COMPETENCY BASED LEARNING MATERIAL
Sector
:
Qualification Title:
TVET TRAINING METHODOLOGY I
Unit of Competency: Maintain Training Facilities
Module Title: Maintaining Training Facilities
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Trainer’s Methodology I
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Technical Education & Skills Development Authority NATIONAL TVET TRAINERS ACADEMY Marikina City
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TRAINING METHODOLOGY 1 COMPETENCY-BASED LEARNING MATERIALS
No .
Unit of Competency
1.
Plan Training Session
Planning Training Session
2.
Facilitate CompetencyBased Training
Delivering CompetencyBased Training
3.
Supervise Work-Based Learning
4.
Conduct Institutional Assessment
Conducting Assessment
5.
Maintain Training Facilities
Maintaining Facilities
6.
Facilitate elearning(Distance Education Mode)
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Module Title
Code
Institutional
Training
Facilitating e- learning (Distance Education Mode)
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MODULE CONTENTS MODULE 5 : Learning Outcomes
LO 1 Plan maintenan ce activities
MAINTAINING TRAINING FACILITIES Progr ess Check No.
Learning Content
Traini ng Durati on
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 Information Sheet No. 5.2-1
Types of Maintenance.
Perform Task Sheet No. 5.2-1
Prepare Tag-Out Bill
Perform Task Sheet No. 5.2-2
Prepare Equipment/Tools Record w/ Code and Drawing Perform Task Sheet No. 5.1-1
Prepare Equipment Maintenance Schedule (Refer to LO1) NTTATESDA QA SYSTEM
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Perform Task Sheet No. 5.1-2
Prepare Maintenance Inspection Checklist (Refer to LO1) Perform Task Sheet No. 5.2-3
Prepare Inspection Report Perform Task Sheet No. 5.2-4
Prepare Work Request
Perform Task Sheet No. 5.2-5
Prepare Equipment Breakdown/Repair Report Perform Task Sheet No. 5.2-6
Prepare Salvage Report
LO 3 Implement housekeep ing activities
a. Housekeeping System
Information Sheet No. 5.3-1
5S
Housekeeping System Perform Task Sheet No. 5.3-1
Prepare Housekeeping Schedule
Perform Task Sheet No. 5.3-2
Prepare Housekeeping Checklist NTTATESDA QA SYSTEM
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b. OHS and Management Information
Waste
Sheet
Occupational Safety
No.
Health
5.3-2
and
Information Sheet No.5.3-3
Waste Management
Perform Task Sheet No. 5.3-3
Prepare Waste Segregation List LO 4 Reporting and Documentation Document maintenan Information Sheet No. 5.4-1 ce inspections 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. Use the Self-checks, Operation Sheets or Job each section to test your own progress. Date Developed: NTTATraining Methodology I TESDA Maintain Training Facilities QA Developed by: SYSTEM
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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 Scheduling maintenance
Read Information Sheet No. 5.1-1 on Maintenance Program Perform Task Sheet No. 5.1-1 Equipment Maintenance Schedule
Practice Self- check
Make equipment maintenance schedule
Make Maintenance Inspection Checklist Perform Task Sheet No. 5.1-2 on Maintenance Inspection Checklist
Feedback
Resources
Compare answer to self- check key answer
Information Sheet No. 5.1- 1 Types of Maintenance Self- Check key answer
Compare your maintenance schedule to Sample Template
Task Sheet No. 5.1-1 Equipment Maintenance Schedule Sample template
Compare your maintenance inspection checklist to Sample Template
Time
Task Sheet No. 5.1-2 Maintenance Inspection Checklist Sample Template
LO 2 MAINTAIN TRAINING EQUIPMENT AND TOOLS
Learning Content Identifying types of maintenance for equipment and tools Preparing maintenance schedule and relevant documents
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Presentation Read information Sheet No. 5.2-1 On Types of Maintenance
Practice Self-check
Feedback
Resources
Compare answer to Self-check Answer Key
Information Sheet No. 5.2-1 on Types of Maintenance Self-check Self-check answer key Information Sheet No. 5.2-1 on the Preparation of Maintenance Schedule Sample template
Read Information Self-check Compare your Sheet No. 5.2-1 on answer to Selfthe preparation of check Answer Key maintenance schedule and Date Developed: Document No. relevant I Training Methodology Issued by: Page 2 of documents Maintain Training Facilities 124 Prepare TAG-OUT Compare your Developed by: BILL of the work to Sample Task Sheet No 5.2-1 Perform Task Revision # ___ Template Sample Template Sheet No. 5.2-1 particular tag-out equipment/ system/ Tag-out Bill test instruments activity in your
Time
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Competency Summary UNIT OF COMPETENCY MODULE TITLE
Maintain Training Facilities
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
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 Date Developed: Document No. NTTATraining Methodology I Issued by: TESDA Maintain Training Facilities Page 4 of QA 124 Developed by: SYSTEM Revision # ___ • •
• • • • • • •
• • •
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 Documents are kept for future use
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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
ASSESSMENT METHODS: • •
Oral questioning Written test
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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 classification/specification and job requirements.
•
Tools and equipment are tagged-out according to its condition.
