PLANT MAINTENANCE NC I – TESDA COURSE MODULE

TESDA TRAINING REGULATIONS FOR PLANT MAINTENANCE NC I COURSE

The TESDA Course in Plant Maintenance NC I consists of competencies that a person must achieve to perform preventive and corrective maintenance, perform planned and unplanned maintenance, fabricate simple items and install machinery.

A student who has achieved this Course in PLANT MAINTENANCE NC I is competent to be:

• Plant Maintenance Mechanic

TRAINEE ENTRY REQUIREMENTS

This section specifies the qualifications of trainees and educational experience. Other requirements like health and physical requirements are also stated. Passing entry written examinations may also be indicated if necessary.

• Must be high school graduate
• With good moral character
• Ability to communicate
• Physically and mentally fit

PLANT MAINTENANCE NC I COURSE

Course Title: MECHANICAL DRAFTING
Level: NC I
Nominal Training Duration : 358 hours

This qualification is designed to develop knowledge, desirable attitudes and skills in Plant Maintenance NC I.

It covers the competencies required to Perform Preventive Maintenance, Perform Corrective Maintenance and Install Machinery.

COMPETENCIES REQUIRED IN PLANT MAINTENANCE NC I

This units of competency comprising this qualification include Basic, Common and Core Competencies. To obtain this course, all units prescribed for this qualification must be achieved.

UNIT CODE	CORE COMPETENCIES
MEE723301	Perform Preventive Maintenance
MEE723302	Perform Planned and Unplanned (Emergency) Maintenance
MEE723303	Fabricate Simple Items
MEE723304	Install Machinery
UNIT CODE	COMMON COMPETENCIES
MEE722201	Apply safety practices
MEE722202	Interpret working drawings and sketches
MEE722204	Perform shop computations (Basic)
MEE722205	Measure workpiece (Basic)
UNIT CODE	BASIC COMPETENCIES (18 Hours)
500311101	Receive and respond to workplace communication
500311102	Work with others
500311103	Demonstrate work values
500311104	Practice basic housekeeping procedures

This section gives the details of the contents of the core units of competency required in PLANT MAINTENANCE NC I. These units of competency are categorized into basic, common and core competencies.

CORE COMPETENCIES

UNIT OF COMPETENCY : PERFORM PREVENTIVE MAINTENANCE
UNIT CODE : MEE723301

This unit covers the knowledge, skills and attitudes involved in the prevention or delay of breakdown through routine maintenance work and primarily through scheduled or periodic inspections.

1. Interpret work instructions
   • Work instruction interpreted and fully understood .
   • Operation manual of machines and parts concerned obtained as reference for manufacturer’s recommendations.
   • Work permits obtained
2. Perform routine maintenance work
   • Machine parts or entire machine cleaned of dust and dirt according to manufacturer’s recommendations.
   • Lubrication points of machine and condition of lubricants checked according to work procedures.
   • Minor adjustments made on loose bolts, drive slacks, guards and covers.
3. Perform inspection procedures
   • Inspection Checklists gathered as guide for inspection. Inspection tools in good condition gathered
   • Operational symptoms of malfunction or impending failure observed through the human senses.
   • Evidence of symptoms of malfunction or impending failure searched through closer inspection of parts.
   • Inspection with the inspection instruments and methods used to detect start of failures such as cracks, unbalance, etc.
   • Findings of inspection with recommended course of action noted in a report in accordance with company procedures.

UNIT OF COMPETENCY : PERFORM PLANNED MAINTENANCE WORK
UNIT CODE : MEE723302

This unit covers the knowledge, skills and attitude required to perform planned and unplanned (emergency) maintenance work.

1. Obtain work instructions
   • Extent of work clearly understood.
   • All materials and tools to be used gathered.
   • Work permit obtained and all safety precautions arranged such as equipment shutdown and danger tags.
2. Dismantle equipment dismantling to gain access to the affected area. according to procedure
   • Machine dismantled and parts inspected closely and cleaned for closer inspection as per manufacturer’s recommended procedure.
   • Safety precautions observed in dismantling
3. Inspect closely for cause of failure
   • Signs of failure determined through visual inspection or use of other methods such as dye penetrant test.
   • Cause of failure of part determined if wear-out, misuse failure or inherent weakness.
   • Note down findings for inclusion in report , history card and failure analysis studies.
4. Replace components
   • Component replaced and machine re-assembled using the reverse of dismantling procedure. Report made and submitted to supervisor.
5. Troubleshoot machine breakdown (In case work is emergency and therefore unplanned)
   • Background data and operational data. about the machine gathered .to define the problem
   • The area suspected where failure is most likely to occur is closely investigated
   • Machine divided mentally into functional zones to check each zone separately in the drawing and/or the actual machine itself the input and output
   • Eliminate by testing those zones unaffected by the fault, until finally it is isolated to one part of the system
   • Machine dismantled and each element of the zone
   • Investigated by testing to pinpoint the particular element in the assembly where the fault lies.
   • Eliminate those elements unaffected by fault by bypassing them or substituting components that are known to work.
   • Cause of failure pinpointed as to wear failure, misuse failure or inherent weakness in design of parts.
   • Note down findings for inclusion in report , history card and failure analysis studies.

