At this level individuals exercise considerable responsibility and accountability within enterprise structures and are required to make primary contributions to the values, goals and operations of the enterprise. They will typically have responsibility for the establishment and review of systems for the site or department. They may work with the assistance of external experts to develop plans and strategies. This unit is particularly useful for maintenance managers, plant engineers and production managers working in a meat industry context.

ELEMENT

PERFORMANCE CRITERIA

1. Prepare maintenance policies

1.1. Maintenance costs, including the cost of poor maintenance procedures, are identified and quantified.

1.2. Management commitment to a productive maintenance strategy is negotiated and confirmed.

1.3. Enterprise performance is benchmarked against agreed standards, and maintenance policies and priorities are developed.

1.4. Maintenance system goals are developed through negotiation with stakeholders.

1.5. Communication strategies are established to build positive workforce attitude and commitment to maintenance.

2. Implement maintenance management system

2.1. Resource requirements are identified, secured and included in enterprise budgets and operational plans.

2.2. Location of the maintenance function and/or team within enterprise structures is determined.

2.3. Profile of the maintenance function and/or team within enterprise structures is determined.

2.4. Roles and responsibilities of equipment users and the maintenance team are clarified and built into position descriptions and work instructions.

2.5. Mentoring and training in the use and care of technology and equipment is provided to support the maintenance strategy.

2.6. Maintenance procedures and schedules are prepared to minimise negative impacts on production, costs, waste and the environment.

2.7. Record keeping systems are developed and maintained.

2.8. Potential risks are analysed and management strategies recommended.

2.9. Contingency plans are prepared in collaboration with the workforce, suppliers and customers.

2.10. Maintenance schedules and procedures are effectively communicated to the team.

3. Monitor and review maintenance management system

3.1. Continuous improvement strategies are developed.

3.2. Performance criteria for maintenance goals are determined and data collection strategies established.

3.3. Performance information and outcomes are analysed and implications reported to stakeholders.

Required skills

Ability to:

consult with key personnel, people on the floor, delegates, suppliers, contractors and equipment manufacturers to determine appropriate maintenance strategies, procedures and schedules

develop maintenance policies and strategies, including establishing criteria for determining maintenance priorities and planning and scheduling routine equipment and overhead maintenance to meet quality system requirements

establish and monitor performance targets for maintenance teams within performance planning and appraisal processes

develop workforce commitment to effective maintenance strategies, including implementing strategies for devolving the identification of maintenance needs to the floor, developing consultative and cooperative problem-solving strategies, and negotiating changes in work practices

develop secure record keeping procedures to document maintenance costs, problems, priorities, solutions, schedules and completions

apply relevant communication and mathematical skills

evaluate and recommend alternative maintenance policies and strategies, including evaluation of the costs and benefits of internal and consultant service models, changes in work roles and responsive/preventative models for maintenance

determine and recommend the need for capital expenditure for the replacement of plant and equipment

identify and apply relevant Occupational Health and Safety (OH&S), regulatory and workplace requirements

manage maintenance costs, including determining total maintenance costs based on maintenance service cost and machine breakdown cost, setting, justifying, and achieving maintenance budgets

monitor performance of the system, including establishing indicators, setting up data collection strategies, analysing data to identify trends and isolate problems or problem areas, and measuring progress against targets

prepare and implement contingency plans for dealing with risks, including equipment breakdowns and failures, including negotiation and planning with production personnel

present reports according to legal and enterprise requirements

review maintenance strategies and goals within the enterprise, continuous improvement and planning processes.

Required knowledge

Knowledge of:

plant and equipment falling under the scope of the maintenance program, including steam generation systems, refrigeration systems, water and effluent systems, processing and production equipment, and building

maintenance issues related to the enterprise and their impact on the productivity of the plant

cost elements in maintenance system costing and budgeting

relevant legislation and regulations (e.g. food safety and food standards), and industrial agreements, and explain the implications for plant and equipment maintenance

costs resulting from poor maintenance and the benefits of a preventative maintenance system

impacts of poor maintenance on meat safety, meat and/or product quality, occupational and environmental safety.

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

The meat industry has specific and clear requirements for evidence. A minimum of three forms of evidence is required to demonstrate competency in the meat industry. This is specifically designed to provide evidence that covers the demonstration in the workplace of all aspects of competency over time.

These requirements are in addition to the requirements for valid, current, authentic and sufficient evidence.

Three forms of evidence means three different kinds of evidence - not three pieces of the same kind. In practice it will mean that most of the unit is covered twice. This increases the legitimacy of the evidence.

All assessment must be conducted against Australian meat industry standards and regulations.

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

Competency must be demonstrated through sustained performance over time, at an appropriate level of responsibility and authority under typical operating and production conditions for the enterprise.

Context of and specific resources for assessment

Resources may include:

a real work environment

relevant documentation, such as:

financial data relating to maintenance costs

manufacturer instructions or operations manuals

regulatory requirements

workplace policy and procedures

relevant equipment and materials.

