Maintain Training Facilities

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COMPETENCY BASED LEARNING

MATERIAL

Sector : TVET

Qualification Title: TRAINING METHODOLOGY I Unit of Competency: Maintain Training Facilities Module Title: Maintaining Training Facilities

NTTA- Trainer’s Methodology I

Date

(2)

Technical Education & Skills Development Authority NATIONAL TVET TRAINERS ACADEMY

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TRAINING METHODOLOGY 1

COMPETENCY-BASED LEARNING MATERIALS

No

.

Unit of Competency

Module Title

Code

1. Plan Training Session Planning Training Session 2. Facilitate

Competency-Based Training Delivering Competency-Based Training

3. Supervise Work-Based

Learning

4. Conduct Institutional

Assessment ConductingAssessment Institutional

5.

_{Maintain Training}

Facilities

Maintaining Training

Facilities

6.

Facilitate

e-learning(Distance Education Mode)

Facilitating e- learning (Distance Education Mode)

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MODULE CONTENTS

MODULE 5 : MAINTAINING TRAINING FACILITIES

Learning

Outcomes Learning Content

Progr ess Check No. Traini ng Durati on

LO 1 Plan

maintenan

ce

activities

Schedule of

Maintenance

Information Sheet No. 5.1-1

Maintenance Program

Perform Task Sheet No.5.1-1

Prepare

Equipment

Maintenance Schedule

Perform Task Sheet No. 5.1-2

Prepare Maintenance

Inspection Checklist

LO 2

Maintain

training

equipment

and tools

Types of Maintenance

Types of Maintenance.

Prepare Tag-Out Bill

Prepare Equipment/Tools

Record w/ Code and Drawing

(5)

Prepare Maintenance

Inspection Checklist (Refer to

LO1)

Prepare Inspection Report

Prepare Work Request

Prepare Equipment

Breakdown/Repair Report

Prepare Salvage Report

LO 3

Implement

housekeep

ing

activities

a. Housekeeping System

5S

Housekeeping System

Prepare Housekeeping

Schedule

Prepare Housekeeping

Checklist

(6)

b. OHS

and

Waste

Management

Occupational Health and

Safety

Information Sheet No.5.3-3

Waste Management

Prepare Waste Segregation

List

LO 4

Document

maintenan

ce

inspection

s

Reporting and Documentation

Report and Documentation

Process

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HOW TO USE THIS COMPETENCY BASED LEARNING MATERIAL

Welcome to the module in ”Maintaining Training Facilities. This module Training contains training materials and activities for you to complete.

The unit of competency "Maintain Training Facilities contains knowledge, skills and attitudes required for TRAINING METHODOLOGY (TM) 1. You are required to go through a series of learning activities in order to complete each learning outcome of the module. In each learning outcome are Information Sheets, Self-Checks, Operation Sheets and Job

Sheets. Follow these activities on your own. If you have questions, don’t

hesitate to ask your facilitator for assistance.

The goal of this course is the development of practical skills. To gain these skills, you must learn basic concepts and terminology. For the most part, you'll get this information from the Information Sheets and TESDA Website, www.tesda.gov.ph

This module was prepared to help you achieve the required competency, in "Maintaining Training Facilities".

This will be the source of information for you to acquire knowledge and skills in this particular competency independently and at your own pace, with minimum supervision or help from your instructor.

Remember to:

 Work through all the information and complete the activities in each section. Read information Sheets and complete the self-check. Suggested references are included to supplement the materials provided in this module.

 Most probably your trainer will also be your supervisor or manager. He/she is there to support you and show you the correct way to do things.

 You will be given plenty of opportunity to ask questions and practice on the job. Make sure you practice your new skills during regular work shifts. This way you will improve both your speed and memory and also your confidence.

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 When you feel confident that you have had sufficient practice, ask your Trainer to evaluate you. The results of your assessment will be recorded in your Record of Achievement.

You need to complete this module before you can perform the next module, Utilize Electronic Media in Facilitating Training.

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SESSION PLAN

Sector : TVET

Qualification Title : Training Methodology I Unit of Competency : Maintain Training Facilities Module Title : Maintaining Training Facilities

Learning Outcomes:

1. Plan maintenance activities

2. Maintain training equipment and tools 3. Implement housekeeping activities 4. Document maintenance inspection A. INTRODUCTION

This module covers the knowledge; skills and attitude in Maintaining Training Facilities of all nine (9) components (refer to module No. 1 – Planning Training Session). This unit of competency has 5 learning outcomes; each learning outcome contains learning activities supported with instruction sheets. Before you perform the required activities, read the instruction Sheet and answer the self check provided to confirm to yourself and your trainer that you are equipped with the knowledge necessary to perform the skills portion of each learning outcome.

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B. LEARNING ACTIVITIES

LO 1 PLAN MAINTENANCE ACTIVITIES

Learning Content Presentation Practice Feedback Resources Time

Scheduling

maintenance Read Information Sheet No. 5.1-1 on Maintenance Program Perform Task Sheet No. 5.1-1 Equipment Maintenance Schedule Perform Task Sheet No. 5.1-2 on Maintenance Inspection Checklist Self- check Make equipment maintenance schedule Make Maintenance Inspection Checklist Compare answer to self- check key answer Compare your maintenance schedule to Sample Template Compare your maintenance inspection checklist to Sample Template

Information Sheet No. 5.1- 1 Types of

Maintenance

Self- Check key answer Task Sheet No. 5.1-1 Equipment Maintenance Schedule

Sample template Task Sheet No. 5.1-2 Maintenance Inspection Checklist

Sample Template

LO 2 MAINTAIN TRAINING EQUIPMENT AND TOOLS

Learning Content Presentation Practice Feedback Resources Time

Identifying types of maintenance for equipment and tools

Read information Sheet No. 5.2-1 On Types of Maintenance

Self-check Compare answer to Self-check Answer Key

Information Sheet No. 5.2-1 on Types of Maintenance Self-check

Self-check answer key Preparing maintenance schedule and relevant Read Information Sheet No. 5.2-1 on the preparation of

Self-check Compare your answer to Self-check Answer Key

Information Sheet No. 5.2-1 on the

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Competency Summary

UNIT OF COMPETENCY Maintain Training Facilities MODULE TITLE Maintaining Training Facilities MODULE DESCRIPTOR:

This module covers the knowledge, skills and attitude in Maintaining Training Facilities. It includes planning maintenance activities, preparing schedule of maintenance, implementation of housekeeping activities, maintaining equipment and tools and documenting maintenance inspection. You will also learn the importance of this unit of competency in Maintaining Training Facilities based on the competency standard promulgated in the Training Regulation in the implementation of Competency-Based TVET Quality Framework (PTQF), what qualifications a Trainer should possess, and the responsibilities in implementing a competency-based training program.

