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 |
Safety case | Safety case refers to: a formal requirement of major hazard facilities in order to procure an operating licence |
Shutdown | Shutdown refers to: the regulatory shutdown of the plant for safety inspections (this is also the only time major maintenance can be done) |
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 includes: 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. |
MTBF | 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. |
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 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. |