Method of assessment

Recommended methods of assessment include:

a third-party referee report of sustained performance at appropriate level of authority and responsibility

assignment focusing on understanding and application of principles and theory to workplace operations

workplace projects with focus on company environment and conditions.

Assessment practices should take into account any relevant language or cultural issues related to Aboriginality or Torres Strait Islander, gender, or language backgrounds other than English. Language and literacy demands of the assessment task should not be higher than those of the work role.

Guidance information for assessment

A current list of resources for this unit of competency is available from MINTRAC www.mintrac.com.au or telephone 1800 817 462.

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 may be:

preventative

responsive

routine.

Maintenance system goals and performance indicators may include:

reductions in backlogs

changes in attitude (e.g. commitment to elimination of defects before they cause breakdowns, prevention, and end to equipment abuse)

costs

frequency of breakdowns

length of time out of action

roles or users of maintenance and problem solving

time of repairs.

Stakeholders may include:

company owners, directors, shareholders and financiers

competitors

management and employees

suppliers, customers and consumers

unions and employer associations.

Maintenance teams may include:

engineers

boiler makers

plumbers and gas fitters

electricians

carpenters

labourers.

Maintenance policies may include:

preventative maintenance strategies, such as:

replacing all parts of a certain type when one fails

replacing all parts after expected or average service life

servicing all equipment according to supplier recommendations and at fixed time intervals after average service life

responsive maintenance strategies, such as:

defined maintenance priorities (e.g. chain breakdowns, chillers overheating versus leaking taps)

defined repair or service turnaround times (e.g. within two hours or days of maintenance report).

Devolution strategies may include:

encouraging work areas to prioritise maintenance within specified budget

including maintenance personnel in problem-solving teams

linking responsive and preventative maintenance to safety requirements and committees

rewarding work area or team identification and achievement of maintenance targets.

Problem-solving strategies may include:

cross functional, problem solving, process improvement or maintenance teams

suggestion boxes

tool boxes, consultative committees and maintenance meetings.

Maintenance problems may include:

breakdowns in lifting equipment, corning vats and smokehouses

bug infested equipment (e.g. water in lubrication systems and electrical boxes)

faulty air knives

faulty thermostats in chillers, freezers, cool stores, display cabinets and hydraulic equipment

leaking taps, hoses and pipes

rust, peeling paint and surface coatings.

Communication may:

be with culturally, ethnically and socially diverse individuals and groups

involve preparation of reports which may be complex, contain information from a range of technical sources and include mathematical and graphic information and data

occur in a variety of sensitive, conflictive, collaborative and supportive environments

be formal or informal and involve face to face and technological or electronic methods

require analysis and presentation of complex concepts, technical information, mathematical information and other data in simple or complex formats

require persuasion, negotiation and assertiveness skills.

Mathematical skills may relate to:

technical and financial modelling

calculations

interpretation and analysis

complex actual and hypothetical mathematical information, such as:

product and product quality

financial operations

personnel

operations

sales and turnover

exports.

OHS requirements may include:

enterprise OH&S policies, procedures and programs

OH&S legal requirements

Personal Protective Equipment (PPE) which may include:

coats and aprons

ear plugs or muffs

eye and facial protection

head-wear

lifting assistance

mesh aprons

protective boot covers

protective hand and arm covering

protective head and hair covering

uniforms

waterproof clothing

work, safety or waterproof footwear

requirements set out in standards and codes of practice.

Regulatory requirements may include:

animal welfare

commercial law, including fair trading and trade practices

consumer law

corporate law, including registration, licensing and financial reporting

environmental and waste management, and sustainable work practices

equal employment opportunity (EEO), anti-discrimination and sexual harassment

Export Control Act

hygiene and sanitation requirements

industrial awards and agreements

relevant regulations

state and territory regulations regarding meat processing

taxation

requirements set out in AS 4696:2007 Australian Standard for Hygienic Production and Transportation of Meat and Meat Products for Human Consumption.

Workplace requirements may include:

enterprise-specific requirements

OH&S requirements

Quality Assurance (QA) requirements

Standard Operating Procedures (SOPs)

the ability to perform the task to production requirements

work instructions.

Maintenance costs include:

service costs:

costs associated with the maintenance service, including labour

the cost of parts and materials

maintenance facilities

equipment and tools

training.

breakdown costs:

costs associated with the loss of production, including damaged or destroyed product

under-used labour

wasted energy and utilities

loss of contract or contract penalties

reduced capacity.

Impacts of poor maintenance on meat safety and meat and product quality may include:

contamination, including physical (e.g. rust, dust, metal and moisture) and microbiological

damaged carcases or product

refrigeration breakdowns causing incorrect temperatures and chilling rates causing toughening, rancidity, weight loss and micro-contamination.

Unit sector

This unit contains employability skills.