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Elements and Performance Criteria

  1. Develop components of reliability strategy for a work/plant area
  2. Assess current practice for maintenance implications
  3. Assist in implementing the reliability strategy

Evidence Required

The Evidence Guide provides advice on assessment and must be read in conjunction with the Performance Criteria required skills and knowledge the Range Statement and the Assessment Guidelines for this Training Package

Overview of assessment requirements

There should be evidence that the maintenance person is routinely applying proactive maintenance strategies in their routine work and that they are aware of why they are important In a TPM environment the operator needs to move to taking ownership of their equipmentplant and maintenance personnel have a role to play in helping this happen and in developing the competence of operating personnel to do so

What critical aspects of evidence are required to demonstrate competency in this unit

Evidence of schedules developed and implemented and improvements recommended

In what context should assessment occur

This unit needs to be assessed in a workplace practising or beginning to implement proactive maintenance

Are there any other units which could or should be assessed with this unit or which relate directly to this unit

This unit could be assessed in conjunction with a technical unit related to maintenance

This unit is related to

MSACMTA Undertake proactive maintenance analyses which covers the analysis skills associated with proactive maintenance

MSACMT481A Undertake proactive maintenance analyses which covers the analysis skills associated with proactive maintenance.

These units are complimentary and in some organisations it may be appropriate for the one person to hold both competencies

This unit is related to

MSACMTA Develop a proactive maintenance strategy which is the highest level unit dealing with proactive maintenance in CM

MSACMT681A Develop a proactive maintenance strategy which is the highest level unit dealing with proactive maintenance in CM.

What method of assessment should apply

Assessors must be satisfied that the person can consistently perform the unit as a whole as defined by the elements performance criteria skills and knowledge A holistic approach should be taken to the assessment

Assessors should gather sufficient fair valid reliable authentic and current evidence from a range of sources Sources of evidence may include direct observation reports from supervisors peers and colleagues project work samples organisation records and questioning Assessment should not require language literacy or numeracy skills beyond those required for the unit

The assessee will have access to all techniques procedures information resources and aids which would normally be available in the workplace

The method of assessment should be discussed and agreed with the assessee prior to the commencement of the assessment

What evidence is required for demonstration of consistent performance

There needs to be evidence that schedules related to proactive maintenance have been developed either in an initial implementation of a proactive maintenance strategy or have been developed as part of continuous improvement to the proactive maintenance strategy

What are the specific resource requirements for this unit

Access to a plant implementingpractising proactive maintenance No other specific resources are required

Range Statement

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.

Total Preventative Maintenance/Total Productive Maintenance (TPM)

Total Preventative Maintenance/Total Productive Maintenance (TPM) is an application of total quality management to maintenance with the intention of increasing reliability, getting it right first time and increasing Overall Equipment Efficiency (OEE).

Reliability Centred Maintenance (RCM)

Reliability Centred Maintenance (RCM) moves maintenance from reactive, or even planned/programmed, towards a focus on uptime and OEE.

Similar strategies

Mean Time Between Failure (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.

Failure Mode and Effects Analysis (FMEA) is a systematic approach that identifies potential failure modes in a system, product, or manufacturing/assembly operation caused by either design or manufacturing/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.

Hazard and Operability Studies (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.

Condition monitoring involves often quite sophisticated monitoring of equipment including such things as vibration monitoring, instrumental analysis of lubricating oil etc to determine the current state of the equipment, monitor the change in this condition and predict when it needs servicing/maintenance to maintain reliability.

Overall Equipment Efficiency (OEE)

Overall Equipment Efficiency (OEE) is the combination of the main factors causing loss of productive capacity from equipment/plant and is:

OEE = availability x performance x quality rate

where:

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 the losses due to rejects, reworks and start up waste.

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%.

Inspection

Inspection may include:

reading dials, gauges, meters

observations including those using sight, hearing, smell, feel

observations of product quality/faults/rejects.

Servicing

Servicing may include:

cleaning

lubricating

topping up

adjusting.

Procedures

Procedures include all work instructions, standard operating procedures, formulas/recipes, batch sheets, temporary instructions and similar instructions provided for the smooth running of the plant. They may be written, verbal, computer based or in some other form.

For the purposes of this Training Package, 'procedures' also includes good operating practice as may be defined by industry codes of practice (e.g. Good Manufacturing Practice (GMP), Responsible Care) and government regulations.