Free Maintenance Technician Electrical Level 4 Course (6Months)

Maintenance Technician Electrical Level 4:

Brief Job Description

Individuals at this job are responsible for maintaining the Electrical/ electronic systems of equipment and machinery. They use laid down procedures andknowledge of the equipment to conduct 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

This job requires the individual to work independently and be judicious in making decisions pertaining to ones area of work. The individual should be result oriented & be able to demonstrate skills for information ordering, oral expression skills along with comprehension. The individual must be physically fit as to be able to maintain unusual working hours.

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

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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

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Maintain 5S at the work premises:

Elements and Performance Criteria

Ensure sorting

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

PC1..    follow the sorting process and check that the tools, fixtures & jigs that are lying on workstations are the ones in use and unnecessary items are not cluttering the workbenches or work surfaces.

PC2..    ensure segregation of waste in hazardous/ non hazardous waste as per the sorting work instructions

PC3..    follow the technique of waste disposal and waste storage in the proper bins as per sop

PC4..    segregate the items which are labelled as red tag items for the process area and keep them in the correct places

PC5.     sort the tools/ equipment/ fasteners/ spare parts as per specifications/ utility into proper trays, cabinets, lockers as mentioned in the 5s guidelines/ work instructions

PC6. .  ensure that areas of material storage areas are not overflowing

PC7.     properly stack 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

PC8.     return the extra material and tools to the designated sections and make sure that no additional material/ tool is lying near the work area

PC9.     follow the floor markings/ area markings used for demarcating the various sections in the plant as per the prescribed instructions and standards

PC10.   follow the proper labeling mechanism of instruments/ boxes/ containers and maintaining reference files/ documents with the codes and the lists

Ensure proper documentation and storage ( organizing , streamlining)

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

PC11.   check that the items in the respective areas have been identified as broken or damaged

PC12.   follow the given instructions and check for labelling of fluids, oils. lubricants, solvents, chemicals etc. and proper storage of the same to avoid spillage, leakage, fire etc

PC13.   make sure that all material and tools are stored in the designated places and in the manner indicated in the 5s instructions

Ensure cleaning of self and the work place

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

PC14.   check whether safety glasses are clean and in good condition

PC15.   keep all outside surfaces of recycling containers are clean

PC16.. ensure that the area has floors swept, machinery clean and generally clean. in case of cleaning, ensure that proper displays are maintained on the floor which indicate potential safety hazards

PC17.. check whether all hoses, cabling & wires are clean, in goodcondition and clamped to avoid any mishap or mix up

PC18.. ensure workbenches and work surfaces are clean and in good condition

PC19.   follow the cleaning schedule for the lighting system to ensure proper illumination

PC20.   store the cleaning material and equipment in the correct location and in good condition

PC21.   ensure self-cleanliness – clean uniform, clean shoes, clean gloves, clean helmets, personal hygiene

Ensure sustenance

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

PC22.   follow the daily cleaning standards and schedules to create a clean working environment

PC23.   attend all training programs for employees on 5 s

PC24.   support the team during the audit of 5 s

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

PC26.   follow the guidelines for what to do and what not to do to build sustainability in 5s as mentioned in the 5s check lists/ work instructions

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.    relevant standards, procedures and policies related to 5S followed 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.    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/unwanted substances on the process/ environment/ machinery/ human body

KU10. have knowledge of best ways of cleaning & 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.

Maintenance Technician Job Description

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.    read 5S instructions put up across the plant premises

GS4.    effectively communicate information to team members inform employees in the plant and concerned functions about 5S

GS5.    question the process head in order to understand the 5S related issues

GS6.    attentively listen with full attention and comprehend the information given by the speaker during 5S training programs

GS7.    use common sense and make judgments during day to day basis

GS8.           use reasoning skills to identify and resolve basic problems using 5S

GS9.           persuade co team members to follow 5 S

GS10. ensure that the co team members understand the importance of using 5 S tool

GS11. use innovative skills to perform and manage 5 S activities at the work desk and the shop floor

GS12. exhibit inquisitive behaviour to seek feedback and question on the existing set patterns of work

GS13. do what is right, not what is a popular practices

GS14. follow shop floor rules& regulations and avoid deviations; make 5S an integral way of life

GS15. ensure self-cleanliness on a daily basis

GS16. demonstrate the will to keep the work area in a clean and orderly manner

Develop understanding of the equipment:

Elements and Performance Criteria

Studying the Operating Manual & other information and activities related to the equipment

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

PC1..    understand the following from the equipment manual Assembly sub systems, sequence Electrical Motors, controls, sensors, fuses, PLCs used Mechanisms & operation including controls, automation Standard parts & ones specific to the machine Wiring / control systems/ circuit diagrams Motherboard Standard recommended spares Consumables required to be used. Precautions, fault detection guidelines Frequency recommended for maintenance vis-a vis operating loads

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 the maintenance team

PC3..    keep the special / standard tool kits ready for usage at short notice.

PC4..    for special purpose equipment made for the organization ensure that the drawings & other information matches with the current status of the equipment.

PC5..    learn new points and update the troubleshooting check sheets available with the manual.

