Free Maintenance Technician Mechanical Level 4 Course (6Months)
Maintenance Technician Mechanical Level 4:
Brief Job Description
Individuals at this job are responsible for maintaining the mechanical 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 andoral expression along with comprehension. The individual must be physically fit 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
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
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.
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 equipments in the plant:
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 Mechanisms & operation including controls Hydraulic/ Pneumatic / electrical controls & automation Standard parts & ones specific to the machine Installation Procedures Recommended procedure & limits of load, speed etc. 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 maintenance team
PC3.. keep the special / standard tool kits ready for usage at short notice. plan as much standardization as possible for mechanical/ hydraulic/ pneumatic connections & fittings
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 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:
PC6.. 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.
PC7.. plan the installation/ shifting activity in totality considering special experts/ external support and material and tools required for the civil, material handling activity , consumables, piping connections, testing cycles and everything mentioned in the equipment manual.
Manpower deployment
To be competent, the user/individual on the job must be able to:
PC8.. discuss with seniors in manufacturing, maintenance for planning activity prior to the schedule to ensure all points are adequately considered.
PC9.. plan for support from production , other specialist teams in maintenance based on their schedules.
Understanding the manufacturing process
To be competent, the user/individual on the job must be able to:
PC10.. study the process cycle while the equipment is working to completely understand the duty conditions and working principles etc.
PC11.. study the standard working , running schedule for the equipment to find slots for maintenance activities
PC11.. study the critical areas to find out possibilities of impending breakdowns, leakages, failures 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. dimensions and type of the existing facility being used for the process
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. 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. 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 the Preventive/Breakdown maintenance 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.. understand from the interfaces in the organization regarding new equipment , re-layout and other similar activities to schedule tasks.
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 replenish / change the consumables.
PC5.. check / confirm any geometric accuracies or internal conditions 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 , close covers , guards & prepare for taking the trials.
PC7.. change the maintenance due / status sticker on the equipment.
PC8.. to attend the breakdown maintenance verify in appropriate sequence for the equipment Leakage from parts Breakage of parts Unusual noise Under-rated performance Any problem condition as reported in the complaint
PC9.. plan sequence of activities for changing , correcting the situation after opening, verifying geometrical conditions, failure of internal parts etc. and ensure the tools , parts, consumables are available at the work place.
PC10.. use appropriate PPE, material handling equipment and tools and carry out the task . Use recommended methods, consumables, tools for Hydraulic , Pneumatic connections Verification of fluid levels, lubrication Tightening of joints, threaded fasteners Alignment/ Lapping in situ of surfaces for appropriate contact area
PC11.. take support from experts, user , team members from maintenance during the activity if required.
PC12.. clock the time for the task so that the scheduling and planning can be improved in future.
PC13.. when carrying out the installation/ shifting activity record the time and unplanned tasks encountered in the activity.
PC14.. 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:
PC15.. take trials of running by increasing duty conditions gradually and verify specified parameters are attained and no abnormalities achieved,
PC16.. study the standard working , running for a few cycles of the equipment to ascertain normal working in presence of the user .
PC17.. handover the equipment to the user.
Documentation & Records
To be competent, the user/individual on the job must be able to:
PC18.. update the history sheet with the replacement details .
PC19.. 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. 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. 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. 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:
- 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.
