SKILL  KNOWLEDGE  SAFETY

MSAPMSUP303A - Identify equipment faults

Description

This unit requires the application of planning, technical knowledge and skills to check and isolate routine and non-routine equipment faults used in production and report on the status of equipment. It applies to all sectors of the industry.

This competency is typically performed by operators demonstrating some relevant theoretical knowledge and using a range of well developed skills requiring some discretion and judgement

Pre Requisites

 Nil

Application

 This competency applies to operators who are required to apply knowledge of materials, product purpose and processes to the identification and isolation of faults in equipment. The key factors are the planning, checking and identification of routine and non-routine faults, in order to return the equipment to production.
The operator will:
  •     identify and plan scope of equipment checks
  •     check settings, adjustments and performance of equipment
  •     check materials for conformity to job requirements
  •     identify and isolate faults in equipment
  •     propose solutions and carry out solutions within scope of authority
  •     complete logs and reports

Performance Criteria

 1. Identify scope of operational check.    
1.1 Identify and classify equipment components and operating systems.
1.2 Match appropriate tests and procedures to the equipment operating systems.
1.3 Identify special test procedures and parameters in manufacturer's specifications and procedures.
1.4 Explain the operating principles of hydraulic, pneumatic, mechanical and electrical/electronic systems as related to workplace equipment.
1.5 Implement measures to control identified hazards in line with procedures and duty of care.
1.6 Observe and undertake checks on the physical condition of equipment as per procedures.
1.7 Record preliminary observations.
1.8 Discuss test procedures with appropriate personnel and obtain necessary permission where required.

2. Plan operational checks.    
2.1 Check specifications and notes from preliminary observations and identify areas to be clarified.
2.2 Plan testing sequence/s noting areas where results and observations should be recorded.
2.3 Identify safe area for testing.
2.4 Make arrangements for any additional resources (including other employees).

3. Check unit through full operational range.    
3.1 Undertake testing, observing relevant safety and operational requirements.
3.2 Confirm results and findings.

4. Identify fault and/or formulate recommendations.    
4.1 Identify impact of fault on work schedule.
4.2 Record proposals for equipment repair based on faults found, cost/time implications and workplace approval systems.
4.3 Explain report to relevant workplace personnel including any options and recommendations.
4.4 Undertake repairs where appropriate in accordance with procedures.

Required Skills & Knowledge

 This describes the essential skills and knowledge and their level required for this unit.
Knowledge and understanding of equipment operation and maintenance practices sufficient to recognise fault and no-fault conditions in standard and non-standard situations and then determine appropriate action which is consistent with operational guidelines is required.
Knowledge of organization procedures and relevant regulatory requirements along with the ability to implement them within appropriate time constraints and work standards.
Application of the knowledge of managing risks using the hierarchy of controls applied to the process. Application of approved hazard control, safety procedures, use of PPE in relation to handling materials, equipment operation and clean up.

Knowledge as a basis for solving processing and material problems, including:
  •     principles of the operation of the equipment to be maintained
  •     functions and troubleshooting of internal components and their problems
  •     routine and non-routine causes of equipment failures and the service conditions which may increase maintenance
  •     maintenance techniques, (eg reactive maintenance, predictive and preventative operational maintenance)
  •     appropriate testing procedures and use of equipment for a range of equipment faults
  •     operating principles for mechanical, hydraulic, pneumatic, electrical/electronic systems
  •     urgency and timeliness factors in planning maintenance activities in relation to production requirements
  •     collection, analysis and reporting of data.

Competence also includes the ability to:
  •     identify and select testing methods based on cost and time effectiveness
  •     conduct inspections, checks and tests on equipment as appropriate
  •     read and interpret circuit diagrams for mechanical, hydraulic, pneumatic and electrical/electronic operating systems
  •     use technical information and manufacturer information to locate relevant data
  •     interpret technical specifications and manufacturer instructions
  •     ensure workplace is safe for testing and maintenance of equipment
  •     identify hazards of the materials and process
  •     implement appropriate procedures for hazard control
  •     use PPE, safely handle products and materials, read relevant safety information
  •     apply safety precautions appropriate to the task.