PC6..    learn while giving support to seniors/ external experts in predictive / breakdown maintenance activity.

Planning the maintenance activity

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

PC7..    plan the time and schedule for preventive maintenance cycle based on the equipment manufacturers recommendations and the history of similar equipment handled, used in the plant.

PC8..    plan the installation/ shifting activity in totality considering special experts/ external support and material and tools required for the civil, material handling activity , consumables, wiring, soldering connections, testing cycles and everything mentioned in the equipment manual.

PC9..    discuss with seniors in manufacturing, maintenance for planning activity prior to the schedule to ensure all points are adequately considered.

PC10.. plan as much as possible standardization of electrical elements such as wires, fuses, plcs etc. while new lines/ shifting activities are being planned

PC11.. plan for support from production , other specialist teams in maintenance based on their schedules.

PC12.. plan support from outside experts for special techniques.

Understanding the manufacturing process

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

PC13.. study the process cycle while the equipment is working to completely understand the duty conditions and working principles etc.

PC14.. study the standard working , running schedule for the equipment to find slots for maintenance activities

PC15.. study the critical areas to find out possibilities of impending breakdowns, fuse blow-outs, failures, life cycles of electrical units etc.

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.    company manufacturing processes & the equipment in use

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.    Soldering connections

KU8.    engineering drawings of existing layout/ equipment

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

KU10. manpower deployment plan for process

KU11. material and information flow of the process

KU12. Electrical / electronic standard parts vendor infrastructure

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.    Enter the information related to maintenance activities in ERP, History sheets

GS6. spell out effectively the findings of the study to the higher management in meetings

GS7. interact with workers and gather all the information related to process requirements

GS8. share operation knowledge with co-workers

GS9. coordinate with the facility planning department team and ensure timely analysis for layout designing

GS10. collate data from various third parties involved (if any) in existing facility design and development

GS11. plan the execution of requirements study for layout design in a effective manner and on timely basis

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

Carry out preventive/breakdown maintenance of the electrical/electronic systems of the equipment:

Elements and Performance Criteria

Preparing for the maintenance activity

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

PC1..     understand the following from the maintenance schedules Calendar for the equipment scheduled for preventive maintenance Standard and special tool kits required for carrying out the task Consumables, replacement spare parts required

PC2..     verify routine check list activities have been conducted by the user-operator

PC3..     be part of the team planning new equipment, installations, layout planning etc. so that the maintenance aspect is planned appropriately in the specifications and norms.

Carrying out the maintenance activity

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

PC4 ..    open the equipment and replace the scheduled spare parts as per the schedule

PC5..     check / confirm internal conditions of wiring , motherboards etc. to verify working status to expected conditions. discuss with the user/ operator to learn about problems /unusual phenomenon noticed on the equipment.

PC6..     assemble back, covers , guards, clamps, insulation etc. & prepare for taking the trials.

PC6..     change the maintenance due / status sticker on the equipment.

PC7..     to attend the breakdown maintenance verify in appropriate sequence for the equipment Charge leakage/ short circuit from parts Breakage of wires, clamps Unusual contacts of electrical wires with moving parts Erratic / problematic performance Any problem condition as reported in the complaint

PC8..     plan sequence of activities for changing, correcting the situation after opening, verifying contact/ insulation conditions, failure of internal wires etc. and ensure the circuit elements, consumables are available at the work place.

PC9..     use appropriate PPE, material handling equipment and tools and carry out the task . Use recommended methods, consumables, tools for Electrical / electronic connections Verification of continuity joints, including soldered

PC10..    take support from experts, user , team members from maintenance during the activity if required.

PC11..    clock the time for the task so that the scheduling and planning can be improved in future.

PC12..    when carrying out the installation/ shifting activity record the time and unplanned tasks encountered in the activity.

PC13..    discuss with seniors in manufacturing, maintenance for improving the activity to ensure all points are adequately considered.

Taking the trials & hand over the equipment for manufacturing process

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

PC14..    take trials of running step by step increasing duty conditions gradually and verify specified parameters are attained and no abnormalities achieved,

PC15..    study the standard working , running for a few cycles of the equipment to ascertain normal working in presence of the user .

PC16..    handover the equipment to the user.

Documentation & Records

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

PC17..    update the history sheet with the replacement details .

PC 18 .. discuss with seniors and decide if any change is necessary for preventive schedules based on the breakdown activity.

Knowledge and Understanding (KU)

The individual on the job needs to know and understand:

KU1.    company manufacturing processes & the equipment in use

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.    Electrical -wiring drawings of existing layout/ equipment

KU9.    operation of electrical equipment viz motors etc . being used for the process

KU10. PLC , SCADA , & electrical elements operation ,testing ,

KU11. material and information flow of the process

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.   Enter the information related to maintenance activities in ERP, History sheets

GS6. spell out effectively the findings of the study to the higher management in meetings

GS7. interact with workers and gather all the information related to process requirements

GS8. share operation knowledge with co-workers

GS9.    coordinate with the facility planning department team and ensure timely analysis for layout designing

GS10. collate data from various third parties involved (if any) in existing facility design and development

GS11. plan the execution of requirements study for layout design in a effective manner and on timely basis

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.