UNIT OF COMPETENCY : FABRICATE SIMPLE ITEMS
UNIT CODE : MEE723303

This unit covers the knowledge, skills and attitude required to fabricate simple parts required for machines being repaired and items required for maintenance work.

1. Interpret work instruction
   • Work instruction on the items to be made interpreted clarified and understood.
   • Materials required listed as per requirement.
2. Prepare materials and tools
   • Materials marked and cut by different cutting methods according to standard procedures
   • Materials processed using required fabricating methods according to standard practices
   • Materials fitted and assembled using joining methods according to drawing requirements
3. Install items
   • Item installed safely using standard installation tools according to workplace procedures.

UNIT OF COMPETENCY : INSTALL MACHINERY
UNIT CODE : MEE723304

This unit covers the knowledge, skills and attitude required to move and install machineries.

1. Prepare designated area
   • Equipment and its connections removed from the designated according to worksite procedure
   • Area cleared of dirt and marked according to requirement and causeways cleared of obstructions.
2. Move machinery
   • Safety practices observed in handling heavy loads.
   • Machinery lifted , and moved according to available handling equipment or any manual method.
   • Machinery lowered into position, bolted and leveled according to standard procedure.
3. Install machinery
   • Machinery installed, cleaned, and compressed air, hydraulic lines and other accessories connected. Manual studied for operational procedures and safety precautions for safe star-up procedures.
4. Test machinery
   • Test machine with operator

COMMON COMPETENCIES

UNIT OF COMPETENCY : APPLY SAFETY PRACTICES
UNIT CODE : MEE722201

This unit covers the competencies required to apply safety practices in the workplace.

1. Identify hazards
   • Hazards are identified correctly in accordance with OHS principles.
   • Safety signs and symbols are identified and adhered to.
2. Use protective clothing and devices
   • Appropriate protective clothing and devices correctly selected and used in accordance with OHS requirements or industry/ company policy.
3. Perform safe handling of tools, equipment and materials
   • Safety procedures for pre-use check and operation of tools and equipment followed in accordance with industry/ company policies.
   • Tools, equipment and materials handled safely in accordance with OHS requirements and industry/ company policies.
4. Perform first aid
   • First aid treatment of injuries are carried out according to recommended procedures.
5. Use fire extinguisher
   • Fire extinguisher selected and operated correctly according to the type of fire.

UNIT OF COMPETENCY : INTERPRET WORKING DRAWINGS And SKETCHES
UNIT CODE : MEE722202

This unit covers the competencies required to read and interpret drawings and sketches.

1. Interpret technical drawing
   • Components, assemblies or objects recognized as required.
   • Dimensions identified as appropriate.
   • Instructions identified and followed as required.
   • Material requirements identified as required.
   • Symbols recognized as appropriate in the drawing.
   • Tolerance, limits and fits identified in the drawing.
2. Prepare freehand sketch of parts
   • Sketch drawn correctly and appropriately.
   • Sketch depicted objects or part appropriately.
   • Dimensions indicated in sketch are clear and correct.
   • Instructions included in sketch are clear and correct.
   • Base line or datum points indicated as required.
3. Interpret details from freehand sketch
   • Components, assemblies or objects recognized as required.
   • Dimensions identified as appropriate.
   • Instructions identified and followed as required.
   • Material requirements identified as required.
   • Symbols recognized as appropriate in the drawing.

UNIT OF COMPETENCY : PERFORM SHOP COMPUTATIONS (BASIC)
UNIT CODE : MEE722204

This unit covers the competencies required to perform
basic calculations using the four fundamental operation.

1. Perform four fundamental operations
   • Simple calculations are performed using four fundamental operations.
2. Perform basic calculations involving fractions and decimals
   • Simple calculations are performed involving fractions and decimals using the four fundamental operations.
   • Decimal are converted into fraction (and vice versa) accurately.
3. Perform basic calculations involving percentages
   • Simple calculations are performed to obtain percentages from information expressed in either fractional or decimal format.
4. Perform basic calculation involving ratio and proportion
   • Simple calculations are performed involving ratio and proportion using whole numbers, fractions and decimals.
5. Perform calculations on algebraic expressions
   • Simple calculations are performed on algebraic expressions using the four fundamental operations.
   • Simple transposition of formulae is carried out to isolate the variable required, involving the four fundamental operations.

