Free Manager Maintenance Course (6Months)

Manager Maintenance Mechanical & Electrical Level 5:

Brief Job Description

Individuals at this job are responsible for maintaining status of continuous running of equipment and machinery. They use computerized systems to oversee routine maintenance and organize repairs. They are also involved in control and monitoring devices and occasionally in the manufacture of items that will help in maintenance.

Personal Attributes

Individuals at this job are responsible for maintaining status of continuous running of equipment and machinery. They use computerized systems to oversee routine maintenance and organize repairs. They are also involved in control and monitoring devices and occasionally in the manufacture of items that will help in maintenance.

Work effectively in a team:

Elements and Performance Criteria

Effective communication

To be competent, the user/individual on the job must be able to:

PC1.   maintain clear communication with colleagues

PC2.   work with colleagues

PC3.   pass on information to colleagues in line with organisational requirements

PC4.. work in ways that show respect for colleagues

PC5.   carry out commitments made to colleagues

PC6.   let colleagues know in good time if cannot carry out commitments, explaining the reasons

PC7.          identify problems in working with colleagues and take the initiative to solve these problems

PC8.          follow the organisations policies and procedures for working with colleagues

PC9.   ability to share resources with other members as per priority of tasks

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1. the organisations policies and procedures for working withcolleagues, role and responsibilities in relation to this

KU2. the importance of effective communication and establishing goodworking relationships with colleagues

KU3. different methods of communication and the circumstances inwhich it is appropriate to use these

KU4. benefits of developing productive working relationships withcolleagues

KU5. the importance of creating an environment of trust and mutualrespect

KU6. whether not meeting commitments, will have implications onindividuals and the organisation

KU7. different types of information that colleagues might need and theimportance of providing this information when it is required

KU8. the importance of problems, from colleagues perspective andhow to provide support, where necessary, to resolve these

Generic Skills (GS)

User/individual on the job needs to know how to:

GS1.    complete well written work with attention to detail

GS2.    read instructions, guidelines/procedures

GS3.    listen effectively and orally communicate information

GS4.           make decisions on a suitable course of action or response

GS5.           plan and organise work to achieve targets and deadlines

GS6.           check that the work meets customer requirements

GS7.    deliver consistent and reliable service to customers

GS8.           apply problem solving approaches in different situations

GS9.           apply balanced judgements to different situations

GS10. apply good attention to detail

GS11. check that the work is complete and free from errors

GS12. get work checked by peers

GS13. work effectively in a team environment

Maintain a safe and healthy working environment:

Elements and Performance Criteria

Identify and report the risks identified

To be competent, the user/individual on the job must be able to:

PC1..   Identify activities which can cause potential injury through sharp objects, burns, fall, electricity, gas leakages, radiation, poisonous fumes, chemicals ,loud noise

PC2.    Inform the concerned authorities about the potential risks identified in the processes, workplace area/ layout, materials used etc

PC3.    Inform the concerned authorities about machine breakdowns, damages which can potentially harm man/ machine during operations

PC4.    Create awareness amongst other by sharing information on the identified risks

Create and sustain a Safe, clean and environment friendly work place

To be competent, the user/individual on the job must be able to:

PC5..   Follow the instructions given on the equipment manual describing the operating process of the equipments

PC6..   Follow the Safety, Health and Environment related practices developed by the organization

PC7.    Operate the machine using the recommended Personal Protective Equipments (PPE)

PC8. . Maintain a clean and safe working environment near the work place and ensure there is no spillage of chemicals, production waste, oil, solvents etc

PC9.    Maintain high standards of personal hygiene at the work place

PC10. Ensure that the waste disposal is done in the designated area and manner as per organization SOP.

