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Elements and Performance Criteria

1. Plan maintenance.
   • Develop work plans for scheduled routine maintenance activities.
   • Develop maintenance plans for unscheduled maintenance activities.
   • Source maintenance providers (internal/external).
   • Develop costings for maintenance work.
   • Implement measures to control identified hazards in line with procedures and duty of care.
   • Document and record required production interruptions, processes and procedures.
   • Obtain clearances for the maintenance work.
2. Organise maintenance.
   • Schedule maintenance activities, with reference to production requirements and availability of resources.
   • Review available maintenance expertise and arrange appropriate training and assessment where necessary.
   • Obtain approvals for maintenance schedule as necessary to coordinate with production requirements.
3. Assemble maintenance requirements.
   • Determine resources required (equipment, personnel and consumables) to meet maintenance schedule.
   • Locate and coordinate supply of consumables, equipment and expertise to meet maintenance schedule.
   • Purchase equipment, consumables and expertise as required.
4. Complete maintenance.
   • Complete maintenance schedule.
   • Make appropriate readings, measurements and recordings and compare to equipment, product and other relevant specifications.
   • Identify areas requiring further testing and recommend appropriate procedures to supervisory staff.
   • Make appropriate adjustments to the maintenance schedule.
   • Complete records as required, noting areas where changes to equipment operation or routine maintenance are required.

Required Skills

This describes the essential skills and knowledge and their level required for this unit

Application of knowledge and understanding of equipment operation planning and maintenance practices sufficient to plan for maintenance requirements in standard and nonstandard situations and then determine appropriate action which is consistent with operation guidelines is required

Knowledge of the enterprises procedures and relevant regulatory requirements along with the ability to implement them within appropriate time constraints and work standards

Application of the knowledge of managing risks using the hierarchy of controls applied to the process Application of approved hazard control safety procedures and the use of PPE in relation to handling materials equipment operation and clean up

Knowledge as a basis for solving processing and material problems including

characteristics and capabilities of equipment materials and processes used

functions and troubleshooting of internal components and their problems

routine and nonroutine causes of equipment failures and the service conditions which may increase maintenance

urgency and timeliness factors in planning maintenance activities in relation to production requirements

proactive predictive preventative and reactive maintenance principles

implications of maintenance for production and work activities

source requirements for maintenance

safety procedures and the use of PPE in relation to handling materials equipment operation and cleanup

the hierarchy of control including engineering controls

Competence also includes the ability to

identify factors in production schedules time and resource requirements including external sources in scheduling maintenance activities

schedule maintenance functions in the most timely and cost effective manner

apply relevant agreements codes of practice or other legislative requirements

ensure workplace is safe for maintenance activities

Language literacy and numeracy requirements

This unit requires the ability to read and interpret typical manufacturer specifications equipment procedures production schedules and material labels as provided to coordinators

Writing is required to the level of completing workplace reports and proposals

Numeracy is also required eg analysing statistical informationhistorical data in the form of tables and graphs

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

A holistic approach should be taken to the assessment

Assessors must be satisfied that the person can consistently perform the unit as a whole as defined by the Elements Performance Criteria and skills and knowledge

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

It is essential that competence is demonstrated in the ability to

recognise potential situations requiring action

implement appropriate action

Consistent performance should be demonstrated For example look to see that

early warning signs of equipment in need of attentionwith potential problems are recognised

planned work sequences are logical and conform with production schedules and work rosters

maintenance schedules for reactive planned and proactive maintenance are coordinated based upon the most appropriate and cost effective method to ensure equipment reliability and optimum performance

plans are initiated and monitored with activities modified for variations in workplace contexts and the environment until final resolution has occurred

Assessment method and context

It is preferred that assessment takes place in an industrial work environment

Competence in this unit may be assessed

on a processing plant allowing for operation under all normal and a range of abnormal conditions

in a situation allowing the generation of evidence of the ability to recognise anticipate and solve problems

using a suitable simulation andor a range of case studiesscenarios

through a combination of these techniques

In all cases it is expected that practical assessment will be combined with targeted questioning to assess the underpinning knowledge and theoretical assessment will be combined with appropriate practicalsimulation or similar assessment Assessors need to be aware of any cultural issues that may affect responses to questions

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

Specific resources for assessment

This section should be read in conjunction with the Range Statement for this unit of competency Resources required include suitable access to an operating plant or equipment that allows for appropriate and realistic simulation A bank of case studiesscenarios and questions will also be required to the extent that they form part of the assessment method Questioning may take place either in the workplace or in an adjacent quiet facility such as an office or lunchroom No other special resources are required

Access must be provided to appropriate learning andor assessment support when required Where applicable physical resources should include equipment modified for people with disabilities

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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. Add any 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.

Where reference is made to industry codes of practice, and/or Australian/international standards, the latest version must be used.

Context

This competency applies to all work environments and sectors within the manufacturing industry. It does not include maintenance which would require trade level skills. It is not intended that this competency would cover performing maintenance which is carried on in a workshop.

This may include:

predictive and preventative operational maintenance

proactive maintenance

reactive maintenance.

Procedures

All operations are performed in accordance with procedures.

Procedures include all relevant workplace procedures, work instructions, temporary instructions and relevant industry and government codes and standards.

Tools and equipment

This competency includes use of equipment and tools such as:

hand tools specific for the task

testing equipment

measuring and aligning equipment

computer equipment

relevant personal protective equipment.

Hazards

Typical hazards to be considered, include:

isolations of energy sources, motive power and process materials

manual handling of machinery components and the need for lifting devices

hot, cold or components containing dangerous materials

external hazards (eg traffic into a maintenance area)

Problems

Respond to/rectify 'non-routine problems' means 'apply known solutions to a variety of predictable problems'.

Typical process and product problems which may require maintenance, include:

equipment performance outside of specification or requirements

equipment breakdown

equipment wear and tear.

Variables

Key variables to be monitored include:

relationship of maintenance plan to production requirements

costs of maintenance

availability of materials and services

documentation and record keeping.

Data and Records

Typical information sources, observed data and plant records may include:

plant data

log sheets

production schedules

operational and performance reports

physical aspects such as noise, smell, feel and pressure

condition monitoring information

planned maintenance schedules

standard operating procedures

manufacturer instructions, specifications and service manuals

machine circuit diagrams for hydraulic/pneumatic and electrical/electronic circuits

plant description manuals.

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