NOMINAL DURATION:

LEARNING OUTCOMES:

At the end of this module you MUST be able to:

1. Plan maintenance activities

2. Maintain training equipment and tools 3. Implement housekeeping activities

4

.

Report and document maintenance procedures

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• Training resources are identified and classified

• Proper inventory of training resources are properly listed

• Concerned department/personnel are informed on the schedule of work according to standard operating procedure

• Regular inspection is applied according to procedures and standards • Occupational Health and Safety and 5S procedures are applied in

maintaining facilities

• Disposal of waste and dangerous chemicals are based on Occupational Health and Safety procedures

• Instructional materials and supplies are secured in accordance with manufacturer’s procedures

• Tools and equipment are identified according to classification/specification and job requirements

• Non- functional tools and equipment are segregated and labeled according to classification

• Safety of tools and equipment are observed in accordance with manufacturer’s instruction

• Conditions of PPE are checked in accordance with manufacturer’s instructions

• Regular inspections are recorded as per company practices • Maintenance and repair activities are documented

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Learning Outcome Summary

LO1. PLAN MAINTENANCE ACTIVITIES

ASSESSMENT CRITERIA:

• Different types of maintenance are explained and identified

• Maintenance work schedule is prepared in accordance with machine/equipment operating time/condition

• Work instructions are prepared according to machine’s manual established by enterprise procedures

• Training resources are identified and classified

• Concerned department/personnel are informed on the schedule of work according to standard operating procedure

CONTENTS:

• The Quality management Cycle (QMC)

• QMC in the Maintenance Program

• Proper Utilization of Equipment and Tools

CONDITIONS:

Participants must be provided with the following: • Maintenance program flow chart

• Quality management cycle flow chart

• Sample template of checklist of training resource • Sample template for inventory of training resources

• Sample template for requisition of instructional equipment, tools, supplies and materials

METHODOLOGIES:

• Lecture/Presentation • Self- paced instruction • Group discussion

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LO2 Maintain Training Equipment and Tools ASSESSMENT CRITERIA:

• Different Types of maintenance are explained and identified

• Tools and equipment are identified according to

classification/specification and job requirements.

• Tools and equipment are tagged-out according to its condition.

• Non- functional tools and equipment are segregated and labeled according to classification.

• Tools and equipment are maintained according to manufacturer’s manual.

• Safety of tools and equipment are observed in accordance with manufacturer’s instruction.

• Conditions of PPE are checked in accordance with manufacturer’s instructions.

CONTENTS:

1. Types of Maintenance

2. Executing Regular Maintenance Activities and Routine Servicing Repair

3. Maintenance Procedures

4. Responding to Failed or Unsafe Equipment 5. Securing of Equipment and Tools

6. Reporting of Complex Faults or Repair Requirements 7. Documenting and Reporting of Maintenance Activities

CONDITIONS:

Participants must be provided with the following:

• Sample template of equipment maintenance activities and routine servicing repair

• Sample template of equipment inspection checklist

• Sample template of equipment checklist of identifying equipment and tools

• Maintenance procedures

• Sample template of reporting complex faults and repair

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• Equipment and tools securing standards • Manufacturer’s Instructions/Manual

METHODOLOGIES:

ASSESSMENT METHOD:

• Oral questioning • Written test

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LO3. IMPLEMENT HOUSEKEEPING ACTIVITIES ASSESSMENT CRITERIA:

• Regular inspection is applied according to procedures and standards.

• Occupational Health and Safety and 5S procedures are applied in maintaining facilities.

• Disposal of waste and dangerous chemicals are based on Occupational Health and Safety procedures.

• Instructional materials and supplies are secured in accordance with manufacturer’s procedures.

CONTENTS:

• Regular inspection procedures and standards.

• Occupational Health and Safety and 5S procedures in maintaining facilities.

• Checking of disposal of waste and dangerous chemicals. • Securing of instructional materials and supplies in safe places

CONDITIONS:

Participants must be provided of the following:

• Copy of regular inspection procedures and standards

• Copy of Occupational Health and Safety manual and 5S procedures • Copy of Occupational Health and Safety ,regulations, organizational

policies and other regulations

• Copy of Instructional materials and equipment securing procedures • Sample template of waste disposal

• Blank form for waste disposal

METHODOLOGIES:

• Lecture/Presentation • Self – paced instruction • Group discussion

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LO4. REPORT AND DOCUMENT MAINTENANCE PROCEDURES

ASSESSMENT CRITERIA:

• Regular inspections are recorded as per company practices • Maintenance and repair activities are documented

• Documents are kept for future use

CONTENTS:

• Reporting and Documentation Process

• Types of Documents in the Maintenance of Facilities

CONDITIONS:

Participants must be provided with the following: • Regular inspection procedures and standards • Organizational policies

• Procedures of keeping documents

METHODOLOGIES:

ASSESSMENT METHOD:

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Learning Experiences

Learning Outcome 1

PLAN MAINTENANCE ACTIVITIES

Learning Activities Special Instructions

Read Information Sheet No. 5.1-1 on the Maintenance Program

Answer learning evaluation on Maintenance Program

Compare answers to Self- check Key Answer

Perform Task Sheet No. 5.1-1 Preparing Equipment

Maintenance Schedule.

Answer learning evaluation on preparing Equipment

Maintenance Schedule.

Compare answer with sample template for Equipment Maintenance Schedule

Perform Task Sheet No. 5.1-2 on preparing Maintenance Inspection Checklist

Answer learning evaluation on preparing Maintenance

Inspection Checklist.

Compare answer with sample template for Maintenance Inspection Checklist

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Learning Outcome No.2

Maintain Training Equipment and Tools

Read Information Sheet No.5.2-1 on Types of Maintenance.

