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Evidence Guide: MSACMT483A - Support proactive maintenance

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

 

MSACMT483A - Support proactive maintenance

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

Lead team in monitoring process and equipment.

  1. Demonstrate to team how to observe the process/equipment continuously and critically using appropriate senses (sight, hearing etc) to identify any potential or actual problems
  2. Identify to team data indicators that must be monitored and recorded
  3. Ensure team monitors identified data indicators frequently and critically
  4. Ensure symptoms of operations outside the desired range of conditions and performance are recognised
  5. Analyse cause of equipment non standard performance within scope of knowledge and skill
  6. Ensure team members take timely and appropriate action to solve problem or to refer problem to appropriate manager or specialist
Demonstrate to team how to observe the process/equipment continuously and critically using appropriate senses (sight, hearing etc) to identify any potential or actual problems

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify to team data indicators that must be monitored and recorded

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure team monitors identified data indicators frequently and critically

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure symptoms of operations outside the desired range of conditions and performance are recognised

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Analyse cause of equipment non standard performance within scope of knowledge and skill

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure team members take timely and appropriate action to solve problem or to refer problem to appropriate manager or specialist

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Apply proactive maintenance strategy.

  1. Obtain and discuss maintenance strategy with relevant people
  2. Identify aspects of maintenance strategy which require specific input from team
  3. Discuss maintenance strategy with team members
  4. Ensure team members have resources and training to be able to make the required contributions
Obtain and discuss maintenance strategy with relevant people

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify aspects of maintenance strategy which require specific input from team

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Discuss maintenance strategy with team members

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure team members have resources and training to be able to make the required contributions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Analyse standard procedures and work practices.

  1. Examine team procedures and practices for compatibility with maintenance strategy
  2. Identify areas where production procedures/practices should be changed to comply with maintenance strategy
  3. Identify areas where maintenance strategy should change to comply with production procedures and practices
  4. Identify other activities or areas where changes might increase equipment reliability
  5. Take appropriate action to have the required changes made
Examine team procedures and practices for compatibility with maintenance strategy

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify areas where production procedures/practices should be changed to comply with maintenance strategy

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify areas where maintenance strategy should change to comply with production procedures and practices

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify other activities or areas where changes might increase equipment reliability

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Take appropriate action to have the required changes made

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Facilitate team contribution to proactive maintenance.

  1. Monitor team's contribution to proactive maintenance
  2. Arrange for competency development of team members as required
  3. Facilitate ongoing examination by the team of process reliability and overall equipment efficiency (OEE)
  4. Arrange for follow through and implementation of team originated improvements
Monitor team's contribution to proactive maintenance

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Arrange for competency development of team members as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Facilitate ongoing examination by the team of process reliability and overall equipment efficiency (OEE)

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Arrange for follow through and implementation of team originated improvements

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 assessment should identify that a team leader is able to provide leadership to a team whose responsibilities include the implementation of a proactive maintenance strategy.

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

Evidence of leadership to a team in supporting a proactive maintenance strategy would be required.

In what context should assessment occur?

Assessment needs to occur in an organisation implementing a proactive maintenance strategy preferably through project based assessment.

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

This unit could be assessed concurrently with other leadership related units.

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?

Evidence from one significant change may be sufficient. For less significant changes, a range of changes will be needed to generate sufficient evidence.

What are the specific resource requirements for this unit?

Access to an organisation implementing a proactive maintenance strategy.

Required Skills and Knowledge

Required skills:

communication techniques

negotiation skills

information finding and analysing/using skills

team work

problem solving

planning and organising

Required knowledge:

understanding of the production process as it applies to the team area of responsibility

understanding of proactive maintenance strategies

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 in the Performance Criteria is detailed below. 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.

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 software (SCADA), enterprise resource planning systems (ERP), Manufacturing resource planning (MRP), and proprietary systems such as SAP etc.

statistical process control systems including six sigma and three sigma

just in time, 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.

Team

Team may include work teams from all sections of the organisation including production, maintenance, technical, administration/finance, sales/marketing.

Strategies may include:

Total Productive Maintenance (TPM)

Reliability Centred Maintenance (RCM)

Root Cause Analysis ( RCA)

Mean Time Between Failures (MBTF)

Failure Mode and Effects Analysis (FMEA)

Condition monitoring

Total Preventative Maintenance/Total Productive Maintenance (TPM) which is an application of total quality management to maintenance with the intention of increasing reliability, getting it right first time and increasing Overall equipment efficiency (OEE).

Reliability Centred Maintenance (RCM) moves maintenance from reactive, or even planned/programmed towards a focus on uptime and OEE.

RCA 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.

Uptime refers to the overall availability of the plant - it is the inverse of downtime - or the unavailability of the plant. Ideal uptime is 100%.

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 (MBTF) 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 MBTF is reducing, then it is an indicator that the maintenance regime is failing.

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 involves often quite sophisticated monitoring of equipment including such things as vibration monitoring, instrumental analysis of lubricating oil etc to determine the current state of the equipment, monitor the change in this condition and predict when it needs servicing/maintenance to maintain reliability.