The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment

A person who demonstrates competency in this unit must be able to evaluate maintenance systems and processes for safe, cost-effective and sustainable operation.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Assessors must be satisfied that the candidate can competently and consistently:

investigate sustainability implications of maintenance processes

identify and review features and functions of maintenance and information systems, trends and implementation strategies and software

evaluate safety and risk management, sustainability, asset reliability and maintainability, lean indices, system design parameters, data generation, collection, reporting, storage and analysis, condition monitoring, facilities and services maintenance response systems, asset categorisation, maintenance scheduling and prioritising, and continuous improvement, implemention

audit plant, facilities and services, provision of parts and consumables provision, labour, skills and technical support

report and document results.

Context of and specific resources for assessment

This unit may be assessed on the job, off the job or a combination of both on and off the job. Where assessment occurs off the job, then a simulated working environment must be used where the range of conditions reflects realistic workplace situations. The competencies covered by this unit would be demonstrated by an individual working alone or as part of a team.

Where applicable, reasonable adjustment must be made to work environments and training situations to accommodate ethnicity, age, gender, demographics and disability.

Access must be provided to appropriate learning and/or assessment support when required. Where applicable, physical resources should include equipment modified for people with disabilities.

Method of assessment

Assessment must satisfy the endorsed Assessment Guidelines of the MEM05 Metal and Engineering Training Package.

Assessment methods must confirm consistency and accuracy of performance (over time and in a range of workplace relevant contexts) together with application of underpinning knowledge.

Assessment methods must be by direct observation of tasks and include questioning on underpinning knowledge to ensure correct interpretation and application.

Assessment may be applied under project-related conditions (real or simulated) and require evidence of process.

Assessment must confirm a reasonable inference that competency is not only able to be satisfied under the particular circumstance, but is able to be transferred to other circumstances.

Assessment may be in conjunction with assessment of other units of competency where required.

Guidance information for assessment

Assessment processes and techniques must be culturally appropriate and appropriate to the language and literacy capacity of the candidate and the work being performed.

Required skills

Required skills include:

identifying WHS, regulatory and risk management compliance requirements for maintenance systems

investigating sustainability implications of maintenance processes

identifying and reviewing features and functions of maintenance and information systems, trends and implementation strategies and software

evaluating organisational maintenance safety and risk management procedures, sustainability, asset reliability and maintainability, lean indices, system design parameters, data generation and collection, reporting, storage and analysis, condition monitoring, implementation, facilities and services maintenance response systems, asset categorisation, maintenance scheduling and prioritising, and continuous improvement

auditing plant, facilities and services, systems for provision of parts and consumables, and adequacy of labour, skills and technical support for maintenance activities

reporting and documenting results of scoping, principles and techniques identification and evaluation of maintenance systems, layouts, schedules, performance analysis, flow charts, calculations, programs and files

Required knowledge

Required knowledge includes:

maintenance requirements of various organisations and industry trends

features of integrated management systems within organisations and industry trends:

monitoring, adjustment, lubrication, consumables, breakdown maintenance required by typical plant equipment and facilities

labour and training requirements for typical maintenance systems

maintenance performance indices, such as mean time between failure (MTBF) and overall equipment efficiency (OEE), and relationship to maintenance strategies, business financial objectives and maintenance system design criteria, such as life cycle cost and break-even point

maintenance management systems, such as terotechnology

maintenance management within ILS

sources of information, software and hardware required by maintenance systems

systems thinking in relation to maintenance, failure analysis, problem solving and decision making processes, constraint and contingency management

compliance requirements of WHS, regulations and standards relevant to maintenance

risk management requirements and analyses for maintenance of plant, including failure mode effects analyses (FMEA)

maintainability and reliability related to life cycle costing, system design, cost predictions and break-even analysis

audit processes for plant, facilities and services, provision of parts and consumables, labour, skills and technical support

maintenance system data generation and collection, reporting and response processes, data storage and performance analysis for process improvement against performance parameters, such as MTBF and OEE

manual and automated condition monitoring, testing and analysis

maintenance system and implementation strategies, including corrective, preventative, predictive, precision, proactive, total productive and reliability centred maintenance

facilities and service maintenance response systems

asset categorisation and maintenance scheduling and prioritising

organisational maintenance safety procedures, such as:

risk management procedures

WHS committees

standard operating procedures

safe work methods statements (SWMS)

material safety data sheets (MSDS)

permits

standards related to significant maintenance or plant modifications

terotechnology

engineering, plant, facilities and services maintenance requirements

continuous process improvement

data generation, analysis, storage and feedback

reporting techniques and documentation required

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Appropriate technical and professional assistance