Answer learning evaluation on Types of Maintenance

Perform Task Sheet No. 5.2-1 Preparing Tag Out Bill

Answer learning evaluation on Preparing Tag Out Bill

Perform Task Sheet No. 5.2-2 Preparing Equipment Record w/ Code & Drawing List

Answer learning evaluation on Preparing Equipment Record w/ Code & Drawing List

Perform Task Sheet No. 5.1-1

Preparing Equipment

Maintenance Schedule (Refer to LO1)

Answer learning evaluation

Preparing Equipment

Maintenance Schedule

Compare answers to Self- check Key Answer

Compare your work to sample template for Tag Out Bill.

Compare your work to sample template for Equipment Record w/ Code &

Drawing.

Compare your work to sample template for Equipment Maintenance Schedule.

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Answer learning evaluation on

Maintenance Inspection

Checklist

Perform Task Sheet No. 5.2-3 Preparing Inspection Report Answer learning evaluation on Inspection Report

Perform Task Sheet No. 5.2-4 Preparing Work Request

Answer learning evaluation on Work Request

Perform Task Sheet No. 5.2-5 Preparing Breakdown/Repair Report

Answer learning evaluation on Breakdown/Repair Report

Perform Task Sheet No. 5.2-6 Preparing Salvage Report

Answer learning evaluation on Salvage Report

Compare your work to sample template for Maintenance Inspection Checklist.

Compare your work to sample template for Inspection Report.

Compare your work to sample template for Work Request.

Compare your work to sample template for Breakdown/Repair Report.

Compare your work to sample template for Salvage Report.

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LEARNING EXPERIENCES

Learning Outcome No.3

IMPLEMENT HOUSEKEEPING ACTIVITIES

Learning Activities Special Instructions

Read Information Sheet No. 5.3-1 on 5S Housekeeping System

Answer learning evaluation on 5 S Housekeeping System

Compare your answers to Self- check key answer.

Perform Task Sheet No. 5.3.1

Preparing Housekeeping

Schedule.

Compare your Housekeeping Schedule to sample template.

Perform Task Sheet No. 5.3-2 on Preparing Housekeeping Checklist

Checklist

Compare your answers to Sample template

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Safety

Read Information Sheet No. 5.3-3 on Waste Management. Answer learning evaluation on Waste Management.

Compare your answers to Self-check key answer

Perform Task Sheet No. 5.3-3 on Preparing Waste

Segregation list .

Answer learning evaluation on Preparing Waste Segregation list

.

Compare your Waste Segregation list to Sample template.

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LEARNING EXPERIENCES

Learning Outcome No.4

DOCUMENT MAINTENANCE INSPECTION

Read Information Sheet No.

5.4-1 on Reporting and Documentation Process

Answer learning evaluation on Reporting and Documenting Process

Compare answers to Self-check answer key.

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INFORMATION SHEET NO.5.1-1

MAINTENANCE PROGRAM

Learning Objectives: After reading this INFORMATION

SHEET, YOU MUST be able to understand the Quality

Management Cycle ( QMC), Maintenance programming and

scheduling.

• The Quality management Cycle (QMC)

•

QMC in the Maintenance Program

• Proper Utilization of Equipment and Tools

DEFINITION OF TERMS

Maintenance Program- is a comprehensive list of

maintenance and its incidents. This would include all

maintenance activities to be undertaken , manpower needed,

maintenance methods to be used, all the materials and

supplies needed for the maintenance and cost involved in the

maintenance.

Maintenance Schedule- Is a list allocating specific

maintenance of an area. Equipment and tools to a specific

period. The maintenance schedule is just a part of the

maintenance program.

A.

The Quality Management

Cycle (QMC)

In preparing the maintenance program, It would be best if we

will adhere to the Quality Management Cycle.

Quality management- is a method for ensuring that all the

activities necessary to design, develop and implement a

product or service are effective with respect to the system and

its performance.

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The following diagram is the Shewhart cycle (PDCA) for

quality improvements. Made popular by Dr. Deming.

The Quality Management Cycle(delete)

The philosophy is to keep improving the quality of an

organization. It is defined by the four key steps:

•

Plan: Design and revised business process components to

improve results.

•

Do: Implement the plan and measure its performance

•

Check: Assess the measurements and report the results

PLAN

DO

IMPLEMENT

CHECK

ASSESS/CORREC

_T

ACT

SUSTAIN

=

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The consolidation phase enables the organization to take

stock of what has been taking place and to ensure made to

processes that require documentation (both to allow processes

to be repeatable and to facilitate recognition of the

achievement of some form of quality standard).

B.

QMC IN THE MAINTENANCE PROGRAM

The philosophy of the Quality Management Cycle can be

applied in the Maintenance Program of an organization. The

first step of the Quality Management cycle in maintenance is

to Plan by preparing all the details of the maintenance

program. Then DO, wherein the organization implements the

methods and strategies of maintenance based on the

maintenance schedule. Then CHECK , here the organization

regular inspects equipment to determine if the required

maintenance procedures are conducted .Finally ACT, here the

organization acts on the result of the inspection conducted

1. Plan. Here in this stage an organization must be able to prepare a

good maintenance program which will define the standards for Best Management Practices. The maintenance program must clearly answer the question on WHY,WHO,WHAT,WHEN, WHERE and HOW.

WHO WHY WHAT How WHERE WHEN

Facilities Maintenance

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Why Maintain?

1. General Objective:

To maintain the optimum condition of physical facilities at acceptable

levels and minimum cost to satisfy the expected demands of TVET programs and activities.

2. Specific Objectives:

• To extend the useful life of physical facilities

• To assure the operational readiness of installed equipment and maximum possible return on investments.

• To properly discard hazardous wastes

• To ensure the safety of personnel using the facilities, physical properties and the environment.

What can we gain from maintaining our facilities?

• Ensured SAFE environment

• Improve MORALE of human resources

• Reduced operational COST

• Increased PRODUCTION

• Prolonged LIFE facilities

• Prompt DELIVERY of services/ product

WHO?

• Who will manage the activities?

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• Who will prepare the report?

Functional Chart of Technical Support Services

In- charge of inventory, data base, procurement and reporting, FINANCIAL

MANAGEMENT AND AVAILABILITY

Administrative Officer Team Manager

Plans, directs. Monitors and evaluates team

operation.

Area Head

(Equipment & Service Vehicles)

Area Head (Ecology) Area Head (Structures& Grounds) Tools and Equipment Service Vehicles Formulates, Schedules,

Supervises/implements and inspect all unit of activities

Building/s

Electrical

Water/Plumbing

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What, Where, When?

