This Production Changeover SOP (Safe Operating Procedure) gives your team a clear method for changing a production line or machine from one product or job to another, including tooling, die and mould changes, guard removal and size or format adjustments. It covers identifying every energy source, individual locks and tags, supporting tooling, manual handling aids, resetting settings, refitting guards, removing locks safely and first-piece trial runs. It's written by WHS specialists, aligned to Australian WHS legislation, and fully editable in Microsoft Word.
Who it's for
Manufacturers and factories
Food and beverage processors
Packaging and printing businesses
Plastics and injection moulding operations
Machine setters and line leaders
Use it to
Train and induct workers in exactly how you expect the task to be done
Keep a clear reference at the machine, in the vehicle or on site
Record competency with the built-in sign-off
Show clients, insurers and auditors your safe work methods are written down
What this SOP covers
Unexpected start-up while guards are off or hands are in the danger zone
Crush, entanglement, amputation or cuts from tooling, dies and moulds
Manual handling of dies, tooling, moulds and heavy parts
Release of hydraulic, pneumatic, spring or gravity energy
Slips, trips and falls from tools, offcuts and leads
Guards missed or poorly refitted after changeover
Noise from nearby running plant
What's included
6 pre-operational checks, from authorisation and a safe stop to identifying all energy sources, the right change parts, lifting aids and a clear work area
A 9-step operating procedure covering notifying others, lockout, removing guards, handling tooling, fitting and securing parts, resetting settings, refitting guards and trial runs
Isolation and energy control for isolating every energy source, personal locks for each worker, releasing stored energy and testing for restart
4 shutdown, housekeeping and post-operation steps
Emergency actions for unexpected start-up, guard failure and trapped workers
PPE checklist and a list of related documents
Competency acknowledgement and worker sign-off
Space for your logo, SOP number, version and review dates
Why use this template
Saves hours compared with writing an SOP from a blank page
Written as clear, numbered steps that workers can follow on the job
Fully editable, so you can match it to your equipment, site and how your team works
The competency sign-off gives you a training record from day one
How it works
Buy online and download straight away. You'll also get an email with your link.
Add your logo, company name, SOP number and dates.
Check it suits your equipment and site, and edit anything you need to.
Train your workers and have them sign the competency acknowledgement.
Need more than one SOP?
This SOP is also included in the Ultimate Manufacturing & Industrial SOP Bundle. At $197 for the whole bundle, it works out much cheaper than buying SOPs one at a time.
Common questions
Can isolation be skipped for a quick changeover?
No. The SOP states that time pressure or production targets are never a reason to bypass lockout. If they conflict, stop and escalate to a supervisor.
Does each worker need their own lock?
Yes. Where more than one employee works on the same machine, each applies their own lock, and only the person who applied a lock or tag may remove it.
Does it cover routine start-up or maintenance?
No. Routine daily starting and stopping is covered by the machine start-up and shutdown procedure, and full scheduled maintenance by your site maintenance procedure.
Can I change it?
Yes. It's a Microsoft Word file, so you can add, remove or change any step, check or hazard, and add your own logo and details.
Does it suit my state?
Yes. It's written to the model WHS laws and suits all states and territories, including Victoria under the OHS Act and Regulations.
What if it doesn't suit my work?
You're covered by our 30-day money-back guarantee if it isn't fit for purpose.
