guido walt slides workshop 2013

8/11/2019 Guido Walt Slides Workshop 2013

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Competence development for Maintenance Techniciansand Maintenance Supervisors

Guido WaltWear-Management

Steering Committeeof the WorldMaintenance Forum

Convenor of CEN/TC

319 WG 9Qualification ofMaintenancePersonnel

Good Morning

Education and Training


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1. Terms and definitions.

2. Tasks of Maintenance Technicians, Supervisors andEngineers.

3. Required competencies of Maintenance Technicians,

Supervisors and Engineers, based on maintenanceand companies objectives.

4. Skills and knowledge.

5. Learning outcomes a paradigm change.

6. Discussion and summary

Index


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Projects:

prEN 15628 is a draft standard from CEN/TC 319.

VocTrainMaint was a Leonardo project running fromOctober 2009 to end of 2011 under the Lifelong

Learning Program and financially supported by theEuropean Commission(http://www.voctrainmaint.eu)

EURIAC is a Leonardo Project running from October2011 to September 2013 under the Lifelong LearningProgram and financially supported by the EuropeanCommission (http://www.euriac.eu).

1. Terms and definitions prEN 15628


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Projects:

Pile Up is a Leonardo Project running from October2011 to September 2013 under the Lifelong LearningProgram and financially supported by the EuropeanCommission (http://www.pile-up.eu).

VEMT is a Leonardo Project running from October2012 to September 2014 under the Lifelong LearningProgram and financially supported by the European

Commission (http://www.validmaint.com).



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International standards: Europe

ENV 13269: 2006 - Guideline on preparation ofmaintenance contracts

EN 13306: 2010 - Maintenance Terminology EN 13460: 2009 - Documents for Maintenance

EN 15331: 2009 - Criteria for design, managementand 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



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International standards: IEC TC 56

IEC 60300-1 - Dependability managementPart 1: Dependability management systems

IEC 60300-2 - Dependability managementPart 2: Guidelines for dependability management

IEC 60300-3-10 - Dependability managementPart 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 thespecification of maintenance support services



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Terms:

Competence

Knowledge

Skills

Level of qualification

Procedure

Qualification



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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 andautonomy.



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Knowledge

The outcome of the assimilation of information throughlearning.

Knowledge is the body of facts, principles, theories andpractices that is related to a field of work or study.



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Skills

The ability to apply knowledge and know-how to completetasks 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 dexterityand the use of methods, material, tools and instruments).



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Levels of qualification

Maintenance Manager /Asset Manager

Management /Engineering training +work experience

Maintenance Supervisor /Engineer

Technically-basedtraining + workexperience

Maintenance Technician Specialist

Maintenance Technician

Vocational training II +work experience

Vocational training I



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Procedure

Documents and instructions which indicate standardizedpractices, operational instructions and technical rules referredto the involved competence.



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Qualification

A formal outcome of an assessment and / or validationprocess which is obtained when a competent body determinesthat an individual has achieved learning outcomes to given

standards.



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2. Maintenance tasks prEN 15628


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Economics :No task

Customer oriented tasks :Commissioned tasks

Process oriented tasks, related toRisks, 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


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Economics :Budget planning, cost monitoring, performance controlling

Customer oriented tasks :Ensure availability and compliance to schedules and quality

Process oriented tasks, related toRisks, 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


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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


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3. Required competencies (prEN 15628)


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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



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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



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10 main skills needed for Maintenance professionals -answered by 16 Maintenance Managers (CH)

3. Required competencies (VocTrainMaint)

1 Method and processes2 Repair techniques and methods

3

4

Fault finding techniques

Preventive activities56

Condition based maintenanceReliability

789

10

Maintenance Concepts/MethodologiesMeasurementsMaintainabilityDocumentation


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Ranking of max. training pay back answered by 18experienced Maintenance Supervisor (CH)

12

ReliabilityCondition based maintenance

3 Fault finding techniques

45 MaintainabilityDocumentation

67

Preventive activitiesMethods and processes

89

10

Repair techniques and methodsMaintenance Concepts / MethodologiesGuiding, control, analysis of work performed



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Relevant competences and skills for MaintenanceTechnician Specialists and Maintenance Supervisors

8 answers (CH)Structure / OrganizationWork Planning/SchedulingTeam Working/ Commcation

English LanguageInformation TechnologyTraining and InstructionsQuality AssuranceEnvironmentAutomationOccupational Health / Safety

Technician148

3758678

Supervisor688

7868678



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8 answers (CH)Objectives-Policies-StrategiesConcepts and MethodologiesRestoration Techniques

TerminologyPartnering and ContractingLaws and RegulationsCondition Based MaintenanceFault Finding TechniquesContinuous ImprovementDocumentation

Technician138

367

5.5767

Supervisor88

5.5

8887788



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7 answers (CH)Energy Efficiency &Sustainable Technology

