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
- 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.