PC11. Inform appropriately the medical officer/ HR in case of self or an employees illness of contagious nature so that preventive actions can be planned for others

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1. relevant standards, procedures and policies related to Health, Safety and Environment followed in the company

KU2. basic knowledge of Safety procedures( fire fighting, first aid) within the organization

KU3. knowledge of various types of PPEs and their usage

KU4. basic knowledge of risks/hazards associated with each occupation in the organization

KU5. how to safely operate various tools and machines and risksassociated with the tools/ equipment

KU6. knowledge of personal hygiene and how an individual an contribute towards creating a highly safe and clean working environment

Generic Skills (GS)

User/individual on the job needs to know how to:

GS1.    write basic level notes and observations

GS2.    read safety instructions put up across the plant premises

GS3.    read safety precautions mentioned in equipment manuals and panels to understand the potential risks associated

GS4.    effectively communicate information to team members

GS5.    informemployees in the plant and concerned functions about events, incidents & potential risks observed related to Safety, Health and Environment.

GS6.    question operator/ supervisor in order to understand the safety related issues

GS7.    attentively listen with full attention and comprehend the information given by the speaker during safety drills and training programs

GS8.    use common sense and make judgments during day to day basis

GS9.           use reasoning skills to identify and resolve basic problems

GS10. use common sense and make judgments during day to day basis

GS11. use reasoning skills to identify and resolve basic problems

Ensure implementation of 5S activities at the shop floor & the office area:

Elements and Performance Criteria

Ensure proper sorting of items at the work place

To be competent, the user/individual on the job must be able to:

PC1..     ensure all recyclable materials are put in designated containers

PC2.      ensure no tools, fixtures & jigs are lying on workstations unless in use and no un-necessary items is lying on workbenches or work surfaces unless in use

PC3.      ensure that the operators and other team members are segregating the waste in hazardous/ non hazardous waste as per the sorting work instructions

PC4.      ensure that all the operators are following the technique of waste disposal and waste storage in the designated bins

PC5..     segregate the items which are labelled at red tag items for the process area and keep them in the correct places

PC6..     ensure that all the tools/ equipment/ fasteners/ spare parts are arranged as per specifications/ utility into proper trays, cabinets, lockers as mentioned in the 5s guidelines/ work instructions

PC7.      check for return of any type of extra material and tools to the designated sections and make sure that no additional material/ tool is lying near the work area

PC8. .   oversee removal of unnecessary equipment, storage, furniture, unneeded inventory, supplies, parts and material

PC9.      ensure that areas of material storage areas are not overflowing

PC10.    ensure proper stacking and storage of the various types of boxes and containers as per the size/ utility to avoid any fall of items/ breakage and also enable easy sorting when required

Ensure proper documentation and storage – streamlining & organizing the workplace

To be competent, the user/individual on the job must be able to:

PC11.    ensure that the team follows the given instructions and checks for labelling of fluids, oils lubricants, solvents, chemicals etc and proper storage of the same to avoid spillage, leakage, fire etc

PC12.    make sure that all material and tools are stored in the designated places and in the manner indicated in the 5s instructions

PC13.    ensure that organizing the workplace takes place with due considerations to the principles of wasted motions, ergonomics, work & method study .

Ensure cleaning of self and the work place

To be competent, the user/individual on the job must be able to:

PC14. ensure that the area has floors swept, machinery clean and is generally neat and tidy in case of cleaning, ensure that correct displays are maintained on the floor which indicate potential safety hazards

PC15..   ensure workbenches and work surfaces are clean and in good condition

PC16..   ensure adherence to the cleaning schedule for the lighting system to ensure proper illumination

PC17..   ensure all recyclable materials are put in designated containers

Ensure standardization

To be competent, the user/individual on the job must be able to:

PC18.    ensure that daily cleaning standards and schedules to create a clean working environment are followed across the plant

PC19..   ensure all recyclable materials are put in designated containers

PC20. . ensure logical and user friendly documentation and file management for all activities across the plant and create guidelines around standardization of processes

PC21.    ensure timely creation and sharing of the 5s checklists

PC22.            ensure that the 5s manual are available as per the timelines Ensure sustenance

To be competent, the user/individual on the job must be able to:

PC23.    ensure team cooperation during the audit of 5 s activities

PC24.    ensure that workmen are periodically trained to address challenges related to 5s

PC25..   participate actively in employee work groups on 5s and encourage team members for active participation

PC26..   oversee that the staff/operators are trained and fully understand 5s procedures

PC27. . ensure that all the guidelines for what to do and what not to do to build sustainability in 5s are mentioned in the 5s check lists/ work instructions and are easily searchable

