Elements and Performance Criteria

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

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.