Competence development for Maintenance Technicians

and Maintenance Supervisors

Guido Walt
Wear-Management
Steering Committee
of the World
Maintenance Forum
Convenor of CEN/TC
319 WG 9
Qualification of
Maintenance
Personnel
Good Morning
Education and Training
1. Terms and definitions.
2. Tasks of Maintenance Technicians, Supervisors and
Engineers.
3. Required competencies of Maintenance Technicians,
Supervisors and Engineers, based on maintenance
and companies objectives.
4. Skills and knowledge.
5. Learning outcomes a paradigm change.
6. Discussion and summary
Index
Projects:
prEN 15628 is a draft standard from CEN/TC 319.
VocTrainMaint was a Leonardo project running from
October 2009 to end of 2011 under the Lifelong
Learning Program and financially supported by the
European Commission
(http://www.voctrainmaint.eu)
EURIAC is a Leonardo Project running from October
2011 to September 2013 under the Lifelong Learning
Program and financially supported by the European
Commission (http://www.euriac.eu).
1. Terms and definitions prEN 15628
Projects:
Pile Up is a Leonardo Project running from October
2011 to September 2013 under the Lifelong Learning
Program and financially supported by the European
Commission (http://www.pile-up.eu).
VEMT is a Leonardo Project running from October
2012 to September 2014 under the Lifelong Learning
Program and financially supported by the European
Commission (http://www.validmaint.com).
1. Terms and definitions prEN 15628
International standards: Europe
ENV 13269: 2006 - Guideline on preparation of
maintenance contracts
EN 13306: 2010 - Maintenance Terminology
EN 13460: 2009 - Documents for Maintenance
EN 15331: 2009 - Criteria for design, management
and control of maintenance services for buildings
EN 15341: 2006 - Key Performance Indicators
CEN/TR 15628: 2007 Qualification of Maintenance
personnel
prEN 15628: 2012 Qualification of Maintenance
personnel
1. Terms and definitions prEN 15628
International standards: IEC TC 56
IEC 60300-1 - Dependability management
Part 1: Dependability management systems
IEC 60300-2 - Dependability management
Part 2: Guidelines for dependability management
IEC 60300-3-10 - Dependability management
Part 3-10: Application guide - Maintainability
IEC 60300-3-14 - Dependability management
Part 3-14: Application guide - Maintenance and
maintenance support
IEC 60300-3-16 - Dependability management (2007)
Part 3-16: Application guide - Guideline for the
specification of maintenance support services
1. Terms and definitions prEN 15628
Terms:
Competence
Knowledge
Skills
Level of qualification
Procedure
Qualification
1. Terms and definitions prEN 15628
Definitions:
Competence
The proven ability to use knowledge, skills and personal,
social and/or methodological ability in work or study
situation and in professional and personal development.
Competence is described in terms of responsibility and
autonomy.
1. Terms and definitions prEN 15628
Knowledge
The outcome of the assimilation of information through
learning.
Knowledge is the body of facts, principles, theories and
practices that is related to a field of work or study.
1. Terms and definitions prEN 15628
Skills
The ability to apply knowledge and know-how to complete
tasks and solve problems.
Skills are described as cognitive (involving the use of logical,
intuitive and creative thinking).
and / or
Skills are described as practical (involving manual dexterity
and the use of methods, material, tools and instruments).
1. Terms and definitions prEN 15628
Levels of qualification
Maintenance Manager /
Asset Manager
Management /
Engineering training +
work experience
Maintenance Supervisor /
Engineer
Technically-based
training + work
experience
Maintenance Technician Specialist
Maintenance Technician
Vocational training II +
work experience
Vocational training I
1. Terms and definitions prEN 15628
Procedure
Documents and instructions which indicate standardized
practices, operational instructions and technical rules referred
to the involved competence.
1. Terms and definitions prEN 15628
Qualification
A formal outcome of an assessment and / or validation
process which is obtained when a competent body determines
that an individual has achieved learning outcomes to given
standards.