Appropriate technical and professional assistance may include:

technical support and advice relating to elements which have intrinsic dangers, such as:

high pressure

energised fluid vessels

high temperatures and heat energy capacity

wiring with high current control voltages above extra low voltage

professional support for technologies, such as:

specialist electric motor drives and controllers

specialist materials, plastics, metal alloys and nano materials

special processes, foundry, alloy welding, heat treatment, sealing and fastening

WHS, regulatory requirements and enterprise procedures

WHS, regulatory requirements and enterprise procedures may include:

WHS Acts and regulations

relevant standards

codes of practice from Australian and overseas engineering and technical associations and societies

ministerial directives

risk assessments

registration requirements

safe work practices

state and territory regulatory requirements

Standards and codes

Standards and codes refer to all relevant Australian and international standards and codes applicable to a particular maintenance system

Systems thinking

Systems thinking refers to the conduct of engineering work in a manner that demonstrates knowledge of how the interaction of different technical systems on equipment, machinery or structures, as well as the skills and techniques of personnel, combine to perform or support engineering-related operations, processes or projects. It embraces determining or establishing how the function of each technical system or component, as well as the skills and techniques of personnel, effects or potentially may effect, outcomes. Systems should be interpreted broadly within the context of the organisation and depending on the project or operation can include equipment, related facilities, material, software, internal services and personnel, and other organisations in the value chain

Continuous improvement

Continuous improvement implementation may relate to plant, products, processes, systems or services, including design, development, implementation or manufacture, commissioning, operation or delivery and maintenance.

Improvement processes may include techniques, such as:

balanced scorecard

current and future state mapping

measuring performance against benchmarks

process improvement, problem solving and decision making

data management, generation, recording, analysing, storing and use of software

training for improvement systems participation

technical training

Constraints and contingencies

Constraints and contingencies may be:

financial

organisational, procedural or cultural

physical constraints, such as limits to resources, limits to site access or logistical limitations

Maintenance systems

Maintenance systems include:

breakdown maintenance

preventive maintenance

predictive maintenance (on-condition)

precision maintenance

proactive maintenance

reliability centred maintenance

total productive maintenance

Lean systems maintenance

Lean maintenance systems aim at maximising machine and process up-time, minimising waste and costs, maintaining quality and delivery and customer service. Maintenance processes and procedures are subject to continuous improvement and are set to complement engineering business objectives

Integrated maintenance management systems (terotechnology)

Terotechnology is an integrated maintenance management system combining management, financial, engineering and other practices for cost-effective maintenance of assets, such as plant, equipment and facilities. It involves the design for reliability and maintainability, manufacture, installation, commissioning and eventual write-off and replacement of the assets. Data is collected and analysed to assess the reliability, life cycle costs and productivity of the assets against the design criteria.

Reliability relates to the productivity of assets, that is, the maintenance of service or product output (quantities) and its quality within cost parameters. In the context of terotechnology, the cost parameters include life cycle costs

Integrated logistic support (ILS)

ILS is the management and technical process through which supportability and logistic support considerations are integrated into the design and taken into account throughout the life cycle of systems/equipment and by which all elements of logistic support are planned, acquired, tested, and provided in a timely and cost-effective manner. Maintenance systems and schedules are part of this process

Maintenance priority

Assets may be prioritised for maintenance according to different criteria and categories, such as:

critical assets:

high cost of replacement

unavailability of replacement or spares

failure will or may immediately endanger life and property

essential to quality

high cost of disruption to production or service delivery

failure would require an immediate response

semi-critical assets:

shutdown produces partial loss of capacity

assett is regulated

difficult to repair

alternative asset may be available

some spare parts are stored

medium priority for response

non-critical:

breakdown affects minimal production loss

asset used infrequently

parts readily available

lowest priority attended to as time and resources allow

Maintenance activity audit

An audit of plant, facilities and services may be used to identify maintenance requirements with details listed in the maintenance database according to different criteria, such as:

criticality, locality, machine type and maintenance activities required

skills and techniques required for corrective actions

sources and availability of spares

specialised corrective skills and techniques for specific equipment

Maintainability

Maintainability refers to the design of product, machines and processes with an objective of reducing maintenance downtime, resources, specialist tools and skills required to maintain reliability. Design techniques may include modular design for ease of replacement, provision of bypass opportunities to isolate the failure for repair while processes continue or provision of substitute equipment

Monitoring and testing

Monitoring and testing may be undertaken for both corrective and proactive and predictive maintenance. Tests may include:

manual inspections

instrumented monitoring

lubricant testing (tribology)

lidar (light for atmospheric particle detection)

gas chromatography

mandatory inspections

performance and condition monitoring

radiographic examination for material imperfections

microwave for non-metallic solid or liquid test

camera and scope techniques

Maintenance system data

Maintenance system data may include:

asset ID and plant warranties

procedural documents:

monitoring and preventative maintenance schedules

SWMS

MSDS

work permits

monitoring reports and system measurements

maintenance actions and costs

spares inventory control