Materials Technology (8answers)Heating/Climate/Cooling/Ventilation

Disposal ManagementContingency Management

Technician

0

7

2

32

Supervisor

5

4

4

45



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Relevant competences and skills for MaintenanceTechnician Specialists

7 answers (CH)Mechanical competenciesBasics in mechanicsIndustrial Hydraulic Systems

Industrial Pneumatic SystemsBearingsRepair Welding / CoatingNone Destructive Testing

Heat TreatmentVibration TechniquesTribology

Knowledge

77

7776

777

Skills

67

7722

167



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Relevant competences and skills for MaintenanceTechnician Specialists

7 answers (CH)Electrical / electroniccompetences

Basics in Electro techniques

Power distributionSafety system

ElectronicsProgrammingInstrumentation & Robotics

Knowledge

7

67

645

Skills

6

44

545



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Relevant competences and skills in Automation64 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 systemsInstrumentation & Robotics Motors, driver units and servo techniquesMachine safety system General safety rules and basic safety systems Safety systems with active components


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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



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Hospitals: 6 answers (CH)Relevant competences and skills in Automation


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



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Chemical, Petrochemical: 6 answers (BR, CN, IT, CH)Relevant competences and skills in Automation


Instrumentation & Robotics Inputs and outputs (sensors and switches) Motors, driver units and servo techniques



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Food industry: 7 answers (CH; DK, FI, PE)Relevant competences and skills in Automation

Programmable Logic Controllers, PLC systems Fault finding in PLC controlled systemsInstrumentation & Robotics Motors, driver units and servo techniques

Machine safety system General safety rules and basic safety systems Safety systems with active components Risk analysesPeripherals Pneumatics



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4. Skills and knowledge (Pile Up)


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Competence

The proven ability to use knowledge, skills and personal, social and/or methodological ability

Competence is described in terms of responsibility andautonomy.


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Process industryOperator: Knowledge for participating in maintenance

and repairs

1. To explain about different maintenance strategies2. To explain equipment manuals3. To know the working regulations4. To understand and explain the working principles of

equipment (like pumps, valves, measure & controlequipment, seals, piping)

5. To understand the principles of electricity in relation tosafety



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Process industryOperator: Practical skills for participating in

maintenance and repairs

1. To recognise, explain unsafe or critical situations andmention possible measures

2. To perform and monitor minor repair and maintenancework 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 safemaintenance work5. To monitor the use of reliable equipments and working

methods during maintenance work



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Process industryOperator: Competencies for participating in

maintenance and repairs

1. To instruct a team on all necessary work stepsautonomously

2. To assume responsibility of his/her own safety and of ateam

3. To coordinate his/her own work schedule and the scheduleof a team concerning

4. To report on the state of maintenance in the plantautonomously and proactively5. To Propose improvements



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5. Learning outcomes


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A paradigm change

Structure of learning outcomes

1. Unit of learning outcomes2. Title of the unit3. Prerequisites

4. Worktasks5. Learning Outcomes

Knowledge Skills - Competence

6. Reference to National Qualification7. Assessments


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Exemple: Unit of learning outcomes in automation forthe Maintenance Personnel (from the EURIAC project):(http://www.euriac.eu/Downloads/Units%20of%20L

O_EURIAC_DRAFT.pdf)


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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


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Assessments

Knowledge and practical skills:

Theoretical test Multiple choice

Example VEMT:Questions : MachiningGrinding with CBN and diamond wheels

Competencies Observation Standardized interviews


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Competence of the Maintenance Staff

Task-related competence

- Skills- Knowledge

+The proven ability to use knowledge,skills and personal, social and/ormethodological abilities

=

Responsibility and Autonomy !

[Recommendation 2008 / C 111/01/CE of the European Parliament and the Councilof 23 April 2008]


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Maintenance:

- Industrial Maintenance

- Maintain Infrastructure

- Building Maintenance

- Hospital Engineering

- Cultural Heritage

- After Sales Services


6 i i d


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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 Di i d


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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 Di i d


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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


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Structure of the Maintenance Staff:

Three levels are currently implemented world-wide:

Maintenance Manager /Asset Manager

Engineering training + workexperience

Maintenance Engineer /Supervisor

Technically-based training +work experience

Maintenance Technician

Specialist

Vocational training + work

experience




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Competence development for Maintenance staff:

CEN/TC 319 Maintenance Focus: Qualification

CEN/TR 15628: 2007 -Maintenance Qualification ofMaintenance personnel

Upgrading to a EuropeanStandard 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)




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Validation and Qualification ofMaintenance 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


Focus on Leadership - The Global Trends


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The 2nd World Maintenance Forum04 06 September 2013Palazzo dei Congressi, Lugano, Switzerland

I hope to meet youin Switzerland.

Thank you for youkind attention.

Guido Waltworld-maintenance.comwear-management.ch

Focus on Leadership - The Global Trends