PC28.    ensure continuous training of the team members on 5s in order to increase their awareness and support implementation

PC29.    ensure that all visual controls, notice boards, symbols etc at the manufacturing place are created, working and are put up as per the requirement

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.    relevant standards, procedures and policies related to 5Sfollowed in the company

KU2.    have basic knowledge of 5S procedures

KU3.    know various types 5s practices followed in various areas

KU4.    understand the 5S checklists provided in the department/ team

KU5.    have skills to identify useful & non useful items

KU6.    have knowledge of labels , signs & colours used as indicators

KU7.    Have knowledge on how to sort and store various types of tools,equipment, material etc

KU8.    know , how to identify various types of waste products

KU9.    understand the impact of waste/ dirt/ dust/unwantedsubstances on the process/ environment/ machinery/ humanbody

KU10. have knowledge of best and environment protective ways ofcleaning & waste disposal

KU11. understand the importance of standardization in processes

KU12. understand the importance of sustainability in 5S

KU13. have knowledge of TQM process

KU14. have knowledge of various materials and storage norms

KU15. understand visual controls, symbols, graphs etc

Generic Skills (GS)

User/individual on the job needs to know how to:

GS1.    write basic level notes and observations

GS2.    note down observations (if any) related to the process

GS3.    write information documents to internal departments/ internal teams

GS4.    read 5S instructions put up across the plant premises

GS5.    effectively communicate information to team members inform employees in the plant and concerned functions about 5S

GS6.    question the process head in order to understand the 5S related issues

GS7.    attentively listen with full attention and comprehend the information given by the speaker during 5S training programs

GS8.    use common sense and make judgments during day to day basis

GS9.           use reasoning skills to identify and resolve basic problems using 5S

GS10. persuade team members to follow 5 S

GS11. ensure that the team members understand the importance of using 5 S tool

GS12. use innovative skills to perform and manage 5 S activities at the work desk and the shop floor

GS13. exhibit inquisitive behaviour to seek feedback and question on the existing set patterns of work emerge, techniques in CA/CI around 5 S work practices

GS14. do what is right, not what is a popular practice

GS15. follow shop floor rules& regulations and avoid deviations

GS16. lead by example in the plant premises while performing activities related to 5S

GS17. ensure self-cleanliness on a daily basis

GS18. demonstrate the will to keep the work area in a clean and orderly manner

GS19. accept additional responsibility for self and the team

GS20. encourage self and other to take greater responsibilities for managing 5S

GS21. identify obstacles and bottlenecks in the process and find basic level solutions for removing these obstacles

GS22. use previous experience in resolving problems and taking decisions

GS23. make timely and independent decisions on the line/ shift within the boundaries of the delegation matrix of the organization

Develop strategies to improve overall reliability and safety:

Elements and Performance Criteria

Planning and scheduling planned and unplanned work

To be competent, the user/individual on the job must be able to:

PC1..     understand the usage cycle of existing equipments and machinery that exist in the plant and any changes in the same owing to customer orders/ npd to be launched.

PC2..     lay down the system for the maintenance cycle of each equipment by sticking appropriate stickers or recording maintenance schedules for routine activities by operator/ M/c technician special periodic by maintenance technician

PC3..     based on the breakdown frequency of machines and equipments divide the manpower into planned and unplanned work

PC4..     plan for contingency against major breakdowns, natural / manmade emergencies to be competent , the user/individual on the job must:

PC5..     based on the nature of equipment preview and decide if any predictive technique can be applied on the equipment viz. vibration, stress analysis , oil analysis, wiring life assessment etc. if so plan the calendar for 2-3 years for this activity for the equipments in the plant.

PC6..     at capacity expansion stage /NPD ensure standardization of critical spares e.g. sensors, plcs, bearings etc.

PC7..     strategize to plan improvements in key performance parameters viz. mean time between breakdown, cost of maintenance, reduce power, water consumption etc.