• What routine actions must be done to keep the device on working order?

• Where is the maintenance activity to be carried out? • When do you perform the maintenance activities?

How to maintain?

The question on how do we implement the maintenance program will center on the 5Ms are as follows:

• Manpower

• Money (Financial Resources)

• Methods and System

• Machines (Facilities) • Materials and Supplies

2. DO. Here in this stage the organization through the clearly

identified Maintenance Program, must be able to practice the Methods and System defined in order to meet the standards (measurable performance levels of maintenance execution) established.

5S

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Preventive Maintenance Corrective Maintenance

Overall, the combination of standards, methods and strategies are elements of an integrated Planted Maintenance System.

SAMPLE EQUIPMENT MAINTENANCE SCHEDULE

In order to perform the maintenance of specific equipment, a Maintenance Schedule is drawn to guide the personnel in the proper methods system . One best source of the list of the maintenance activities of an equipment is its manufacturer’s manual, In the absence of it, the plan can be derived from the known maintenance methods of the equipment.

Below is the sample Equipment Maintenance Schedule For Desktop Computer in the Practical Work area/ Computer Laboratory of a Training Center for PC Operations. You may see that that this maintenance schedule is for a specific equipment only, denoted by unique property code.

SAMPLE TEMPLATE NO. 2 EQUIPMENT MAINTENANCE SCHEDULE

EQUIPMENT TYPE Desktop Computer

EQUIPMENT CODE Computer 1

LOCATION Practical Work Area / Computer Laboratory

ACTIVITI

ES MANPOWER

Schedule for the Month of_____________ Dai ly Every Oth er Day Wee kly Every 15th Day Mont hly Remarks 1. Clean computers and printers IT Personnel x 2.Check computer

for viruses IT Personnel X 3. Clean

computer

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4. Check electric and computer connectio ns IT Personnel x 5.Turn off unit when not in use or at the end of the day. IT Personnel x

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3. CHECK. To determine if the maintenance program is implemented

according to what is planned, an assessment must be done. The result of the assessment will then be recorded and recorded to the proper authorities for the immediate action.

Regular inspections are conducted to assure that the maintenance activities are done on the date and time it was planned and that the performance levels adhered to the defined standard.

SAMPLE EQUIPMENT INSPECTION CHECKLIST

Below is a sample Maintenance Inspection Checklist. You may note that this checklist pertains to the same equipment with the Maintenance Schedule (see sample). This checklist will confirm if the maintenance activities have been performed in order to prolong the life of this particular equipment. The Inspection items are stated in a question form as these serve as the criteria or standards of maintenance.

Sample Template No. 3 : MAINTENANCE INSPECTION CHECKLIST Equipment Type : Desktop Computer

Property Code :

Number : Computer 1 / 1001A

Location : Practical Work Area / Computer Laboratory

YES NO INSPECTION ITEMS

√ 1. Are the peripherals (keyboard, mouse, etc.)

returned to their proper places?

√ 2. Is the computer unit turned off when not in use?

√ 3. Is the computer unit in good working condition?

√ 4. Is the equipment arranged for the purpose of

safety and ease in maintenance?

√ 5. Is the auto- voltage regulator (AVR) and/or UPS

turned off when not in use√√?

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4.

ACT. The inspection will allow the organization to determine if the

standards of maintenance are met. This will also allow the

identification of further improvement in the process and procedures. Hence, the results of the inspection must be properly documented and reported to the proper authorities for immediate action or correction needed.

C. PROPER UTILIZATION OF EQUIPMENT AND TOOLS

The proper use of the training tools and equipment is the first and foremost task in the maintenance. The proper use of tools and equipment is a very important task of the worker in any trade. They must be able to use them in accordance to the manufacturer’s manuals as this would evidently extend the life of the equipment and tools.

USER’S MANUAL

: For the Safe and Proper Operation of an Equipment

or Tools.

When using equipment and simple tools, it is best to read the manufacturer’s and

/or user’s manuals. This would indicate the part of the equipment, the functions of each part and the way to maintain it. We must always refer to it for reference. The user’s manuals must be kept handy and within the Quality Control Area where the equipment is kept for immediate reference.

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TASK SHEET NO. 5.1-1

Module Title: Maintaining Training Facilities

Learning Outcome: Prepare Schedule of Maintenance Task: Prepare an Equipment Maintenance Schedule Learning Objectives:

After reading the Information Sheet No. 5.1-1, Using the Blank Template, YOU MUST be able to prepare EQUIPMENT MAINTENANCE SCHEDULE of the particular equipment in your workplace.

Time Allotment: 30 mins.

Materials and equipment needed:

1. Template #1

2. Sample template # 1

3. TR/CBC

4. Inventory of Tools and Equipment 5. Laptop/PC

Procedures:

1. Prepare all your reference materials and laptop/PC

2. Identify only one type of equipment from the Inventory of Tools and Equipment.

3. Fill up all items in Template #1.

4. Tick the schedule corresponding to each given activity.

5. Call your facilitator who will guide you and check your work after doing this activity.

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Performance Criteria Checklist

CRITERIA Ye

s No

Trainees were oriented about the task Materials and equipment are provided

Safety of tools and equipment were observed in accordance with the manufacturer’s instruction

PPE condition was checked in accordance with the manufacturer’s instruction

The performance of the trainees were evaluated based on Performance Criteria

Feedback to trainees was provided.

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TASK SHEET NO. 5.1-2

Learning Outcome: Prepare Schedule of Maintenance Task: Prepare Maintenance Inspection Checklist

Learning Objectives:

After reading the information Sheet No. 5.1-2, YOU MUST be able to

Prepare an inspection Checklist on the same equipment you have chosen in Task Sheet No. 5.1-1.

1 Template #2

2 Sample template #2

3 TR/CBC

4 Inventory of Tools and Equipment 5 Laptop/PC

Procedures:

2. Identify the same equipment you have chosen in Task Sheet No.

5.1-1.

4. Tick the box corresponding to each given inspection items.

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CRITERIA Ye

s No

Trainees were oriented about the task. Materials and equipment were provided.

Safety of tools and equipment were observed in accordance with the manufacturer’s instruction.

PPE condition was checked in accordance with the manufacturer’s instruction.

The performance of the trainees was evaluated based on Performance Criteria.

