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Evidence Guide: MSACMT481A - Undertake proactive maintenance analyses

Student: __________________________________________________

Signature: _________________________________________________

Tips for gathering evidence to demonstrate your skills

The important thing to remember when gathering evidence is that the more evidence the better - that is, the more evidence you gather to demonstrate your skills, the more confident an assessor can be that you have learned the skills not just at one point in time, but are continuing to apply and develop those skills (as opposed to just learning for the test!). Furthermore, one piece of evidence that you collect will not usualy demonstrate all the required criteria for a unit of competency, whereas multiple overlapping pieces of evidence will usually do the trick!

From the Wiki University

 

MSACMT481A - Undertake proactive maintenance analyses

What evidence can you provide to prove your understanding of each of the following citeria?

Liaise with operator

  1. Establish a relationship with the operator/s of equipment/plant
  2. Ensure the operator has the required skills and resources to keep the equipment/plant clean
  3. Ensure the operator is able to effectively monitor the operation of the equipment/plant
  4. Regularly communicate with operator about the Overall Equipment Efficiency (OEE) of their equipment/plant
  5. Involve operator, team leader and other key personnel in identification of skill needs and means of skill acquisition to fill any identified gaps
Establish a relationship with the operator/s of equipment/plant

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure the operator has the required skills and resources to keep the equipment/plant clean

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure the operator is able to effectively monitor the operation of the equipment/plant

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Regularly communicate with operator about the Overall Equipment Efficiency (OEE) of their equipment/plant

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Involve operator, team leader and other key personnel in identification of skill needs and means of skill acquisition to fill any identified gaps

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Analyse history

  1. Analyse Mean Time Between Failures ( MTBF) (or similar statistical history analysis)from maintenance records
  2. Analyse performance data of the equipment/plant
  3. Identify causes of changes to historic trends/status
  4. Determine methods of ensuring causes of improvements are locked in and deterioration resolved
Analyse Mean Time Between Failures ( MTBF) (or similar statistical history analysis)from maintenance records

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Analyse performance data of the equipment/plant

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify causes of changes to historic trends/status

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine methods of ensuring causes of improvements are locked in and deterioration resolved

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Undertake Failure Mode Effects Analysis (FMEA) (or similar)

  1. Undertake analysis
  2. Record results of analysis
  3. Investigate methods of eliminating possibility of failure and/or minimising the impact of the failure
  4. Liaise with operator, team leader and other key personnel regarding possible solutions
  5. Select most appropriate solution
  6. Implement selected solutions
Undertake analysis

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Record results of analysis

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Investigate methods of eliminating possibility of failure and/or minimising the impact of the failure

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Liaise with operator, team leader and other key personnel regarding possible solutions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Select most appropriate solution

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Implement selected solutions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Undertake condition monitoring analysis

  1. Obtain data for condition monitoring analysis
  2. Interpret condition monitoring data
  3. Predict required maintenance type and timing from condition monitoring data
  4. Liaise with operator, team leader and other key personnel regarding implications of condition monitoring report
  5. Involve team members in development of changes to maintenance strategy to ensure awareness, learning and commitment
Obtain data for condition monitoring analysis

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Interpret condition monitoring data

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Predict required maintenance type and timing from condition monitoring data

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Liaise with operator, team leader and other key personnel regarding implications of condition monitoring report

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Involve team members in development of changes to maintenance strategy to ensure awareness, learning and commitment

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

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

The person will be able to undertake a range of predictive maintenance analyses as well as support operations staff, and implement an advanced maintenance strategy.

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

Evidence should be available as to the analyses undertaken and the support provided.

In what context should assessment occur?

Assessment needs to occur in an organisation using predictive maintenance strategies or a simulation in a workshop or by case study.

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

This unit may be assessed concurrently with other relevant maintenance units.

This unit is related to:

MSACMT280A Undertake root cause analysis

MSACMT281A Contribute to the application of a proactive maintenance strategy, and

MSACMT681A Develop a proactive maintenance strategy which cover different aspects/levels of this area.

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?

Generally evidence will be required from a range of predictive maintenance analyses in order to have sufficient evidence.

What are the specific resource requirements for this unit?

Access to an organisation using predictive maintenance procedures.

Required Skills and Knowledge

Required skills:

communication

teamwork

analysis

problem solving

mathematics

planning

reading and interpreting engineering specifications/drawings

computer use

prioritising

recording data.

Required knowledge:

cleaning needs, techniques and principles

methods of assessing skill gaps and filling them

techniques for determining MTBF or similar

techniques for undertaking FMEA or similar

underpinning principles of competitive manufacturing strategies being implemented and how to adapt them to maintenance

root cause analysis

condition monitoring.

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.

Competitive manufacturing

Competitive manufacturing is used to describe the range of systemic manufacturing practice concepts and approaches. It covers but is not limited to:

lean manufacturing

agile manufacturing

preventative and predictive maintenance approaches

monitoring and data gathering systems such as Systems Control and Data Acquisition (SCADA) software, Enterprise Resource Planning (ERP) systems, Manufacturing Resource Planning (MRP), and proprietary systems such as SAP etc.

statistical process control systems including six sigma and three sigma

Just in Time (JIT), kanban and other pull related manufacturing control systems

supply, value, and demand chain monitoring and analysis

other continuous improvement systems.

Competitive manufacturing should be interpreted so as to take into account the stage of implementation of competitive manufacturing approaches, the enterprise's size and work organisation, culture, regulatory environment and manufacturing sector.

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

Mean Time Between Failure (MTBF)

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.

There are many possible causes of any problem. Eliminating some will have no impact, others will ameliorate the problem. However, elimination of the root cause will eliminate the problem. There should only be one root cause for any problem and so the analysis should continue until this one cause is found. Elimination of the root cause permanently eliminates the problem.

Failure Mode and Effects Analysis (FMEA)

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

In this unit condition monitoring is used to describe the process of analysing the implications of condition monitoring data for proactive maintenance whether it be obtained from non destructive testing reports, visual assessment by experts, diagnostic reports obtained from SCADA or other enterprise or equipment software and product or process quality analyses. It does not require the actual undertaking of the NDT or condition monitoring assessment or test. If this is required appropriate units from other Training Packages will be required.