Diagnosing breakdown problems

To be competent, the user/individual on the job must be able to:

PC8..     immediately report to the spot where breakdown has taken place

PC9..     understand the reason for breakdown

PC10..   identify problems quickly by performing root cause analysis to devise a solution to fix the same. Use CFT approach , TOPS 8D , fault trees , equipment manual as necessary

PC11..   take immediate / permanent corrective actions so that the problem is contained & is not repeated. deploy horizontally if applicable

PC12..   make changes if any , as required in the preventive maintenance schedules based on findings in the breakdown maintenance actions.

PC13..   collect all the information related to the problem and document the same in equipment history sheets in organization ERP/records in order to refer in future

carrying out quality inspections on jobs

To be competent, the user/individual on the job must be able to:

PC14..   carry out readings of important parameters e.g. geometrical accuracies etc with help of in- plant specialists/ standards room staff as necessary.

PC15..   equipment to be run after ensuring all parts are assembled including protective guards Fluids / lubricants taken care of for replacement, quantity Electrical connections, wiring as per the diagram connected/ clamped and taped.

Maintenance Spares, store, special fixtures etc,

To be competent, the user/individual on the job must be able to:

PC16..   carry maintenance spares stock based on the equipment manufacturers recommendations

PC17..   classify special fixtures, fittings, electronic items, plc s etc in such a way that vendor selection, ordering is organized and distributed amongst the manpower available as per their capabilities.

PC18..   investigate possibilities to review spares stock that can be kept at equipment suppliers end to reduce inventory holding costs.

Manpower deployment

To be competent, the user/individual on the job must be able to:

PC19..   plan the manpower in consultation with Plant management according to the schedules for routine- preventive , breakdown , Predictive activities and expertise required based on the equipments in the plant for mechanical, Electrical, Electronic co-ordination with external experts and equipment manufacturers installation of new equipment re- layout requirements

PC 20.. plan and deploy manpower on the basis of employed & outsourced experts as per the policies of the organization

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.    company manufacturing processes

KU2.    existing layout for the processes

KU3.    sequence of operations for each process

KU4.    facility planning methodology being followed in the company

KU5.           future capacity expansions plans (if any) of the company

KU6.           complete knowledge of the process in consideration

KU7.    dimensions and type of the existing facility being used for the process

KU8.    engineering drawings of existing layout

KU9.    operation of machinery and equipments being used for the process

KU10. manpower deployment plan for process

KU11. material and information flow of the process

KU12. capacity utilization levels and the cost of manufacturing being incurred

KU13. media of information flow like SAP , ERP etc.

Generic Skills (GS)

User/individual on the job needs to know how to:

GS1.    read the information displayed at the workplace

GS2.    draft a pictorial representation of the existing layout for better comprehension

GS3.    compile all the data related to study of existing facility in form of presentations and reports

GS4.    communicate with shop floor workers gathering inputs/requirements

GS5. spell out effectively the findings of the study to the higher management in meetings

GS6. interact with workers and gather all the information related to process requirements

GS7. share operation knowledge with co-workers

GS8.    coordinate with the facility planning department team and ensure timely analysis for layout designing

GS9.    collate data from various third parties involved (if any) in existing facility design and development

GS10. plan the execution of requirements study for layout design in a effective manner and on timely basis

GS11. Plan Improvements in carbon credits, consumption of resources

GS12. analyze the way in which the existing facility layout is in operation and think of more economic and feasible measures for existing layout modification/redesigning

Assessment Guidelines

1. Criteria for assessment for each Qualification Pack will be created by the Sector Skill Council. Each Element/ Performance Criteria (PC) will be assigned marks proportional to its importance in NOS. SSC will also lay down proportion of marks for Theory and Skills Practical for each Element/ PC.

• The assessment for the theory part will be based on knowledge bank of questions created by the SSC.

• Assessment will be conducted for all compulsory NOS, and where applicable, on the selected elective/option NOS/set of NOS.

• Individual assessment agencies will create unique question papers for theory part for each candidate at each examination/training center (as per assessment criteria below).

• Individual assessment agencies will create unique evaluations for skill practical for every student at each examination/ training center based on these criteria.

• To pass the Qualification Pack assessment, every trainee should score the Recommended Pass % aggregate for the QP.

• In case of unsuccessful completion, the trainee may seek reassessment on the Qualification Pack.