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Evidence Guide: MSS405083A - Adapt a proactive maintenance strategy for a seasonal or cyclical business

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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!

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MSS405083A - Adapt a proactive maintenance strategy for a seasonal or cyclical business

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

Interpret proactive maintenance strategy

  1. Analyse proactive maintenance strategy
  2. Identify areas which may conflict with cyclical requirements
  3. Identify critical conditions which must be met in order to maintain plant reliability until season end
  4. Compile cycle requirements for proactive maintenance strategy
Analyse proactive maintenance strategy

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Identify areas which may conflict with cyclical requirements

Completed
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Identify critical conditions which must be met in order to maintain plant reliability until season end

Completed
Date:

Teacher:
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Compile cycle requirements for proactive maintenance strategy

Completed
Date:

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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, range statement and the Assessment Guidelines for the Training Package.

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

A person who demonstrates competency in this unit must be able to provide evidence of the ability to:

analyse the equipment availability requirements of a seasonal or cyclical operation

consider a variety of proactive maintenance strategies for suitability to a seasonal or cyclical operation

consult operators, maintenance, management and other stakeholders in decisions on proactive maintenance strategies

monitor the implementation of selected proactive maintenance strategies and make required adjustments.

Context of and specific resources for assessment

Assessment of performance must be undertaken in a workplace using or implementing one or more competitive systems and practices.

Access may be required to:

workplace procedures and plans relevant to work area

specifications and documentation relating to planned, currently being implemented, or implemented changes to work processes and procedures relevant to the assessee

documentation and information in relation to production, waste, overheads and hazard control/management

reports from supervisors/managers

case studies and scenarios to assess responses to contingencies.

Method of assessment

A holistic approach should be taken to the assessment.

Competence in this unit may be assessed by using a combination of the following to generate evidence:

demonstration in the workplace

workplace projects

suitable simulation

case studies/scenarios (particularly for assessment of contingencies, improvement scenarios, and so on)

targeted questioning

reports from supervisors, peers and colleagues (third-party reports)

portfolio of evidence.

In all cases it is expected that practical assessment will be combined with targeted questioning to assess underpinning knowledge.

Where applicable, reasonable adjustment must be made to work environments and training situations to accommodate ethnicity, age, gender, demographics and disability.

Guidance information for assessment

Assessment processes and techniques must be culturally appropriate and appropriate to the oracy, language and literacy capacity of the candidate and the work being performed.

Required Skills and Knowledge

Required skills

Required skills include:

considering the impact of seasonal and cyclical production requirements on equipment availability requirements

prioritising maintenance activities critical to production

communicating with others using a variety of media and techniques

adapting personal communication strategy to different levels of literacy and numeracy in target individuals and groups

working in a team

analysing quantitative and qualitative information to determine proactive maintenance strategy options

solving problems to root cause

applying basic arithmetic and statistical techniques

planning complex strategies, including consideration of timelines, resources, benefit/cost, implementation requirements, and monitoring and adjustment considerations

reading and interpreting engineering specifications, drawings and charts

using information system terminals and computers

prioritising options, including reasons and recommendations

recording data

Required knowledge

Required knowledge includes:

processing equipment and products of the organisation

start-up, shutdown and isolation considerations for the organisation

skills required by operators and maintenance personnel to achieve effective proactive maintenance strategy implementation

characteristics and strengths of different types of strategies, techniques and tools, such as:

total productive maintenance (TPM)

reliability centred maintenance (RCM)

mean time between failure (MBTF

failure mode effects analysis (FMEA)

condition monitoring

root cause analysis (RCA)

holistic costs of different strategies combining cost of maintenance with costs of lost production, sales, and so on, as relevant to the organisation

business goals sufficient to match the strategy to the business needs

strategic thinking and its application to proactive maintenance

principles of process equipment and how to improve its reliability

resources required and how to obtain them

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 systems and practices

Competitive systems and practices may include, but are not limited to:

lean operations

agile operations

preventative and predictive maintenance approaches

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

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

Competitive systems and practices should be interpreted so as to take into account:

the stage of implementation of competitive systems and practices

the size of the enterprise

the work organisation, culture, regulatory environment and the industry sector

Critical conditions

Critical conditions are those factors which must be undertaken or determined in order to maintain plant reliability during processing season. These may include:

maximum load factors

lubrication schedules

correct operating temperatures

cleaning and waste removal schedules

equipment inspection and test schedules

development of standard operating procedures and training of operators

Ancillary equipment

Ancillary equipment includes other plant, such as:

boilers

utilities

plants

waste treatment and hazard control equipment (e.g. fire ring mains, fire monitors, steam curtains, gas (or other loss of containment) monitors, blast protection and flare stacks)

TPM

TPM refers to:

an application of total quality management to maintenance with the intention of increasing reliability, getting it right first time and increasing OEE

RCM

RCM includes:

moving maintenance from reactive, or even planned/programmed towards a focus on uptime and OEE

RCA

RCA is a structured problem solving technique. Typically 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.

MBTF

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.

FMEA

FMEA is a systematic approach that identifies potential failure modes in a system, product, or operations/assembly operation caused by either design or operations/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 Hazard and Operability Studies (HAZOP) for design and modification.

Uptime

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%

OEE

OEE is the combination of the main factors causing loss of productive capacity from equipment/plant and is where:

OEE = availability x performance x quality rate

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

Condition monitoring

Condition monitoring involves often 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

HAZOP

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.