1. Terms and definitions prEN 15628
2. Maintenance tasks prEN 15628
Economics :
No task
Customer oriented tasks :
Commissioned tasks
Process oriented tasks, related to
Risks, steps, equipments, resources, monitoring, recording
Staff oriented tasks:
Team working and cooperation
Cooperation with external partners :
Target oriented and safety-conscious cooperation
2.1. Maintenance Technician Specialists
Economics :
Budget planning, cost monitoring, performance controlling
Customer oriented tasks :
Ensure availability and compliance to schedules and quality
Process oriented tasks, related to
Risks, job safety, safety culture, strategies implementation
Staff oriented tasks, related to
Leading, planning, assessments, training, responsibility
Cooperation with external partners :
Coordinating, briefing, budget-, schedule-, quality control
2.2. Tasks of Maintenance Supervisors
Economics :
Budget planning, cost management, Performance controlling
Customer oriented tasks :
Ensure availability, quality, low costs, LCC, communication
Process oriented tasks :
Establishing plant specific strategies, KPIs, SHE, Know-how
Staff oriented tasks :
Optimizing required work force and ensure qualification
Cooperation with external partners :
Keeping good relations and erecting a network
2.3. Tasks of Maintenance Managers
3. Required competencies (prEN 15628)
Maintenance Technician Specialist :
1. To perform or ensure safe execution of tasks
2. To act promptly in case of failure or malfunction
3. To perform or ensure proper execution of tasks
4. To ensure availability of supporting material
5. To coordinate / supervise onsite tasks
6. To ensure quality of maintenance tasks
7. To use and ensure the use of IT systems
3. Required competencies (prEN 15628)
Maintenance Supervisor :
1. To ensure implementation of strategies / policies
2. To plan maintenance tasks
3. To organise maintenance resources (incl. personnel)
4. To ensure compliance with regulations (SHE)
5. To ensure and improve efficiency and effectiveness
6. To manage the performance of contractors
7. To communicate and fulfil entrepreneurial obligation
3. Required competencies (prEN 15628)
10 main skills needed for Maintenance professionals -
answered by 16 Maintenance Managers (CH)
3. Required competencies (VocTrainMaint)
1 Method and processes
2 Repair techniques and methods
3
4
Fault finding techniques
Preventive activities
5
6
Condition based maintenance
Reliability
7
8
9
10
Maintenance Concepts/Methodologies
Measurements
Maintainability
Documentation
Ranking of max. training pay back answered by 18
experienced Maintenance Supervisor (CH)
1
2
Reliability
Condition based maintenance
3 Fault finding techniques
4
5
Maintainability
Documentation
6
7
Preventive activities
Methods and processes
8
9
10
Repair techniques and methods
Maintenance Concepts / Methodologies
Guiding, control, analysis of work performed
3. Required competencies (VocTrainMaint)
Relevant competences and skills for Maintenance
Technician Specialists and Maintenance Supervisors
8 answers (CH)
Structure / Organization
Work Planning/Scheduling
Team Working/ Commcation
English Language
Information Technology
Training and Instructions
Quality Assurance
Environment
Automation
Occupational Health / Safety
Technician
1
4
8
3
7
5
8
6
7
8
Supervisor
6
8
8
7
8
6
8
6
7
8
3. Required competencies (VocTrainMaint)
Relevant competences and skills for Maintenance
Technician Specialists and Maintenance Supervisors
8 answers (CH)
Objectives-Policies-Strategies
Concepts and Methodologies
Restoration Techniques
Terminology
Partnering and Contracting
Laws and Regulations
Condition Based Maintenance
Fault Finding Techniques
Continuous Improvement
Documentation
Technician
1
3
8
3
6
7
5.5
7
6
7
Supervisor
8
8
5.5
8
8
8
7
7
8
8
3. Required competencies (VocTrainMaint)
Relevant competences and skills for Maintenance
Technician Specialists and Maintenance Supervisors
7 answers (CH)
Energy Efficiency &
Sustainable Technology
Materials Technology (8
answers)
Heating/Climate/Cooling/
Ventilation
Disposal Management
Contingency Management
Technician
0
7
2
3
2
Supervisor
5
4
4
4
5
3. Required competencies (VocTrainMaint)
Relevant competences and skills for Maintenance
Technician Specialists
7 answers (CH)
Mechanical competencies
Basics in mechanics
Industrial Hydraulic Systems
Industrial Pneumatic Systems
Bearings
Repair Welding / Coating
None Destructive Testing
Heat Treatment
Vibration Techniques
Tribology
Knowledge
7
7
7
7
7
6
7
7
7
Skills
6
7
7
7
2
2
1
6
7
3. Required competencies (VocTrainMaint)
Relevant competences and skills for Maintenance
Technician Specialists
7 answers (CH)
Electrical / electronic
competences
Basics in Electro techniques
Power distribution
Safety system
Electronics
Programming
Instrumentation & Robotics
Knowledge
7
6
7
6
4
5
Skills
6
4
4
5
4
5
3. Required competencies (VocTrainMaint)
Relevant competences and skills in Automation
64 questionnaires were answered correctly sent-in from:
Switzerland 25, Finland 13, Denmark 5, Sweden 3,
Slovakia 3, Netherlands 2, Hungary 2, Germany 1, Italy 1,
France 1, Poland 1, Portugal 1, Czech Republic 1, Brazil 1,
China 1, Morocco 1, Peru 1, Saudi Arabia 1.
