination

• Cellular/flow production

• Set-up/changeover reduction


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Quick changeover

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


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Understand quick changeover

• Understand the benefits of using quick changeover as a competitive manufacturing tool.

• Identify how quick changeover can reduce waste in your work area.


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Chapter 1Understand the principles

of quick changeover

This chapter explains how to:

1.1 Reduce waste with quick changeover

1.2 Determine the benefits of quick changeover


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The seven wastes

1. Overproduction

2. Defects

3. Inventory

4. Motion

5. Processing

6. Transportation

7. Waiting


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Benefits of quick changeover

• Reduce batch sizes

• Increase available space

• Reduce inventory costs

• Allow product to flow from one process to the next


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Benefits of quick changeover cont …

• Permit uninterrupted (smoothed) production with no bottlenecks or delays

• Increase production flexibility

• Improve on-time delivery – quick changeover supports the ability to meet customer demands

• Increase changeover accuracy


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Benefits of quick changeover cont …

• Reduce defect rates

• Reduce start-up scrap/waste

• Improve equipment utilisation/yield

• Increase profitability without new capital equipment purchase


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Design a quick changeover

You need to understand:

• the principles of quick changeover

• the design of a quick changeover procedure in order to be able to improve it.


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Chapter 2Design a quick changeover


2.1 Identify internal and external activities

2.2 Convert internal activities to external activities

2.3 Eliminate the need for adjustment

2.4 Remove the need to set up completely

2.5 Improve ergonomics and OHS


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Internal and external activities

• Internal set-up activities – can only be carried out when the machine or plant has stopped.

• External set-up activities – can be completed while the machine is operating.


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Design modifications

• Use dedicated equipment to ensure that the right equipment is always ready and waiting.

• Ergonomically designed mobile die carts get dies into position rapidly.

• Well-located and ergonomically designed tool boards improve access to necessary equipment.

• Press-mounted roller rails move the die into the pre-staging position.


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Design modifications cont …

• Quick-change die cassettes easily slide in and out of the platen.

• Quick-release clamps for die cassettes clamp the dies in place rapidly.

• Locating pins for aligning dies can remove the need to adjust the die.

• Standardising shut heights using a liner removes the need for press stroke adjustments.


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Ergonomics and OHS

• Standing is better than sitting

• Workstations are adjustable

• Work rhythm

• Don’t remain in one position for too long

• Ergonomic 5S is essential


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Implement quick changeover procedures

• Understand the steps involved.

• Understand importance of preparation, communication, teamwork.

• Be aware of any OHS hazards.

• Regularly update and improve OHS procedures.


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Chapter 3Implement a quick changeover


3.1 Prepare for quick changeover

3.2 Implement a quick changeover in your work area

3.3 Continuously improve procedures

3.4 Improve OHS


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Preparing for a quick changeover

• Know when changeover is required.

• Obtain all required tools, parts and materials.

• Communicate with everyone involved in the changeover.


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Factors for successful changeover

• Preparation

• Training

• Timing

• Teamwork communication

• Standardisation

• Right tools in the right place


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Convey information about changeovers by:

• production plans

• production kanbans (pull systems)

• noticeboards

• email

• toolbox talks

• work authority.


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Materials required • Standard operating procedures (SOP)

• Job safety analyses

• Work permits

• Pre-start checklist

• Authority to change

• Quality criteria

• Control charts

• Data collection tools


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Pre-start checklist for die changeover

Before you begin the die changeover, check that you have:

informed all relevant persons

positioned the tool board

positioned the new die in the pre-staging area

prepared die and accessories by performing external set-ups

electrically and mechanically isolated the equipment

removed all hazards in the work area.


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Review changeover

• How did we perform?

• Where there any problems?

• Are we improving?

• What recommendations can we make?

• Identify, discuss and document improvements.


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PDCA cycle

Plan ahead for changeTake action to improve the process

Execute the plan, taking small steps in controlled circumstances

Study the results


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Improve OHS in quick changeovers

• Undertake regular job safety analyses

• Update procedures

• Retrain


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Job safety analysis

1. Document the activity

2. Identify the hazards

3. Document the control measures

4. Identify who is responsible

5. Monitor and review


Employability skills (a)

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