Assessor Resource

MSS405082A
Adapt a proactive maintenance strategy to the process operations sector

Assessment tool

Version 1.0
Issue Date: March 2024


This unit applies to an individual in a continuous manufacturing sector, such as chemical, hydrocarbons and refining, smelting and cement, which is seeking to improve the efficiency and reliability of equipment. Typically such an organisation will also be engaged in implementing competitive systems and practices. As continuous manufacturers, such as the chemical, hydrocarbons and refining sectors, are often also major hazard facilities this will influence the proactive maintenance choices which need to be made.

The unit covers the selection of appropriate strategies, techniques and tools and the adapting of them to the organisations needs. It also covers the application of the strategies to new areas and the improvement of operation in existing areas. This would typically be done in a team environment and in consultation with all key stakeholders.

This unit requires the application of skills associated with problem solving, initiative, enterprise, planning and organising in order to adapt a proactive maintenance strategy to meet specific needs of the enterprise. This work is done in the context of using computer technology and also requires aspects of self-management and learning to ensure improvement of own performance.

This unit of competency covers the skills and knowledge required to develop and apply a proactive maintenance strategy for continuous manufacturing processes which may also be major hazard facilities or similar.

You may want to include more information here about the target group and the purpose of the assessments (eg formative, summative, recognition)

Prerequisites

MSS405081A Develop a proactive maintenance strategy


Employability Skills

This unit contains employability skills.




Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

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.

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

A person who demonstrates competency in this unit must be able to provide evidence of the ability to:

analyse hazards and risks and determine implications for proactive maintenance strategies

consider a variety of proactive maintenance strategies for suitability to an organisation

consult operators, maintenance, management and other stakeholders in decisions on proactive maintenance strategies

monitor implementation of selected proactive maintenance strategies and make appropriate adjustments.

Context of and specific resources for assessment

Assessment of performance must be undertaken in a workplace using or implementing one or more competitive systems and practices.

Access may be required to:

workplace procedures and plans relevant to work area

specifications and documentation relating to planned, currently being implemented, or implemented changes to work processes and procedures relevant to the assessee

documentation and information in relation to production, waste, overheads and hazard control/management

reports from supervisors/managers

case studies and scenarios to assess responses to contingencies.

Method of assessment

A holistic approach should be taken to the assessment.

Competence in this unit may be assessed by using a combination of the following to generate evidence:

demonstration in the workplace

workplace projects

suitable simulation

case studies/scenarios (particularly for assessment of contingencies, improvement scenarios, and so on)

targeted questioning

reports from supervisors, peers and colleagues (third-party reports)

portfolio of evidence.

In all cases it is expected that practical assessment will be combined with targeted questioning to assess underpinning knowledge.

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

Guidance information for assessment

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


Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assingnment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)


Assessment Tasks

Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.

Required skills

Required skills include:

communicating with others using a variety of media and techniques

adapting personal communication strategy to different levels of literacy and numeracy in target individuals and groups

working in a team

analysing quantitative and qualitative information to determine proactive maintenance strategy options

applying a structured approach to integrating hazard management considerations to the development of a proactive maintenance strategy

solving problems to root cause

applying basic mathematical and statistical techniques

planning complex strategies, including consideration of timelines, resources, benefit/cost, implementation requirements, and monitoring and adjustment considerations

reading and interpreting engineering specifications, drawings and charts

using information system terminals and computers

prioritising options, including reasons and recommendations

recording data

Required knowledge

Required knowledge includes:

continuous manufacturing equipment and products of the organisation

start-up, shutdown and isolation considerations for the organisation

skills required by operators and maintenance personnel to achieve effective proactive maintenance strategy implementation

characteristics and strengths of different types of strategies, techniques and tools, such as:

total preventative maintenance/total productive maintenance (TPM)

reliability centred maintenance (RCM)

mean time between failure (MTBF)

failure mode and effects analysis (FMEA)

condition monitoring

root cause analysis (RCA)

holistic costs of different strategies combining cost of maintenance with costs of lost production, sales, and so on, as relevant to the organisation

business goals sufficient to match the strategy to the business needs

strategic thinking and its application to proactive maintenance

principles of process equipment and how to improve its reliability

resources required and how to obtain them

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.

