1

Interpret client brief or contract requirements

1.1

Determine required features of the integrated maintenance management system

1.2

Interpret parameters to the brief or contract

1.3

Determine stakeholders to be consulted in design process

1.4

Research current maintenance systems and management techniques relevant to brief or contract, including lean systems maintenance, systems thinking, continuous improvement, and constraint and contingency management

1.5

Assess OHS regulatory, sustainability or environmental issues relevant to contract or brief

1.6

Seek appropriate technical and professional assistance as required

1.7

Provide initial advice on feasibility based on specified or anticipated operations, including expectations for equipment availability and budget for maintenance

2

Prepare concept proposal

2.1

Establish integrated maintenance management system options for plant and plant support services

2.2

Establish facilities and service maintenance response system options

2.3

Categorise maintainable assets

2.4

Establish data collection, storage, analysis and system feedback requirements

2.5

Establish personnel participation and development requirements.

2.6

Carry out required modelling and calculations using appropriate software and validation techniques

2.7

Generate a range of solutions to the design brief ensuring conformity with OHS requirements

2.8

Determine social and sustainability implications of solutions

2.9

Review concept proposals with client to identify most appropriate solution

3

Design and handover integrated maintenance management system

3.1

Develop integrated maintenance management system design

3.2

Provide documentation, diagrams, specifications and instructions

3.3

Consult with client and stakeholders on features and operation of final design

3.4

Obtain sign-off on design

3.5

Monitor implementation with stakeholders and make any necessary adjustments to design

Required skills

Required skills include:

designing maintenance system proposals that are properly integrated with engineering and business objectives

categorising maintainable assets

determining maintainable features of plant and equipment and parameters to the brief or contract

determining OHS, regulatory, risk management and sustainability requirements

advising clients based on discipline knowledge and OHS and regulatory standards

establishing maintenance management system options for plant and plant support services, facilities and service maintenance response system options, data collection, storage, analysis and system feedback requirements, and personnel participation and development requirements

investigating faults in existing designs and proposing solutions

analysing financial costs and management implications of maintenance management systems, including life cycle cost and break-even

modelling and calculating using appropriate software and validation techniques

generating and evaluating a range of solutions for feasibility against design criteria

planning for staffing requirements and training to operate maintenance management system

communicating, negotiating and reviewing with stakeholders and client throughout process to obtain agreement on proposal and sign-off on design

documenting design with drawings, specifications and instructions

Required knowledge

Required knowledge includes:

current maintenance management techniques and systems

options and trends in performance analysis, modelling and simulation software

design techniques for reliability, maintainability and life cycle costing

maintenance system options, such as corrective, preventative, predictive (condition monitoring), precision, RCM, proactive or TPM

economic, social and environmental implications of maintenance management systems

OHS and regulatory requirements, codes of practice, standards, risk management and registration requirements

technical and professional support services required to comply with license, legal and indemnity requirements

processes for investigation, such as developing options, modelling and calculating, generating a range of solutions, completing feasibility and evaluation studies and preparing proposals

maintainable features of assets

asset importance, such as risk to operations, critical plant, semi-critical and remainder of plant

strategies for critical assets to maintain reliability, such as back-up assets, storing spares and use of redundant monitoring

maintenance activities, online and break-down, such as manual and instrumented monitoring, adjustments, lubrications, lubricant testing, alignments, balancing, machining, fabricating, assembling and mounting, and reporting results

management of spares inventory recognising cost and criticality of assets

techniques for:

continuous improvement

problem solving and decision making

root cause analysis (RCA) or failure mode and effects analysis (FMEA) or design review based on failure mode (DRBFM), and Pareto analysis

theory of constraints (TOC)

integrated maintenance data systems, including analysis, collection, handling, storage, scheduling, recording and reporting

maintenance and operational system control documents, such as flowcharts, schedule and report templates, network specifications, data analysis and feedback procedures

monitoring options, such as manual and sensor/transducer options

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

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

design a maintenance system proposal integrated with engineering and business objectives

interpret maintainable features of plant and equipment and parameters to the brief or contract

advise client on maintenance system options

research current maintenance management techniques and systems

establish maintenance management system options

categorise maintainable assets

determine sustainability and OHS, regulatory and risk management requirements

model and calculate using appropriate software and validation techniques

generate and evaluate a range of solutions for feasibility against design criteria

communicate, negotiate and review with stakeholders and client throughout process to obtain agreement on proposal and sign-off on design

document design with drawings, specifications and instructions.

Context of and specific resources for assessment

Full assessment of this unit would normally need to be undertaken on the job in the context of a commercial design project and software. Assessment of some elements of the maintenance system design process may be possible off the job providing full plant simulation facilities and software are available that reflect realistic workplace situations.

