McCain Junior Leadership

1. Plant Start Up, Shutdown and Change Over Wally van Jaarsveld

2. OPERATE A PRODUCTION PROCESS Almost every food-processing factory would have machines and equipment that processes and packages the food produced Therefore, before commencing this session you need to select a piece of machinery or equipment that plays a significant role in a production process and use it as a ‘model’ to provide evidence for your competency

3. OPERATE A PRODUCTION PROCESS 1. Prepare the equipment and process for operation 2. Operate and monitor the process 3. Shut down the process

4. OPERATE A PRODUCTION PROCESS SECTION 1: PREPARING THE EQUIPMENT AND PROCESS FOR OPERATION Steps 1.1Confirming the availability of materials to meet operating requirements Steps 1.2Identifying and confirming cleaning and maintenance requirements and status Steps 1.3Fitting and adjusting machine components and related attachments to meet operating requirements Steps 1.4Entering processing/operating parameters as required to meet safety and production requirements Steps 1.5Checking and adjusting equipment performance as required Steps 1.6Carrying out pre-start checks as required by workplace requirements

5. Activity 1.1 List the variety of raw materials used in the process selected, and briefly comment on how you go about checking their quality Activity 1.2 Briefly describe the cleaning and maintenance requirements for the machine you selected

6. Activity 1.3 List the types of attachments used in the machine selected; if any. Activity 1.4 What parameters are important in the operation with which you are concerned? List them with specifications Activity 1.5 List the types of checks you have to conduct to ensure that the selected machine is performing as it should.

7. Activity 1.6 List the types of checks you have to conduct before starting the selected machine to ensure it is performing as it should

8. OPERATE A PRODUCTION PROCESS SECTION 2: OPERATING AND MONITORING THE PROCESS Step 2.1. Starting and operating the process according to workplace procedures Step 2.2. Monitoring equipment to identify variation in operating conditions Step 2.3. Identifying variation in equipment operation and report maintenance requirements according to workplace reporting requirements Step 2.4. Monitoring the process to confirm that specifications are met Step 2.5.Identifying, rectifying and/or reporting out-of-specification product/process outcomes to maintain the process within specification Step 2.6. Ensuring the workplace meets housekeeping standards Step 2.7.Maintaining workplace records according to workplace recording requirements

9. Activity 2.1 Describe how you will ensure that the machine you selected has started and is operating correctly. What do you look for to ensure that that is happening Activity 2.2 Briefly describe the way you monitor the operation of your machine and list the parameters you observe Activity 2.3 Briefly list the type of variations in the working conditions of your machine and describe your workplace requirements as far as recording and reporting machine maintenance operations are concerned.

10. Activity 2.4 What parameters are important in the production process with which you are concerned? List them with specifications Activity 2.5 Go back to the parameters listed previously and list how you rectify and/or report the problem if it happens Activity 2.6 Describe the by-products of the operation that you are concerned with and the workplace procedure for maintaining the working area in a clean and safe condition to continue working while the production process is proceeding

11. Activity 2.7 List the types of records that you need to complete to comply with your workplace reporting requirements

12. OPERATE A PRODUCTION PROCESS SECTION 3: SHUTTING DOWN THE PROCESS Step 3.1. Identifying the appropriate shut down procedure Step 3.2 Shutting down the process according to workplace procedures Step 3.3. Identifying and reporting maintenance requirements according to workplace reporting requirements

13. Activity 3.1 and 3.2 With reference to the SOP or machine manual, describe and list in order, the steps taken to shut down the machine selected. Be as specific as the SOP suggests Activity 3.3 What is your company’s procedure for reporting maintenance requirements?

15. PRODUCT CHANGEOVER

17. Getting replacement parts

18. Cooling down

19. Mechanical modifications

20. Calibrating, adjusting

21. Heating up

22. Putting tools away

23. Getting back to process conditions

25. Setup

27. GONE IN 14 SECONDS

29. Allow faster production cycles

30. Faster cycles increase production flexibility

32. Prior preparation

33. Training

34. Proper tools + special tools

35. Consistent techniques and practices

36. Continuous improvement

37. Measure and track each changeover

39. Makes the operation less flexible, less responsive

40. Creates inventory