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SELF-CHECK On Learning Outcome 1

Directions: Choose a best answer for each number.

1. It is a comprehensive list of maintenance and its incidence.

a. Maintenance Schedule b. Maintenance Program c. None of the above

2. What can we gain from maintaining our facilities? a. Improve morale of human resources

b. Reduced operation cost c. All of the above

3. The philosophy to keep improving the quality of an organization is defined by four keys:

a. Plan, Do, Act and Check b. Plan, Do, Check and Act c. None of the above

4. The best reference for the proper use and maintenance of an equipment is the:

a. Maintenance program

b. User’s or Manufacture’s manuals c. Inspection checklist

5. The question on how do we implement the maintenance program will center on the 5Ms which include:

a. Manpower, Money (Financial Resources), Methods and Systems b. Machines (Facilities), Mechanical, Money

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Answer Key

Model Answer to Self- check On Learning Outcome 2

1. b. Maintenance Program

2. c. All of the above

3. b. Plan, Do, Check and Act

4. a. Manpower, Money.(Financial Resources), Methods and Systems 5. b. User’s or Manufacturer’s Manuals

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INFORMATION SHEET NO. 5.2-1

Types of Maintenance

After reading this INFORMATION SHEET, YOU MUST be able understand the different types of maintenance and maintenance program to be used in your workplace/area, and be able to implement and carry out Maintenance system in your prospective areas / workplace.

Contents:

Types of maintenance Tag-Out Bill

The principal objectives of maintenance can be clearly defined as follows: 1. To extend the useful life of assets (i.e. every part of the site,

building and contents).

2. To assure the optimum availability of installed equipment for protection (or service) and obtain the maximum possible return of investment.

3. To ensure operational readiness of all equipment required for emergency use.

4. To ensure the safety of personnel using facilities.

DEFINITION OF TERMS:

Maintenance - work that is done regularly to keep equipmen ,building

and grounds in good condition and working order.

A. Planned Maintenance – Work activities are performed as

scheduled/ expected. Work is based- on pre- conceived/ planned activities.

Sample: Changing of oil of car engine, this is controlled by two factors a). mileage, b). time or whichever comes first.

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1. Preventive Maintenance - Maintenance performed to PREVENT or

FIND failures BEFORE they develop into a breakdown.

• Time- Based Maintenance – based on calendar days or

running hours or usage. (Inspection, cleaning, lubrication, programmed replacement and repairs). Example: Change oil every months or every 5,000 km.

• Conditioned- Based Maintenance – visual monitoring

and condition monitoring technique (temperature, hydraulic fluid wear, surface condition, crack, leaks, vibration, corrosion/erosion, electric insulation, etc.)

1. Predictive Maintenance – Maintenance performed at a

predetermined periods when the maintenance activity is most cost effective and before the equipment fails.

2. Corrective Maintenance - Maintenance performed to

CORRECT or REPAIR a failure.

• Controlled Maintenance – Condition improvement/enhancement of equipment.

Example: Engine overhaul. Also referred to as Proactive Maintenance – maintenance performed to stabilize the reliability of machines or equipment.

• Breakdown Maintenance – Repair done when the

equipment fails while in operation. Also referred to as Reactive Maintenance – maintenance performed as a reaction to failure.

B. Unplanned Maintenance – Maintenance performed unexpectedly.

B.1. Emergency – maintenance performed to put the item on

hand IMMEDIATELY to avoid serious consequences, i.e. Loss of production, disrupted schedule, extensive damage to assets, idle workers or for safety reasons

Example: A hacksaw blade breaks-up during operation, this is an unplanted situation, what you need to do is buy new blade and replace it.

DIAGRAM 1 Types of Maintenance

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Tag – Out Bill:

A system of documents being applied to warn or let you know whether something in your workplace should either be operated with extra care or left alone.

Purposes of Tag-Out Bill

1. To provide a procedure to prevent the improper operation of a component, piece of equipment a system, or portion of a system that is isolated or in an abnormal condition.

2. To provide a procedure in operating an instrument that is unreliable or not in normal operation condition.

3. To provide separate procedures when accomplishing certain planned maintenance system.

Tag – Out Bill on:

Corrective Maintenance

An equipment must be tagged – out if you are working on one that must have its power supply working on the equipment.

Preventive Maintenance

Power switches should be tagged-out when the technical manual of the equipment directs you secure the electrical power.

Tag-out Documents

• Tag out Logs • Caution Tags

• Danger Tags

• Out of – Calibration Labels • Out of – Commission Labels

Preventive

PLANNED UNPLANNED

Corrective Emergency

Time-Based Condition-_Based Controlled Breakdow_n Predictive

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Equipment Tag-out Procedures

1. Post Danger Tags, Caution Tags and instrument Out-of Commission Tags/out-of Calibration labels following authorized procedures.

2. Do not remove or break posted safety tags without proper authorization.

Tag-out activity should be supported by properly accomplished document.

Example of Tag Out Bill

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01 1/2/10 Danger Power switch under repair 1/10/10

02 2/24/1

0 Warning Transformer perimeter fence warning signs installation 3/3/10

03 6/5/10 Caution On-going grinding activity 6/5/10

Prepared by: Approved:

______________________ ______

______________ Trainer

Supervisor

Tag-out activity should be supported by properly accomplished document shown above.

I. PREVENTIVE MAINTENANCE

Preventive Maintenance of Machines / Facilities Coverage:

• Structure and Surroundings • Included services

• Tools and Equipment • Vehicles

Preventive Maintenance of Materials and Supplies • Office

• Training

Sample Template 4 : OPERATION OF EQUIPMENT Equipment

Type Desktop Computer

Equipment

Code Computer 1

Location Practical Work Area / Computer Laboratory

Operation Procedures :

1. Check power cords and cables. Check connections. 2. Turn on AVR/UPS and then turn on the computer.

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3. Use the computer properly.

4. Scan the computer and any removable devices regularly. 5. Properly shut down the computer when not in use.

6. Turn off the AVR/UPS after shutting down the computer.

7. Return the mouse and keyboard to their proper place after use.

SAFETY

• The freedom from danger, injury or damage.

• According to Japanese Standard, an addition to 5S is Safety, thus 5S will become 5S + 1

Ways to learn and understand SAFETY

• Accidental Experiences. Experiences which were caused by accidents.