UNIT OF COMPETENCY : MEASURE WORKPIECE (BASIC)
UNIT CODE : MEE722205

This unit covers the competencies required to measure workpieces using measuring instruments such as steel rule, Vernier caliper, micrometer, etc.

1. Select and use measuring tools
   • Measuring tools are selected and used according to the level of accuracy required.
   • Measurements taken are accurate to the finest graduation of the selected measuring instrument.
   • Measuring technique used is correct and appropriate to the device used.
2. Clean and store measuring tools
   • Care and storage of devices undertaken to manufacturer’s specifications or standard operating procedures.

UNIT OF COMPETENCY : PREPARE BASIC ENGINEERING DRAWING
UNIT CODE : MEE311301

This unit covers the knowledge, skills and attitudes required to prepare basic engineering drawings .

1. Identify drawing requirements
   • Specifications and other data are determined from customer, work specification, actual sample or relevant documents.
   • Drawing requirements are verified by relevant personnel and timeframes for completion are established in accordance with standard operating procedures.
2. Prepare engineering drawing or make changes to existing drawings
   • Drafting principles are applied to produce a drawing that is consistent with standard operating procedures.
   • Dimensions, notes and specifications are indicated in the drawing in accordance with drafting principles and standards
   • Drafting is accomplished safely and to prescribed procedures
   • Completed drawing is presented for approval in accordance with standard operating procedures
3. Prepare engineering parts list
   • Component parts are identified and organized by component type and/or in accordance with company/customer requirements
   • Drawings and/or parts lists records are completed in accordance with standard operating procedures.
4. Issue approved drawing
   • Approved drawing and/or parts lists are copied and issued to relevant personnel in accordance with standard operating procedures.
   • Approved drawings and/or parts lists are stored and catalogued in accordance with standard operating procedures.

UNIT OF COMPETENCY : PERFORM BASIC ENGINEERING DETAIL DRAFTING
UNIT CODE : MEE311302

This unit covers the knowledge, skills and attitude required to prepare basic engineering detail drawings.

1. Prepare assembly, layout and detail drawings
   • Drawings are prepared in accordance with local or international standards
   • Layout, assembly and component drawings are prepared consistent with the specifications
   • Drawings are dimensioned and labeled using supplied tolerances in accordance with relevant local and international standards
   • Drawing are produced to specification in accordance with standard operating procedures
   • Standard drawing symbols are used to specify requirements in accordance with local or international standards or equivalent
   • Drawing requirements are verified by relevant personnel and timeframes for completion are established in accordance with standard operating procedures.
2. Determine component and/or material requirement
   • Components and/or materials are selected from supplier/ manufacturer’s catalogues using design specifications
3. Issue approved drawing
   • Completed drawing is presented for approval in accordance with standard operating procedures
   • Approved drawings are copied and issued to relevant personnel in accordance with standard operating procedures.
   • Approved drawings are stored and catalogued in accordance with standard operating procedures.

BASIC COMPETENCIES

UNIT OF COMPETENCY : RECEIVE AND RESPOND TO WORKPLACE COMMUNICATION
UNIT CODE : 500311101

This unit covers the knowledge, skills and attitudes required to receive, respond and act on verbal and written communication.

1. Follow routine spoken messages
   • Required information is gathered by listening attentively and correctly interpreting or understanding information/instructions
   • Instructions/information are properly recorded
   • Instructions are acted upon immediately in accordance with information received
   • Clarification is sought from workplace supervisor on all occasions when any instruction/information is not clear
2. Perform workplace duties following written notices
   • Written notices and instructions are read and interpreted correctly in accordance with organizational guidelines
   • Routine written instruction are followed in sequence
   • Feedback is given to workplace supervisor based on the instructions/information received

UNIT OF COMPETENCY : WORK WITH OTHERS
UNIT CODE : 500311102

This unit covers the skills, knowledge and attitudes required to develop workplace relationship and contribute in workplace activities.

1. Develop effective workplace relationship
   • Duties and responsibilities are done in a positive manner to promote cooperation and good relationship
   • Assistance is sought from workgroup when difficulties arise and addressed through discussions
   • Feedback provided by others in the team is encouraged, acknowledged and acted upon
   • Differences in personal values and beliefs are respected and acknowledged in the development
2. Contribute to work group activities
   • Support is provided to team members to ensure workgroup goals are met
   • Constructive contributions to workgroup goals and tasks are made according to organizational requirements
   • Information relevant to work is shared with team members to ensure designated goals are met

UNIT OF COMPETENCY : DEMONSTRATE WORK VALUES
UNIT CODE : 500311103

This unit covers the knowledge, skills, and attitude in demonstrating proper work values.