3. Required competencies (EURIAC)
Programmable Logic Controllers, PLC systems
Fault finding in PLC controlled systems
Instrumentation & Robotics
Motors, driver units and servo techniques
Machine safety system
General safety rules and basic safety systems
Safety systems with active components
Facility Management: 7 answers (KSA, CH, DK, FI, HU)
Relevant competences and skills in Automation
Programmable Logic Controllers, PLC systems
Fault finding in PLC controlled systems
Instrumentation & Robotics
Inputs and outputs (sensors and switches)
Motors, driver units and servo techniques
Machine safety system
General safety rules and basic safety systems
Safety systems with active components
Safe PLC systems
3. Required competencies (EURIAC)
Hospitals: 6 answers (CH)
Relevant competences and skills in Automation
Programmable Logic Controllers, PLC systems
Fault finding in PLC controlled systems
Instrumentation & Robotics
Inputs and outputs (sensors and switches)
Motors, driver units and servo techniques
Machine safety system
General safety rules and basic safety systems
Safety systems with active components
Risk analyses
3. Required competencies (EURIAC)
Chemical, Petrochemical: 6 answers (BR, CN, IT, CH)
Relevant competences and skills in Automation
Programmable Logic Controllers, PLC systems
Fault finding in PLC controlled systems
Instrumentation & Robotics
Inputs and outputs (sensors and switches)
Motors, driver units and servo techniques
3. Required competencies (EURIAC)
Food industry: 7 answers (CH; DK, FI, PE)
Relevant competences and skills in Automation
Programmable Logic Controllers, PLC systems
Fault finding in PLC controlled systems
Instrumentation & Robotics
Motors, driver units and servo techniques
Machine safety system
General safety rules and basic safety systems
Safety systems with active components
Risk analyses
Peripherals
Pneumatics
3. Required competencies (EURIAC)
4. Skills and knowledge(Pile Up)
4. Skills and knowledge(Pile Up)
Competence
The proven ability to use
knowledge,
skills and
personal, social and/or methodological ability
Competence is described in terms of responsibility and
autonomy.
