Applying set-up reduction techniques

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This standard covers the competences required for applying set-up reduction techniques. It involves applying the principles and processes of set-up reduction to a machine, equipment or process set-up, changeover, clean-down or turnaround activity that is a bottleneck or constraint which affects the process, such as capacity, flexibility, lead time, inventory or other business performance measure.

You will be expected to identify and confirm where the problems occur within the set-up process, and to determine where improvements can be made. You will need to set suitable quantifiable objectives and targets against which the improvements are to be made. The activities will require you to co-ordinate and carry out set-up reduction activities on different machines, equipment or processes, and to make improvements to the current set-up, such as reduced set-up time, improved safety, improved quality and improved work practice.

You will also be required to produce changes to standard operating procedures for the new set-up, which include all of the new steps to be carried out, the time required for each step, differentiation between internal and external steps, standard equipment and its location (such as cutting tools, clamps, hand tools, inspection equipment) and information required for a quick set-up, and its location (such as computer numerical control (CNC) programs, drawings and manufacturing instructions).

Your responsibilities will require you to comply with organisational policy and procedures for the activities undertaken, and to report any problems that you cannot solve, or that are outside your responsibility, to the relevant authority. You will be expected to take full responsibility for your own actions within the activity, and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to the techniques and procedures used. You will need to understand the principles and procedures of set-up reduction, and its application, in adequate depth to provide a sound basis for carrying out the activities to the required criteria.

Applying safe working practices will be a key issue throughout.

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1. work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
2. identify any equipment or process set-up activity that is a bottleneck or constraint which affects productivity
3. co-ordinate and carry out the set-up reduction activity on the chosen equipment or process, using the appropriate techniques
4. identify and confirm problems or conditions within the current set-up, where improvements can be made
5. define quantifiable objectives/targets for improvements to the chosen set-up
6. implement improvements to the current set-up, to meet the identified objectives and targets
7. produce changes to standard operating procedures (SOPs) or other approved documentation that will embed the improvements made to the set-up requirements

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1. how to work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
2. how equipment or a process is selected for a set-up reduction activity
3. from whom authority is gained for the release of people and resources for the set-up reduction activity
4. the application of the Deming cycle (plan, do, check, act)
5. how to structure and run a set-up reduction activity
6. how to distinguish between internal and external activities with reference to set-up
7. how improvements to the set-up can be achieved
8. how to evaluate improvement ideas and select those that will give most benefit for the least spend
9. how to set quantifiable targets and objectives for the improved set-up
10. how to correlate information to create or update standard operating procedures (SOPs) or other approved documentation
11. problem solving and the application of root cause analysis
12. the difference between motion' andwork'
13. what constitutes a value adding and non-value adding activity
14. the extent of your own authority, and to whom you should report in the event of problems that you cannot resolve

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1. Implement improvements to the current set-up which cover three of the following:
   1. reduced set-up time
   2. improved safety
   3. improved quality
   4. improved work practice
   5. improved regulatory compliance
   6. reduced cost
2. Identify and implement improvements to the new set-up, which covers three of the following:
   1. all of the new steps, and the time required for each step
   2. differentiation between internal and external steps
   3. standard equipment and its location
   4. information required for a quick set-up, and its location
   5. methods and standards
   6. co-ordination of documentation

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3

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31 Mar 2028

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Current

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Original

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Enginuity

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SEMBIT311

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Associate Professionals and Technical Occupations, Business and Finance Associate Professionals, Business Management, Business, Administration and Law

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2127

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Engineering; business; improvement; techniques; applying; set-up reduction; constraints; improvements

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