The competencies covered by this unit would be demonstrated by an individual working alone or as part of a team.

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

Access must be provided to appropriate learning and/or assessment support when required. Where applicable, physical resources should include equipment modified for people with disabilities.

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 its 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 able not only 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.

Integrated maintenance management systems

Integrated maintenance management systems usually combine management, financial, engineering and other practices for cost-effective maintenance of assets such as plant, equipment and facilities. These systems involve the design for reliability and maintainability, manufacture, installation, commissioning and eventual write-off and replacement of the assets. Data is collected and analysed to assess the reliability, life cycle costs and productivity of the assets against the design criteria.

Reliability relates to the productivity of assets, that is, the maintenance of service or product output (quantities) and its quality within cost parameters. Systems may also include consideration of:

maintenance priority

maintenance activity audit

monitoring and testing

maintenance system data

facilities and service maintenance response systems

maintainability

Parameters to the brief

The design brief may include the design of new equipment or fault analysis, rectification or modification to an existing design. Parameters to the design brief may include:

determination of the degree of innovation and creativity expected by the client

design process limits and budgets

product cost limits and budgets

performance specifications

equipment availability, capacities and restrictions

specified administrative, communication and approval procedures

other special features and limits in the design brief

Maintenance systems

Maintenance systems may include:

break-down maintenance

preventive maintenance

predictive maintenance (On-condition)

precision maintenance

proactive maintenance

reliability centred maintenance

total productive maintenance

Lean systems maintenance

Lean maintenance systems aim at maximising machine and process uptime, minimising waste and costs, maintaining quality and delivery and customer service. Maintenance processes and procedures are subject to continuous improvement and are set to complement engineering business objectives. Processes covered under the lean systems maintenance reference include:

process improvement

problem solving and decision making

RCA, FMEA or DRBFM

application of TOC

Systems thinking

Systems thinking:

is the process of developing solutions within the context of an entire system

recognises that an improvement in one subsystem can adversely affect another subsystem

Continuous improvement

Continuous improvement implementation may relate to:

plant, products, processes, systems or services, including design, development, implementation or manufacture, commissioning, operation or delivery and maintenance

Constraints and contingencies

Contingencies are unplanned events that may require a maintenance system response. Examples may include:

breakdowns

loss of services

sudden increases or decreases in production

regulatory change

Constraints are limitations on possible maintenance system solutions. These may be technical or physical constraints, such as:

lack of spare parts

delays in supply

shortage of skilled workers

limits to site access or logistical limitations

financial, regulatory or internal procedures constraints

OHS, regulatory requirements and enterprise procedures

OHS, regulatory requirements and enterprise procedures may include:

OHS Acts and regulations

relevant standards

industry codes of practice

risk assessments

registration requirements

safe work practices

state and territory regulatory requirements applying to electrical work

Appropriate technical and professional assistance

Appropriate technical and professional assistance may include:

technical support and advice relating to elements which have intrinsic dangers, for example:

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

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 OHS impact on employees, community and customer

Data collection, storage and analysis

Manual methods or maintenance management software may be employed for:

management of asset data, maintenance inventory, maintaining essential documentation (e.g. material safety data sheets (MSDS), work permits and databases)

planning, data recording and analysis

generation of documents, such as work orders, inventory reorders, and reports for process improvement or design feedback

Software options include:

computer maintenance management (CMM)

computer-aided process planning (CAPP)

system control and data acquisition (SCADA)/distributed control systems (DCS)

automated storage and retrieval systems (ASRS)

enterprise resource planning (ERP)

quality assurance (QA) and quality control (QC) systems software

Personnel participation and development requirements

Personnel, participation and development requirements in the maintenance system include the determination of labour requirements and functions for:

autonomous and supervised maintenance-related activities, such as monitoring, adjustment, lubrication, disassembly, repair or replacement of parts, balancing and assembly

installation, alignment and recommissioning in accordance with standard procedures

participation in process improvement, including:

measuring performance against benchmarks, such as life cycle costs, time between failures (TBF), and overall equipment effectiveness (OEE), as appropriate to individual job functions in design or operations

data management, generation, recording, analysing, storing and use of software

required training, including:

training for systems participation

technical training

Appropriate software and validation techniques

Software may be employed for:

performance analysis/modelling. Underpinning program techniques and algorithms should be understood, such as the use of FEA and numerical methods within object oriented modelling techniques

Validation techniques include:

comparison of traditional solutions for simple design problems with software solutions to the same design problems

review of previously implemented design challenges which were completed using the software