Leading set-up reduction activities

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This standard covers the competences required for leading set-up reduction activities. It involves co-ordinating 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 confirm where the problems occur within the set-up process, and to confirm where improvements can be made. You will need to agree suitable quantifiable objectives and targets against which the improvements are to be made. The activities will require you to co-ordinate the set-up reduction activities on different machines or processes, and to co-ordinate improvements to the current set-up, which will include such items as reduced set-up time, improved safety, improved quality and improved work practice.

You will also be required to approve 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 and advising on 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. approve the identification of an equipment  or process set-up activity that is a bottleneck or constraint which affects productivity
3. lead the set-up reduction activity on the chosen equipment or process, using the appropriate techniques
4. approve the identification of problems or conditions within the current set-up, where improvements can be made
5. agree quantifiable objectives/targets for improvements to the chosen set-up
6. lead improvements to the current set-up, to meet the identified objectives and targets
7. implement and monitor progress of the improvements to the set-up activities
8. approve the production of 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 to plan the resources and time needed to carry out the agreed activity
3. how equipment or a process is selected for a set-up reduction activity
4. from whom authority is gained for the release of people and resources for the set-up reduction activity
5. the application of the Deming cycle (plan, do, check, act)
6. how to structure and run a set-up reduction activity
7. how to distinguish between internal and external activities with reference to set-up
8. how improvements to the set-up can be achieved
9. how to evaluate improvement ideas and select those that will give most benefit for the least spend
10. how to set quantifiable targets and objectives for the improved set-up
11. how to correlate information to create or update standard operating procedures (SOPs) or other approved documentation for the revised set-up
12. problem solving and the application of root cause analysis
13. the difference between 'motion' and 'work'
14. what constitutes a value adding and non-value adding activity
15. 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.    Lead the activities within your area of responsibility to include all of the following:

1. set out and communicate the purpose of the improvement activities
2. involve the team in planning how the improvement activity will be achieved
3. ensure each team member has individual objectives and understands how these objectives contribute to the overall improvement objective
4. provide advice and support the team to achieve both team and individual improvement objectives
5. motivate the team to present their own improvement ideas
6. encourage the team and/or individuals to take the lead where appropriate
7. agree the implementation of the improvement ideas
8. negotiate any physical and/or financial resources required to implement the improvement activity (where appropriate)
9. monitor the progress of improvement activities
10. deal with any organisational problems identified during the improvement activity

 

2.    Co-ordinate 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
   
    

3.    Co-ordinate 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 (such as cutting tools, clamps, hand tools, inspection equipment)
4. information required for a quick set-up, and its location
5. methods and standards
6. documentation for co-ordination control
   

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3

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2028

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Current

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Original

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Enginuity

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SEMBIT412

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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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