1. Define the purpose of work
   • One’s unique sense of purpose for working and the why’s of work are identified, reflected on and clearly defined for one’s development as a person and as a member of society.
   • Personal mission is in harmony with company’s values
2. Apply work values/ethics
   • Work values/ethics/concepts are classified and reaffirmed in accordance with the transparent company ethical standards, policies and guidelines.
   • Work practices are undertaken in compliance with industry work ethical standards, organizational policy and guidelines
   • Personal behavior and relationships with co-workers and/or clients are conducted in accordance with ethical standards, policy and guidelines.
   • Company resources are used in accordance with transparent company ethical standard, policies and guidelines.
3. Deal with ethical problems
   • Company ethical standards, organizational policy and guidelines on the prevention and reporting of unethical conduct are accessed and applied in accordance with transparent company ethical standard, policies and guidelines.
   • Work incidents/situations are reported and/or resolved in accordance with company protocol/guidelines.
   • Resolution and/or referral of ethical problems identified are used as learning opportunities.
4. Maintain integrity of conduct in the workplace
   • Personal work practices and values are demonstrated consistently with acceptable ethical conduct and company’s core values.
   • Instructions to co-workers are provided based on ethical, lawful and reasonable directives.
   • Company values/practices are shared with co-workers using appropriate behavior and language.

UNIT OF COMPETENCY : PRACTICE HOUSEKEEPING PROCEDURES
UNIT CODE : 500311104

This unit covers the knowledge, skills and attitudes required to apply the basic housekeeping procedures.

1. Sort and remove unnecessary items
   • Reusable, recyclable materials are sorted in accordance with company/office procedures
   • Unnecessary items are removed and disposed of in accordance with company or office procedures
2. Arrange items
   • Items are arranged in accordance with company/office housekeeping procedures
   • Work area is arranged according to job requirements
   • Activities are prioritized based on instructions.
   • Items are provided with clear and visible identification marks based on procedure
   • Safety equipment and evacuation passages are kept clear and accessible based on instructions
3. Maintain work area, tools and equipment
   • Cleanliness and orderliness of work area is maintained in accordance with company/office procedures
   • Tools and equipment are cleaned in accordance with manufacturer’s instructions/manual
   • Minor repairs are performed on tools and equipment in accordance with manufacturer’s instruction/manual
   • Defective tools and equipment are reported to immediate supervisor
4. Follow standardized work process and procedures
   • Materials for common use are maintained in designated area based on procedures
   • Work is performed according to standard work procedures
   • Abnormal incidents are reported to immediate supervisor
5. Perform work spontaneously
   • Work is performed as per instruction
   • Company and office decorum are followed and complied with
   • Work is performed in accordance with occupational health and safety (OHS) requirements

DEFINITION OF TERMS

• Prevention Maintenance – A collection of systematic actions performed to retained equipment in satisfactory operational condition and to prevent sudden malfunction. It includes routine, repetitive inspections, calibration, overhauls and lubrication.
• Breakdown maintenance – Work on a non-routine, non-repetitive basis performed to restore an item to a satisfactory condition after a malfunction has caused a degradation of the item below the specified performance level. (Sometimes called emergency maintenance)
• Corrective maintenance – Study of equipment failures and breakdowns and taking the action necessary to prevent recurrence.
• Planned maintenance – Maintenance that requires an extended equipment shutdown that needs to be planned and scheduled in advance.
• Breakdown – Failure that renders a machine totally inoperable or – Failure that leads to an unacceptable reduction in performance.
• Troubleshooting – A logical system of investigation designed to yield the correct cause of breakdown in the shortest possible time and with least likelihood of error
• Downtime – Period of time during which an item is not in a condition to perform its intended use.
• History card – A record of usage events and action as appropriate relating to a particular item
• Incident report – Document reporting the departure of an item from an acceptable condition has occurred.
• Job report – A statement recording the work done and the condition of an item.
• Work order – A written instruction detailing work to be carried out.
• Job specification – A document describing the work to be done.
• Work requisition – A document requesting work to be carried out.
• Lubrication – ‘to make smooth and slippery’ two contacting surfaces by introducing a lubricant that separates these surfaces in contact to reduce the effect of friction
• Wear – The transformation of matter by use and it results in a diminishing of the dimension of machinery parts.