• Safety Education. A means of developing awareness of the dangers inherent in a situation, thus enabling the learner to avoid or

minimize corresponding injuries.

SAFETY PRECAUTIONS

Concerning People

• When working, wear appropriate protective clothing. • Make sure that the safety hat is worn properly.

• Do not wear the gloves when operating equipment except when any part thereof is hot.

• Never remove safety devices or safety covers from equipment. • Be careful of high voltages. Never touch switches with wet hands. • When repairing power lines, turn off the main power supply first. • Should an accident occur, it should be reported immediately to the

proper authority no matter how trivial. Concerning Facilities

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• The equipment and the floor are around the equipment must be free from dust and any chipping.

• Workbenches must be strong and sturdy, and their surfaces treated with non-skid materials.

TIPS IN PREPARING A CHECKLIST

1. Keep it simple – one page per checklist. 2. Follow a logical sequence.

3. Use bullet enumerated points, if relevant. 4. Consider the 5WH.

5. Avoid making assumptions.

6. From each item in your checklist, other items will naturally originate from it.

SAMPLE TEMPLATE 5

: EQUIPMENT RECORD W/ CODE AND DRAWING LIST

EQUIPMENT RECORD W/ CODE AND DRAWING

N

o. Location Eqpt. No. Qnty Title Description No.PO Drawing Ref.

1 M 04 G 1001 3 Pipeline Booster Pump Welrs Pumps Ltd. Size/Type OK Serial No. A11556-001 B11556-002 10200 GO 02 1020 E 2 M04 G 1002 2 Motor Brook Crompton Frame: 280th 10200 GO 02 1021 E

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SAMPLE TEMPLATE

OF EQUIPMENT MAINTENANCE SHEDULE

(Refer to LO1)

SAMPLE TEMPLATE

OF EQUIPMENT INSPECTION CHECKLIST

(Refer to LO1)

What can we gain from maintaining our facilities?

• Ensured SAFE environment

• Improved MORALE of human resources

• Reduced operational COST

• Increased PRODUCTION

• Prolonged LIFE of facilities

• Prompt DELIVERY of services/products

SAMPLE TEMPLATE 6

Prevention of damage to the environment

Prevention of accidents (to save lives and limbs)

Prevention of failures, damages.

PLANET

PEOPLE

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FACILITY TYPE INCIDENT ACTION TAKEN PROGRESS / _REMARKS

Printer – HP

Deskjet 695C Overheating Sent to HP service center for repair

Cannot be

repaired; replace printer

Monitor of PC

No. 1 Black out Sentcomputer to

technician

Cannot be

repaired; replace monitor

Monitor of PC

No. 2 Static screen Sentcomputer to

technician Buy monitor parts and replace damaged parts Monitor of PC

No. 3 Halfvisibility screen Sentcomputer to

technician

Buy monitor

parts and

replace

damaged parts

Reported by: Date

Signature Over Printed Name

SAMPLE TEMPLATE 7

: WORK REQUEST

WORK REQUEST

Unit No. 5-20

Description:

Compressor, instrumentation air, No. 1 Observation:

V-BELTS WORN Date Reported: Aug. 15, 2010 Should be replaced Reported by:

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Activity: Date completed: Sign:

Spare parts used:

SAMPLE TEMPLATE 8

: BREAKDOWN / REPAIR REPORT

Area /

Section : Practical Work Area / Computer Laboratory

I : IT Personnel (Name)

FACILITY TYPE _BREAKDOWNNATURE OF RECOMMENDATION

Printer – HP Deskjet

695C Overheating Sent to HP service center for repair

Reported by: Date

Sample Template 9

: SALVAGE REPORT

Area /

Section : Practical Work Area / Computer Laboratory

Area /

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Speed Color Printer cartridge for other floor model printer

Reported by: Date

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TASK SHEET NO. 5.2-1

On Learning Outcome 4

Learning Outcome: Maintain Training Equipment and Tools Task Title:

Prepare Tag-out Bill

Learning Objective:

Given Tag-out Bill documents, materials, equipment and procedures, you must be able to prepare Tag-out Bill using blank template No. 3.

1. Template #3

2. Sample template #3

3. TR/CBC

6. Bond paper, ball pen and pencil

7. Tag-out Bill documents and procedures

Steps/Procedures:

2. Identify a piece of equipment (you have chosen in task sheet no.

5.1-1) with improper operation of equipment of a component or a portion of system that is isolated or in abnormal operation.

3. Write the name of equipment or system components description in column 4 ”Description”.

4. Fill up all other items in Blank template #3.

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CRITERIA Ye

s No

Did the trainer prepare the needed tools and equipment for the task?

Was there a full utilization of work areas/resources?

Was the safety of tools and equipment observed in accordance with the manufacturer’s instruction?

Is PPE condition checked in accordance with the manufacturer’s instruction?

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TASK SHEET NO. 5.2-2

Learning Outcome: Maintain Training Equipment and Tools Task: Prepare an Equipment Record with Code and Drawing Learning Objectives:

After reading the Information Sheet No. 5.2-1, using the Blank Template 5, YOU MUST be able to prepare Equipment Record w/ Code and Drawing.

Time Allotment:

1. Template 5

2. Sample template 5 3. TR/CBC

4. Invoice/Acceptance Report

5. Previous inventory report (if available) 6. Laptop/PC

7. Ballpen

8. Any Manual/Instruction for Recording (if available)

Procedures:

2. Fill up all items in Template 5.

3. Observe safety of tools and equipment.

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CRITERIA Ye

s No

The trainer prepares the needed tools and equipment for the task.

All needed forms and documents were provided.

Safety of tools and equipment was observed in accordance with the manufacturer’s instruction.

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TASK SHEET NO. 5.1-1

On Learning Outcome 4 – Equipment Maintenance Schedule

(Refer to LO1)

TASK SHEET NO. 5.1-2

On Learning Outcome 4 – Maintenance Inspection Checklist

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TASK SHEET NO. 5.2-3

on Learning Outcome No.4

Learning Outcome: Maintain Training Equipment and Tools Task: Prepare an Inspection Report

After reading the Information Sheet No. 5.2-1, using the Blank Template 5, YOU MUST be able to prepare Inspection Report based on the

Maintenance Inspection Checklist result.