Process industry
Operator: Knowledge for participating in maintenance
and repairs
1. To explain about different maintenance strategies
2. To explain equipment manuals
3. To know the working regulations
4. To understand and explain the working principles of
equipment (like pumps, valves, measure & control
equipment, seals, piping)
5. To understand the principles of electricity in relation to
safety
4. Skills and knowledge(Pile Up)
Process industry
Operator: Practical skills for participating in
maintenance and repairs
1. To recognise, explain unsafe or critical situations and
mention possible measures
2. To perform and monitor minor repair and maintenance
work according audited procedures on mechanical,
electrical and instrument field
3. To assist and cooperate with maintenance personnel
4. To organise and use tools for doing proper and safe
maintenance work
5. To monitor the use of reliable equipments and working
methods during maintenance work
4. Skills and knowledge(Pile Up)
Process industry
Operator: Competencies for participating in
maintenance and repairs
1. To instruct a team on all necessary work steps
autonomously
2. To assume responsibility of his/her own safety and of a
team
3. To coordinate his/her own work schedule and the schedule
of a team concerning
4. To report on the state of maintenance in the plant
autonomously and proactively
5. To Propose improvements
4. Skills and knowledge(Pile Up)
5. Learning outcomes
5. Learning outcomes
A paradigm change
Structure of learning outcomes
1. Unit of learning outcomes
2. Title of the unit
3. Prerequisites
4. Worktasks
5. Learning Outcomes
Knowledge Skills - Competence
6. Reference to National Qualification
7. Assessments
5. Learning outcomes
Exemple: Unit of learning outcomes in automation for
the Maintenance Personnel (from the EURIAC project):
(http://www.euriac.eu/Downloads/Units%20of%20L
O_EURIAC_DRAFT.pdf)
5. Learning outcomes
Index: Learning outcomes for Maintenance Technicians
(Pile Up project draft 2012)
Mechanical
Non Destructive Testing (NTD)
Electrical
General tasks
Reporting
Personal competencies
Health, safety, environment
5. Learning outcomes
Assessments
Knowledge and practical skills:
Theoretical test Multiple choice
Example VEMT:
Questions : Machining
Grinding with CBN and diamond wheels
Competencies
Observation
Standardized interviews
6. Discussion and summary
6. Discussion and summary
Competence of the Maintenance Staff
Task-related competence
- Skills
- Knowledge
+
The proven ability to use knowledge,
skills and personal, social and/or
methodological abilities
=
Responsibility and Autonomy !
[Recommendation 2008 / C 111/01/CE of the European Parliament and the Council
of 23 April 2008]
Maintenance:
- Industrial Maintenance
- Maintain Infrastructure
- Building Maintenance
- Hospital Engineering
- Cultural Heritage
- After Sales Services
6. Discussion and summary
Excellence in Maintenance includes:
- Maintenance Policies in line with Corporate Strategies
- Support, Processes, Tools
- Organizational Models - IEC standards Risk Assessment
- KPIs (Availability, Maintainability, OEM, SHE and Quality)
- Continuous Improvement (TPM)
- Compliance with the Budget
6. Discussion and summary
Leadership is based on:
Communication to
- the Executive Management
- Communication to Staff and other Business Units
Compliance with
- Relevant Laws
- Operational Instructions and the current State of the Art
6. Discussion and summary
Duties and Tasks oriented Maintenance:
Clear descriptions of maintenance duties / tasks are a must.
Preparation:
Analysis of the tasks
Procurement of necessary equipments / resources;
Selection of the appropriate working method;
Preparation of the required documentation
Implementation:
Execution of the commissioned activities;
Implementation of activity recording and transfers;
Assure a clear and transparent documentation.
6. Discussion and summary
Structure of the Maintenance Staff:
Three levels are currently implemented world-wide:
Maintenance Manager /
Asset Manager
Engineering training + work
experience
Maintenance Engineer /
Supervisor
Technically-based training +
work experience
Maintenance Technician
Specialist
Vocational training + work
experience
6. Discussion and summary
Competence development for Maintenance staff:
CEN/TC 319 Maintenance Focus: Qualification
CEN/TR 15628: 2007 -
Maintenance Qualification of
Maintenance personnel
Upgrading to a European
Standard EN 15628
Leonardo de Vinci projects Focus: Learning outcomes
Maintenance Manager EuroMaint (2006 to 2008)
Maintenance Engineer /
Supervisor
VocTrainMaint
(2009 to 2011)
Maintenance Technician EURIAC + Pile Up
(2011 to 2013)
6. Discussion and summary
Validation and Qualification of Maintenance staff:
Key points:
- Internal Partnership (Quality Circle, TPM, ..)
- Competent Maintenance Personnel
- Qualified Maintenance Suppliers
- Team working / Communication (TPM)
Leadership is measured by
- Validation of Maintenance Personnel
- Assessing the Performance
- Qualification of Maintenance Suppliers
6. Discussion and summary
The 2
nd
World Maintenance Forum
04 06 September 2013
Palazzo dei Congressi, Lugano, Switzerland
I hope to meet you
in Switzerland.
Thank you for you
kind attention.
Guido Walt
world-maintenance.com
wear-management.ch
Focus on Leadership - The Global Trends