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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

Range Statement

This field allows for different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.

Competitive systems and practices include one or more of:

lean operations

agile operations

preventative and predictive maintenance approaches

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.

Strategies include one or more of:

mean time between failure (MTBF) which 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) which is a systematic approach that identifies potential failure modes in a system, product or equipment based operations caused by either design or operation/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

industry sectors have highly adapted forms of FMEA and which may practice traditional FMEA in their routine maintenance while using another technique, such as Hazard and Operability Studies (HAZOP) for design and modification. 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 which often involves 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.

Inspection includes one or more of:

reading dials, gauges and meters

observations, including those using sight, hearing, smell and feel

observations of product quality/faults/rejects.

Servicing includes one or more of:

cleaning

lubricating

topping up

adjusting.

Procedures (written, verbal, visual, computer based, etc.) include one or more of:

work instructions

standard operating procedures (SOPs)

safe work method statements

formulas/recipes

batch sheets

temporary instructions

any similar instructions provided for the smooth running of the plant.

Performance Evidence

Evidence required to demonstrate competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria and include the ability, for one (1) or more work/plant areas, to:

source information from manuals and other technical documentation or software

effectively communicate with users on equipment operational and maintenance history

develop schedules for maintenance activities, including seeking technical assistance, where appropriate

differentiate between proactive and traditional maintenance strategies.

Knowledge Evidence

Must provide evidence that demonstrates knowledge relevant to their job role sufficient to fulfil their job role independently, including:

requirements of the proactive maintenance strategy being implemented

operating principles and procedures for equipment/plant subject to proactive maintenance strategy

purpose and processes for data collection in proactive maintenance strategies

procedures relevant to own job and organisation implementation of proactive maintenance

methods of making/recommending improvements.