Time Allotment:

1. Template 6

4. Maintenance Inspection Checklist 5. Laptop/PC

6. Ballpen

7. Any Maintenance Inspection Manual/Instruction (if available)

Procedures:

1. Prepare all your reference materials and laptop/PC.

2. Fill up all items in Template 6 based on the Maintenance

Inspection Checklist result.

3. Segregate and label inspected equipment.

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CRITERIA Ye s No

Full utilization of facilities and resources. All needed forms for the task were provided.

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TASK SHEET NO. 5.2-4

Learning Outcome: Maintain Training Equipment and Tools Task: Prepare a Work Request

After reading the Information Sheet No. 5.2-1, using the Blank Template 7, YOU MUST be able to prepare Work Request based on the Inspection

Report or Breakdown/Repair Report.

Time Allotment:

1. Template 7

4. Inspection Report or Breakdown/Repair Report

5. Laptop/PC 6. Ballpen

Procedures:

1. Prepare all your reference materials and laptop/PC.

2. Fill up all items in Template 7 based on the Inspection

Report or Breakdown/Repair Report. 3. Identify damaged equipment and tools.

4. Indicate the damage/problem of the equipment/tools. 5. Recommend possible solution.

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Trainer oriented student about the task. All needed forms for the task were provided.

All needed manufacturer and instruction manual were provided. Full utilization of facilities and resources.

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Learning Outcome: Maintain Training Equipment and Tools Task: Prepare a Breakdown/Repair Report

After reading the Information Sheet No. 5.2-1, using the Blank Template 8, YOU MUST be able to prepare Breakdown/Repair Report.

Time Allotment:

1. Template 8 2. Sample template 8 3. TR/CBC 4. Equipment Record 5. Laptop/PC 6. Ballpen Procedures:

1. Prepare all your reference materials and laptop/PC. 2. Fill up all items in Template 8.

3. Identify the damaged tools/equipment.

4. Identify the nature of breakdown of the equipment.

5. Recommend possible solution.

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Did the trainer prepare the needed equipment for the task? Is the condition of PPE checked in accordance with the manufacturer’s instruction?

Is the safety of tools and equipment observed in accordance with the manufacturer’s instruction?

Did the trainer provide feedback to trainees?

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Learning Outcome: Maintain Training Equipment and Tools Task: Prepare Salvage Report

After reading the information Sheet No. 5.2-1, YOU MUST be able to prepare a Salvage Report on the same equipment you have chosen.

1. Template # 9

2. Sample template #9 3. TR/CBC

6. Pencil/Pen

7. Manual of Procedures

Procedures:

2. Identify the same equipment you have chosen. Indicate the

Property Number.

4. Tick the box corresponding to each given inspection items. 5. Call your facilitator who will guide you and check your work

after doing this activity.

CRITERIA Ye

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The condition of PPE was checked in accordance with the manufacturer’s instruction.

The safety of tools and equipment were observed in accordance with the manufacturer’s instruction.

Feedback was provided to trainees. Activities were monitored.

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____________1. Work that is done regularly to keep equipment,

building and grounds in good condition.

____________ 2. Work activities are performed as schedule/

expected. Work is based- on pre-conceived/planned activities.

____________ 3. Maintenance performed unexpectedly.

____________ 4. Maintenance performed at a predetermined

periods when the maintenance activity is most cost effective

and before the equipment fails.

____________ 5. Condition improvement/enhancement of

equipment.

____________ 6. Repair done when the equipment fails while in

operation.

____________ 7. A system of documents being applied to warm

or let you know whether something in your workplace should

either be operated with extra care or left alone.

____________ 8. Based on calendar days or running hours or

usage (Inspection, cleaning, lubrication, programmed

replacements and repairs).

____________ 9. Visual monitoring and condition monitoring

technique (temperature, hydraulic fluid, wear, surface

condition, crack, leaks, vibration, corrosion/erosion, electric

insulation etc.).

____________ 10. Maintenance performed to PREVENT or FINDS

failures BEFORE they develop into a breakdown.

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Model answer to Self-check on Learning Outcome 4

1. Maintenance

2. Planned Maintenance

3. Unplanned Maintenance

4. Predictive Maintenance

5. Controlled Maintenance

6. Breakdown Maintenance

7. Tag-Out Bill

8. Timed-Based Maintenance

9. Condition- Based- Maintenance

10. Preventive Maintenance

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Learning objectives: After reading this INFORMATION SHEET, YOU MUST be able to understand the application of 5S Housekeeping system your workplace.

5S is a reference to five Japanese words that described standardized cleanup:

Definition of Terms:

5S – is a systematize approach to organize work areas, keep rules and standards and maintain the discipline needed to do a good job; 5S is a reference to five Japanese words that described standardized cleanup:

5S means good housekeeping and workplace organization.

5S

SEIRI (SORT)

• TIDINESS, ORGANIZATION,

• Taking out and disposing of unnecessary items.

Seiri

(Sort)

Shitsuke

(Self-Discipline)

Seiton

(Systematize)

Seiketsu

(Sanitize)

Seiso

(Sweep)

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• Refers to the practice of sorting and through all the toiols, materials, etc., in the work area and keeping only essential items. Everything else stored or discarded. The leads to fewer hazards and less clutter to interfere with productive work.

• Note that…. Things that clutter the workplace that are not needed should be taken out. They usually occupy space and restrict physical movement. Further , this condition has a psychological effect that usually clutters one’ attitude.

SEITON (Systematize )

• ORDERLINESS. Focuses on the need for orderly work place .Tools, equipment, and materials must be systematically arranged for the easiest and most efficient access.

• Arrangement/organization of necessary items in good order for use.

• Items in the work place are arranged for ease of access and repeated use.

• Assign a place for everything. The most often used item should be nearest and ergonomically situated, meaning – there should be little effort required in accessing, using and returning the equipment , tools and parts, even documents. There must be a place for everything, and everything must be in place.

SEISO (SWEEP)

• CLEANLINESS; Cleaning of the work place.

• Cleaning even if things are NOT DIRTY. A regular cleaning schedule prevents things from having change to get dirty.

• Indicates the needs to keep the work place clean as well as neat. Cleaning in Japanese companies is a daily activity. At the end of each shift, the work area I cleaned up and everything restored to its place.

SEIKETSU ((Standardize)

• STANDARDS: Maintaining the workplace in high standard housekeeping.