Language, literacy and numeracy requirements
This unit requires the ability to read and interpret typical equipment specifications schematics and diagrams.
Writing is required to the level of completing workplace forms and production reports.
Basic numeracy is required, to the level of calculating equipment throughputs and performance.

Range Statement

 Context
This competency applies to all work environments and sectors within the industry. It does not include maintenance that would require trade level skills. It is not intended that this competency would cover maintenance that is carried on in a workshop.

Procedures
All operations are performed in accordance with procedures.
Procedures mean all relevant workplace procedures, work instructions, temporary instructions, standard operating procedures, plant description manuals, manufacturer's instructions, specifications, service manuals, machine circuit diagrams for hydraulic/pneumatic and electrical/electronic circuits and relevant industry and government codes and standards.

Tools and equipment
This competency includes use of equipment and tools such as:
  •     hand tools specific for the task
  •     product testing equipment (eg flowmeter, scales, tape measure, micrometer, caliper, ultrasonic thickness)
  •     machinery measuring equipment (eg vibration meter, tachometer, current tester, thermal imaging, temperature gauge)
  •     measuring and aligning equipment.

Hazards
Typical hazards include:
  •     rotating and moving machinery
  •     process materials, solids, fluids and gases under pressure or flowing
  •     temporary connections or by-passes
  •     electrical, hydraulic or pneumatic energy sources
  •     out-of-specification operation.

Problems
Respond to/rectify 'non-routine problems' means 'apply known solutions to a variety of predictable problems'. Typical process and product problems may include:
  •     out-of-specification product or variations
  •     response of equipment to materials variations
  •     new or changed materials
  •     changed equipment settings (eg higher speed or throughput)
  •     equipment in need of maintenance
  •     procedures requiring update or modification.

Variables
Key variables to be monitored include:
  •     equipment performance (eg speed, output, variations)
  •     equipment component performance
  •     sequences and timing of operations
  •     materials changes (desired and not desired).

Data and Records
Typical information sources, observed data and plant records may include:
  •     plant data
  •     log sheets
  •     operational and performance reports
  •     physical aspects such as noise, smell, feel and pressure condition monitoring information
  •     planned maintenance schedules
  •     procedures.

Evidence Guide

 Overview of assessment
A holistic approach should be taken to the assessment.
Assessors must be satisfied that the person can consistently perform the unit as a whole, as defined by the Elements, Performance Criteria and skills and knowledge.

Critical aspects for assessment and evidence required to demonstrate competency in this unit
It is essential that competence is demonstrated in the knowledge and skills defined in this unit. These may include the ability to:
  •     understand the procedures and know the importance of critical operational systems
  •     recognise potential situations requiring action and then implement appropriate action.

Consistent performance should be demonstrated. For example, look to see that:
  •     early warning signs of equipment in need of attention/with potential problems are recognised
  •     appropriate tests are undertaken and tests are analysed appropriately
  •     proposals for equipment repair are based upon the most appropriate and cost effective method to return equipment to full performance in a timely manner
  •     items initiated are followed through until final resolution has occurred.

Assessment method and context
It is preferred that assessment takes place on industrial equipment in a work environment.

Competence in this unit may be assessed:
  •     on a processing plant, allowing for operation under all normal and a range of abnormal conditions
  •     in a situation allowing the generation of evidence of the ability to recognise, anticipate and solve problems
  •     by using a suitable simulation and/or a range of case studies/scenarios
  •     through a combination of these techniques.

In all cases it is expected that practical assessment will be combined with targeted questioning to assess the underpinning knowledge and theoretical assessment will be combined with appropriate practical/simulation or similar assessment. Assessors need to be aware of any cultural issues that may affect responses to questions.
Assessment processes and techniques must be culturally appropriate and appropriate to the oracy, language and literacy capacity of the assessee and the work being performed.

Specific resources for assessment
This section should be read in conjunction with the Range Statement for this unit of competency. Resources required include suitable access to an operating plant or equipment that allows for appropriate and realistic simulation. A bank of case studies/scenarios and questions will also be required to the extent that they form part of the assessment method. Questioning may take place either in the workplace, or in an adjacent, quiet facility such as an office or lunchroom. No other special resources are required.
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.

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