Competitive systems and practices

Competitive systems and practices may include, but are not limited to:

lean operations

agile operations

preventative and predictive maintenance approaches

monitoring and data gathering systems, such as Systems Control and Data Acquisition (SCADA) software, Enterprise Resource Planning (ERP) systems, Materials Resource Planning (MRP) and proprietary systems

statistical process control systems, including six sigma and three sigma

Just in Time (JIT), kanban and other pull-related operations control systems

supply, value, and demand chain monitoring and analysis

5S

continuous improvement (kaizen)

breakthrough improvement (kaizen blitz)

cause/effect diagrams

overall equipment effectiveness (OEE)

takt time

process mapping

problem solving

run charts

standard procedures

current reality tree

Competitive systems and practices should be interpreted so as to take into account:

the stage of implementation of competitive systems and practices

the size of the enterprise

the work organisation, culture, regulatory environment and the industry sector

Safety case

Safety case refers to:

a formal requirement of major hazard facilities in order to procure an operating licence

Shutdown

Shutdown refers to:

the regulatory shutdown of the plant for safety inspections (this is also the only time major maintenance can be done)

Ancillary equipment

Ancillary equipment includes other plant, such as:

boilers

utilities

plants

waste treatment and hazard control equipment (e.g. fire ring mains, fire monitors, steam curtains, gas (or other loss of containment) monitors, blast protection and flare stacks)

TPM

TPM includes:

an application of total quality management to maintenance with the intention of increasing reliability, getting it right first time and increasing OEE

RCM

RCM includes:

moving maintenance from reactive, or even planned/programmed towards a focus on uptime and OEE

RCA

RCA is a structured problem solving technique. Typically there are many possible causes of any problem. Eliminating some will have no impact, others will ameliorate the problem. However, elimination of the root cause will eliminate the problem. There should only be one root cause for any problem and so the analysis should continue until this one cause is found. Elimination of the root cause permanently eliminates the problem.

MTBF

MTBF is one key measure of the effectiveness of a maintenance procedure, and is an indicator as to whether root causes are being found and resolved. If MTBF is reducing, then it is an indicator that the maintenance regime is failing.

FMEA

FMEA is a systematic approach that identifies potential failure modes in a system, product, or operations/assembly operation caused by either design or operations/assembly process deficiencies. It also identifies critical or significant design or process characteristics that require special controls to prevent or detect failure modes. FMEA is a tool used to prevent problems from occurring. Some industry sectors have highly adapted forms of FMEA and may practice traditional FMEA in say their routine maintenance while using another technique, such as HAZOP, for design and modification.

Uptime

Uptime refers to:

the overall availability of the plant (it is the inverse of downtime) or the unavailability of the plant. Ideal uptime is 100%

OEE

OEE is the combination of the main factors causing loss of productive capacity from equipment/plant and is where:

OEE = availability x performance x quality rate

availability takes into account losses due to breakdown, set-up and adjustments

performance takes into account losses due to minor stoppages, reduced speed and idling

quality rate takes into account t losses due to rejects, reworks and start-up waste

Condition monitoring

Condition monitoring involves often quite sophisticated monitoring of equipment, including such things as:

vibration monitoring

instrumental analysis of lubricating oil, and so on to determine the current state of the equipment, monitor the change in this condition and predict when it needs servicing/maintenance to maintain reliability

HAZOP

HAZOP is a form of FMEA which has been practiced by the process industries for over 30 years and examines the implications of changes in process conditions to process stability.

Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.

Observation Checklist

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Analyse proactive maintenance strategy 
Identify areas which may conflict with hazard or operations requirements 
Analyse data arising from incident reports (and similar) for maintenance implications 
Compile hazard control implications for proactive maintenance strategy 

Forms

Assessment Cover Sheet

MSS405082A - Adapt a proactive maintenance strategy to the process operations sector
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I declare that the assessment tasks submitted for this unit are my own work.

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Assessment Record Sheet

MSS405082A - Adapt a proactive maintenance strategy to the process operations sector

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Student ID:

Assessment task 1: [title] Result: Competent Not yet competent

(add lines for each task)

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Overall assessment result: Competent Not yet competent

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