Setup Reduction and Quick Changeover

Programme Summary

Reduce changeover losses through structured observation, task redesign and controlled trials. Participants distinguish internal from external setup activities, identify avoidable adjustments and prepare practical changes to tools, methods and coordination. The course connects shorter changeovers with quality and safety requirements, enabling teams to develop repeatable setup standards and verify improvements without increasing start up defects or operational risk.

Training Objectives

1 Measure changeover losses consistently and accurately; 2 Separate internal and external setup activities; 3 Identify practical setup simplification opportunities; 4 Protect safety and first piece quality; 5 Standardise and verify improved changeover performance.

Learning Outcomes

1 Create a detailed changeover activity record; 2 Classify internal and external setup tasks; 3 Develop a justified setup improvement proposal; 4 Prepare a safe repeatable changeover standard; 5 Define measures confirming sustained setup reduction.

Target Audience

Production Supervisors; Manufacturing Engineers; Maintenance Planners; Setup Technicians; Lean Coordinators.

Target Industries

Packaging Manufacturing; Automotive Manufacturing; Food Manufacturing; Plastics Manufacturing; Printing Operations; Metalworking.

Course Contents

• Module 1 Changeover Performance: Clear setup start and finish definitions; Downtime quality loss and capacity effects; Baseline data and operational constraints.
• Module 2 Observing the Current Setup: Activity timing and movement observation; Tools materials adjustments and waiting; Recording parallel tasks and safety controls.
• Module 3 Internal and External Activities: Tasks requiring stopped equipment; Preparation and verification before shutdown; Safe conversion opportunities and limitations.
• Module 4 Simplifying Setup Work: Fixtures connections and adjustment reduction; Tool organisation and preset conditions; Error prevention and consistent positioning.
• Module 5 Coordination and Parallel Work: Task allocation and communication routines; Sequencing dependencies and access conflicts; Safe team working and isolation interfaces.
• Module 6 Quality and Safety Assurance: First piece checks and release criteria; Risk review of proposed setup changes; Preventing bypassed guards and controls.
• Module 7 Standardisation and Monitoring: Clear setup instructions and visual aids; Training ownership and performance measures; Reviewing drift and sustaining improvements.
• Module 8 Setup Improvement Workshop: Redesigning a fictional changeover sequence; Calculating expected gains and constraints; Presenting a safe trial and verification plan.

Assessment

• 40 single best answer questions, including applied scenarios; one mark per question.
• 60 minute invigilated digital examination with identity verification. Approved accessibility adjustments preserve the assessed competence.
• Supplied reference pack and calculator permitted; external internet and AI prohibited.
• Individual applied assessment (30 minutes): Analyse a supplied changeover record, redesign the task sequence and present a trial plan with safety, quality and performance checks.
• Assessment criteria: Accurate task and loss analysis; Feasible safe setup redesign; Effective quality and sustainment controls.
• Pass each component separately: 30/40 written marks (75%) and at least 70% on the applied task.
• All mandatory criteria must pass: Preserve isolation guarding and release controls.
• Individual results and feedback are provided. One reassessment may follow coaching under the published enrolment terms.

Certification

• Successful learners receive a TQCSI Arabia digital Certificate of Successful Completion.
• The certificate records the learner name, exact programme title, teaching hours, completion date and unique verification reference.
• Verified identity, full attendance and separate written and applied passes are required; all mandatory critical criteria must be met.
• Proposed issue target: within 30 calendar days of approved results and settlement of applicable fees.
• Records setup reduction planning skills; equipment modifications and isolation arrangements require separate competent approval.
• Attendance confirmation may record completed hours for unsuccessful learners; it does not certify successful completion.

Programme Profile

Number of daysNumber of daysNumber of days

222

Total teaching hoursTotal teaching hoursTotal teaching hours

12 hours; breaks, pre course work and formal final assessments excluded.12 hours; breaks, pre course work and formal final assessments excluded.12 hours; breaks, pre course work and formal final assessments excluded.

Delegates allowedDelegates allowedDelegates allowed

Maximum 20 delegates.Maximum 20 delegates.Maximum 20 delegates.

Training prerequisitesTraining prerequisitesTraining prerequisites

Production or maintenance experience and familiarity with equipment changeovers are required. Basic Lean knowledge is recommended.Production or maintenance experience and familiarity with equipment changeovers are required. Basic Lean knowledge is recommended.Production or maintenance experience and familiarity with equipment changeovers are required. Basic Lean knowledge is recommended.

Pre course assignment and assessmentPre course assignment and assessmentPre course assignment and assessment

Review a supplied changeover video transcript for 25 minutes and identify downtime start and end points.Review a supplied changeover video transcript for 25 minutes and identify downtime start and end points.Review a supplied changeover video transcript for 25 minutes and identify downtime start and end points.

End of course assessmentEnd of course assessmentEnd of course assessment

40 question written exam (60 minutes) and individual applied task (30 minutes).40 question written exam (60 minutes) and individual applied task (30 minutes).40 question written exam (60 minutes) and individual applied task (30 minutes).

Passing criteriaPassing criteriaPassing criteria

75% written and 70% applied, passed separately; full attendance. All mandatory criteria must pass.75% written and 70% applied, passed separately; full attendance. All mandatory criteria must pass.75% written and 70% applied, passed separately; full attendance. All mandatory criteria must pass.