• Allows for control and consistency. Basic housekeeping standard apply everywhere in the facility. Everyone knows exactly what his or her responsibilities are. Housekeeping duties are part of regular

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• EVALUATE workstation according to the Housekeeping Standard Checklist.

• IMPLEMENT a periodic clean – up schedule; and an award and sanction scheme.

Tips in Preparing A Checklist

1. Keep it simple – one page per checklist 2. Follow a logical sequence

3. Use bullet enumerated points, if relevant

4. Avoid making assumptions

5. From each item in your checklist, other items will naturally originate from it.

SHITSUKE (Self-Discipline)

• SUSTAINING DISCIPLINE .Doing things spontaneously without having to be told.

• “ teach by doing “ .

• It is good discipline to leave the workplace cleaner than when it is found.

• Refers to maintaining standards and keeping the facility in safe and efficient order day after day, year after year.

Safety

as defined may be the freedom from danger injury or damage.

According to Japan standard, a new addition to the 5S is safety, hence it will become 5S + 1. Still part of the housekeeping system, safety

becomes an important task to be perform.

SAFETY PRECAUTIONS

These are general safety precaution concerning people and facilities. Although these may vary depending on the trade which they are in. Concerning People

• When working wear appropriate clothing.

• Make sure that the safety hat is worn properly.

• Do not wear gloves when operating equipment except hen any part thereof is hot.

• Never remove safety devices or safety cover from equipment. • Be careful of high voltages. Never touch switches with wet hands.

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• When repairing power lines turn off the main power supply first. • Should an accident occur, it should be reported immediately to

proper authority no matter how trivia.

Concerning Facilities

• Facilities must be adequately illuminated, clear neat and dry.

• Keep the ate organized so there are no obstacles lying around the floor.

• The equipment and the floor area round the equipment must be free from dust and any chipping.

• Workbenches must be strong and sturdy, and their surfaces treated with non-skid materials.

Facilities to be considered for housekeeping activities:

• Quality Control Area

• Assessment Area

• Practical Work Area

• Learning Resource Center

• Computer Laboratory

• Contextual Area • Support Area • Trainers Area

• Distance Learning Area

Sample Housekeeping Schedule

Below is a sample template for a Housekeeping Schedule pertaining to the cleanliness and orderliness of a particular Section/Area of a CBT facilities – Practical Work Area or Computer Laboratory.

The frequency with which you carry out housekeeping duties may vary according to the task some activities may need to be done daily, some weekly, some monthly, some annually, depending on your particular circumstances. For instance, if you are located in a high crime area, you may wish to carry out physical security checks more often than if you were situate elsewhere.

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ACTIVITIES MANPOW_ER Schedule for the Month of ________________ I 2 3 4 5 6 7 8 9 ₀1 1₁ 1₂ 1₃ 1₄ 1₅ 1. Clean computers and printers Utility Personnel χ χ χ χ χ χ χ χ χ χ χ χ χ χ χ 2. Clean computer tables and chairs Utility Personnel χ χ χ χ χ χ χ χ 3. Arran ge table and chairs Utility Personnel χ χ χ χ χ χ χ χ χ χ χ χ χ χ χ 4. Clean

floor PersonnelUtility χ χ χ χ χ χ χ χ χ χ χ χ χ χ χ 5. Clean walls and windows Utility Personnel χ 6. Dispo

se waste PersonnelUtility χ χ χ χ χ χ χ χ χ χ χ χ χ χ χ

To be included: • Training equipment • LCD projector • Projector screen • Audio visual • Computer set • Air conditioning • Water dispenser • Support equipment • Fax machine • Photo copier • Telephone

Sample Housekeeping Inspection Checklist

An inspection checklist would help you to maintain and standardize the housekeeping procedures in the workplace. This checklist will give you the standards or criteria on how to implement the housekeeping schedule. This shall serve also as reminder to all concerned in the upkeep of the cleanliness and orderliness of the work area.

Below is a simple Housekeeping Inspection Checklist of the Practical work Are/Computer Laboratory. The inspection items are your criteria when doing your inspection. These are stated in a form of a question answerable by Yes or No to determine if the criteria was met.

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You may notice that the inspection items are related to the activities that you have identified in the Housekeeping Schedule. However, you can derived as many inspection items or criteria for inspection on every activity that you have stated in your Housekeeping Schedule. Hence, you need to write them for conciseness and completeness.

Sample Template 11 : HOUSEKEEPING INSPECTION CHECKLIST

Section/Area: Practical work Area , Computer Laboratory In- Charge:

YES NO INSPECTION ITEMS

1. Are the peripherals (keyboard, mouse, etc.) returned to their proper places?

2. Are the walls, ceiling, floor and other furniture and fixtures well clean and in other?

3. Is the computer unit in working condition? 4. Are all areas well lighted and ventilated? 5. Is the equipment arranged for the purpose of

safety and ease in maintenance?

6. Are the equipment well clean, in order and arranged for safety and maintenance?

7. Are the tables and chairs properly arranged according to the floor layout?

8. Is the computer unit free from any virus?

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The word ‘ Security” in the general usage is synonymous with “ safety “ but as technical term “ security “ means that something not only is

secure but that it has been secured. Part of a good housekeeping program is the stress on security in the work area and of the tools and equipment. Here are some security policies and procedures that we may apply in the workplace.

Physical Property

Keep your premises physically secure. Always ensure you know who in the building. Prevent visitors casually wandering into your premises. If

appropriate , fit an alarm, lock valuable asset (e.g. laptops, ,mobiles and the servers) in a secure room. Try to keep items out of direct public view.

Education

Let everyone know what is expected of them. Make sure they know the value of the information they handle and are aware of any procedures you have developed to combat threats. Make sure people know what their responsibilities are.

Access control

If you run a multi-user computer system, use the appropriate access control software to keep unauthorized persons away from information held on your computer systems. Make sure everyone who needs access has their own ID and password and ensure they can only access what they need in order to do their job.

Clear desks

Establish a practice of clearing desks at the end of each day. This need not be a complex process simply ensure that staff have lockable drawers or cupboards in which to place their work, and make sure these are locked and the keys removed.

Destruction

If you have sensitive information which you wouldn’t want to fall into the wrong hands, destroy any copies you don’t need. ,if you have a lot of paper copies, modern shredders provide an inexpensive and effective solution. Some organizations use specialists destruction companies; this is normally only necessary if you have a lot of highly sensitive material.