MEM14092A

Integrate maintenance fundamentals into an engineering task

1

Investigate requirements of equipment or component maintenance task

1.1

Review the context and parameters of the maintenance task in consultation with stakeholders

1.2

Review equipment or component original design and any subsequent modifications and repairs

1.3

Review current performance specifications

1.4

Determine engineering scientific principles and design techniques required for equipment or component maintenance

2

Investigate alternatives of repair, replacement or modification

2.1

Review preventative maintenance system requirements or defect/failure details to determine if replacement is required

2.2

Review equipment or component condition analysis reports, including the results of any required NDT

2.3

Review maintenance repair techniques and processes, standard parts, labour and skill requirements

2.4

Consider life cycle design and sustainability implications of maintenance design and maintenance activities

2.5

Determine specification, documentation and graphical techniques required to define designs

2.6

Confirm WHS and regulatory requirements, codes of practice, standards, risk management and registration requirements relevant to repair and modification design projects

2.7

Assess the need for technical and professional assistance

2.8

Consider software options for repair and modification design, such as computer-aided design (CAD), stress analysis and project management software

2.9

Decide if repair, replacement or modification is appropriate and seek any necessary approvals

3

Apply repair and modification design techniques

3.1

Plan, schedule and coordinate the repair or modification design task

3.2

Apply the design process and scientific principles to repair and modification design proposals

3.3

Determine materials, components, maintenance processes, equipment and tools required to implement design

3.4

Create adequate and accurate calculations, preliminary graphics and maintain design process records, including use of software, as appropriate

3.5

Assess repair and modification designs against design criteria

3.6

Apply systems thinking to problem solving and decision making techniques in dealing with contingencies and constraints for continuous improvement and development of design options

3.7

Incorporate professional and technical assistance, as required

3.8

Use specification, documentation and graphical techniques, modelling, mock-up or prototyping techniques, as appropriate, to define repair or modification

4

Report results

4.1

Record results of investigations, application and development of repair and modification design

4.2

Provide appropriate documentation, such as calculations, specifications, diagrams, CAD files, mock-ups or prototypes

Required skills

Required skills include:

determining or confirming scientific principles and maintenance design techniques, WHS and regulatory requirements, and design specification requirements required to meet maintenance brief

evaluating multiple solutions, materials and components, maintenance repair processes and techniques, standard parts, skill requirements, equipment and tools

investigating life cycle design and sustainability, technical and professional assistance alternatives for repair, replacement or improvement, and software options for maintenance planning and design

planning, scheduling and coordinating the maintenance task

applying design process and scientific principles to component and hardware selection and design proposals

solving problems and making decisions with systems thinking for contingencies and constraints, and continuous improvement

defining designs, specifying and documenting and applying graphical techniques, modelling, mock-up or prototyping techniques

creating and maintaining adequate and accurate calculations and design process records

reporting and documenting results of investigations, application of principles and techniques, calculations, specifications, diagrams, CAD files, mock-ups or prototypes of designs

Required knowledge

Required knowledge includes:

sustainability implications of maintenance processes, materials and products, including consideration of life cycle analysis

design processes and techniques

concurrent engineering techniques, systems thinking, problem solving and decision making, and continuous improvement methods

WHS Acts and regulations, codes of practice, standards, registration and risk assessment for design, maintenance and prototyping activities

procedures for planning, scheduling and coordination of maintenance design

typical maintenance criteria, such as:

strength and servicability of repairs compared to original

function and aesthetics

maintainability and manufacturability

preventative maintenance evaluatuion criteria, such as mean time between failure (MBTF) and failure mode effects analysis (FMEA)

required quality, cost and sustainability

design calculations techniques

typical maintenance design requirements of various industries

typical repairs, parts, skills and maintenance processes

hardware specifications and catalogues

typical maintenance plant, equipment and tools

plant condition and maintenance assessment techniques

typical maintenance techniques and technologies for monitoring, preventative maintenance, online and breakdown maintenance, disassembly, repair, reassembly and recommission

design calculations layout and documentation for design checking and maintenance records

design process documentation and reports, including specifications and CAD graphics

software for maintenance planning and repair and modification design, including CAD and stress analysis software

software and systems, such as system control and data acquisition (SCADA) and distributed control systems (DCS) for maintenance control and information distribution

developments in repair and modification design

options for mock-up, modelling and prototyping

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 apply repair and modification techniques consistent with a design brief information, relevant standards and conventions.

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

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

communicate, negotiate and review maintenance brief with stakeholders

determine or confirm scientific principles and design techniques, WHS and regulatory requirements, and design specification requirements

evaluate multiple solutions

investigate life cycle design, sustainability, technical and professional assistance required, and maintenance alternatives for repairs and modifications

plan, schedule and coordinate the maintenance task

solve problems and make decisions with systems thinking for contingencies and constraints, and continuous improvement

define designs, specify and document and apply graphical techniques, modelling, mock-up or prototyping techniques

select components and hardware

create and maintain adequate and accurate calculations and design process records

report and document results and processes.

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 an appropriate simulation 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. The assessment environment should not disadvantage the candidate.

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.

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.

Maintenance repair and modification requirements

Maintenance repair and modification requirements may include:

scheduled maintenance required under the maintenance management system

unscheduled maintenance as a result of system/component failure

repairs to restore systems/components to operation

modifications to improve system/component reliability or maintainability

maintenance schedule change or equipment or component modification required because of a change in equipment performance requirements (e.g. changed production or product design)

competitive market pressure and ‘lean maintenance’

changes in available maintenance technology

resources supply (e.g. materials, labour and skills)

introduction or changes to asset technologies (e.g. mechanical, fluid, electrical, electronic and system control)

sustainability relevant to repair and modification design tasks

WHS, risk and applicable standards and code requirements

Planning processes

Planning processes may include:

establishing maintenance parameters and design criteria

contributing to the negotiation and advice process

preliminary planning, investigations and costing

identifying design, development, prototyping activities and skills requirements

planning and scheduling design activities

improving, adjusting and rescheduling as required by emergency contingencies and constraints

Design process

Where equipment or component repair or modification design is required the design process includes:

establish design parameters and criteria

research, measurement, experimentation and investigation

generating ideas

synthesis, problem solving and decision making, and addressing constraints

apply scientific principles, calculation and graphics, prototyping and mock-up techniques if required

selection of components and hardware

evaluating solutions against design criteria

consultation, adjustments and agreement

finalise design and sign-off

Design criteria

Design criteria may include:

function and fit for purpose

aesthetics

manufacturability and maintainability

sustainability

cost constraints

ergonomics and anthropometrics and physiology

facilities, plant, services and skills available

WHS and risk

Sustainability

Sustainability is used to mean the entire sustainable performance of the organisation/plant, including:

meeting all regulatory requirements

conforming to all industry covenants, protocols and best practice guides

minimising ecological and environmental footprint of process, plant and product

maximising economic benefit of process plant and product to the organisation and the community

minimising the negative WHS impact on employees, community and customer

Life cycle assessment

Life cycle analysis can be used to improve sustainability of repaired or modified equipment or components. It may be applied to all aspects of the repair or modification process

Appropriate licensed technical and professional assistance

Appropriate licensed 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

risk assessments

registration requirements

safe work practices

state and territory regulatory requirements applying to electrical work

Standards and codes

Standards and codes refer to all relevant Australian and international standards and codes applicable to a particular maintenance repair and modification design task

Prototyping

Prototyping may include:

mock-ups, physical and virtual modelling with post-processing for computer numeric control (CNC) and rapid prototyping

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

Unit sector

Planning