• • • •
to
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 • Sample template of documenting and reporting of maintenance activities Date Developed: Document No. NTTATraining Methodology I Issued by: TESDA Maintain Training Facilities Page 7 of QA 124 Developed by: SYSTEM Revision # ___
• •
Equipment and tools securing standards Manufacturer’s Instructions/Manual
METHODOLOGIES: • • •
Lecture/Presentation Self- paced instruction Group discussion
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
ASSESSMENT METHODS: NTTATESDA QA SYSTEM
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• Oral questioning • Written test 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: • • •
Lecture/Presentation Self- paced instruction Group discussion
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. Compare answers to Self- check Key Answer learning evaluation on Answer Types of Maintenance Perform Task Sheet No. 5.2-1 Preparing Tag Out Bill Answer learning evaluation on Compare your work to sample template Preparing Tag Out Bill for Tag Out Bill. Perform Task Sheet No. 5.2-2 Preparing Equipment Record w/ Code & Drawing List Answer learning evaluation on Compare your work to sample template Preparing Equipment Record for Equipment Record w/ Code & w/ Code & Drawing List Drawing. Perform Task Sheet No. 5.1-1 Preparing Equipment Maintenance Schedule (Refer to LO1) Answer learning evaluation Compare your work to sample template Preparing Equipment for Equipment Maintenance Schedule. Maintenance Schedule Perform Task Sheet No. 5.1-2 Preparing Maintenance Inspection Checklist (Refer to LO1) NTTATESDA QA SYSTEM
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Compare your work to sample template Answer learning evaluation on for Maintenance Inspection Checklist. Maintenance Inspection Checklist Perform Task Sheet No. 5.2-3 Preparing Inspection Report Compare your work to sample template for Inspection Report. Answer learning evaluation on Inspection Report Perform Task Sheet No. 5.2-4 Preparing Work Request Compare your work to sample template for Work Request. Answer learning evaluation on Work Request Perform Task Sheet No. 5.2-5 Preparing Breakdown/Repair Compare your work to sample template Report for Breakdown/Repair Report. Answer learning evaluation on Breakdown/Repair Report Perform Task Sheet No. 5.2-6 Preparing Salvage Report Compare your work to sample template for Salvage Report. Answer learning evaluation on 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 Answer learning evaluation on to sample template. Preparing Housekeeping Schedule. Perform Task Sheet No. 5.3-2 on Preparing Housekeeping Checklist Compare Answer learning evaluation on template Preparing Housekeeping Checklist
your
answers
to
Sample
Read Information Sheet No. 5.3-2 on Occupational Health and Safety Compare your answers to Self-check Answer learning evaluation on key answer. Occupational Health and Date Developed: Document No. NTTATraining Methodology I Issued by: TESDA Maintain Training Facilities Page 14 of QA 124 Developed by: SYSTEM Revision # ___
Safety Read Information Sheet No. Compare your answers to Self-check 5.3-3 on Waste Management. key answer Answer learning evaluation on Waste Management. Perform Task Sheet No. 5.3-3 on Preparing Waste Segregation list . Answer learning evaluation on Preparing Waste Segregation list .
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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. 5.41 on Reporting and Documentation Process Answer learning evaluation on Reporting and Documenting Process
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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. Contents: • 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. NTTATESDA QA SYSTEM
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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) PLAN
DO
CHECK
ACT
= = = =
PLAN
IMPLEMENT
ASSESS/CORREC T
SUSTAIN
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 to decisions makers Act: Decides on changes needed to improve the process.
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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
Facilities Maintenance
WHERE WHEN NTTATESDA QA SYSTEM
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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? • • • • • • •
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Who Who Who Who Who Who Who
will will will will will will will
manage the activities? monitor and evaluate the operations? prepare the maintenance schedule? implement the program? keep the records? conduct inspection? certify and accept the work?
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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
Plans, directs. Monitors and evaluates team operation. Team Manager
Administrative Officer
Area Head (Structures& Grounds)
Area Head (Equipment & Service Vehicles)
Building/s
Area Head (Ecology)
Tools and Equipment
Electrical Service Vehicles Water/Plumbing
Formulates, Schedules, Supervises/implements and inspect all unit of activities
Communication
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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: • • •
• • 2.
Manpower Money (Financial Resources) Methods and System Machines (Facilities) Materials and Supplies
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
Maintenance Methods and System
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Preventive Corrective Maintenance
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 SCHEDULE
EQUIPMENT MAINTENANCE
EQUIPMENT TYPE
Desktop Computer
EQUIPMENT CODE
Computer 1
LOCATION
Practical Work Area / Computer Laboratory
ACTIVITI ES
1. Clean computers and printers 2.Check computer for viruses 3. Clean computer peripherals
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Schedule for the Month of_____________ MANPOW Dai Eve Wee Eve Mont Remarks ER ly ry kly ry hly Oth 15th er Day Day IT Personnel
x
IT Personnel
X
IT Personnel
x
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4. Check electric and computer connectio ns 5.Turn off unit when not in use or at the end of the day.
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IT Personnel
IT Personnel
x
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 Property Code Number Location Laboratory YES
NO
√ √ √ √ √ √
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: :
Desktop Computer : :
Computer 1 / 1001A Practical Work Area / Computer
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√√? 6. Is the computer unit free from any virus.?
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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 Module Title: Maintaining Training Facilities 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. Time Allotment: 30 mins. Materials and equipment needed: 1 Template #2 2 Sample template #2 3 TR/CBC 4 Inventory of Tools and Equipment 5 Laptop/PC Procedures: 1. Prepare all your reference materials and laptop/PC 2. Identify the same equipment you have chosen in Task Sheet No. 5.1-1. 3. Fill up all items in Template #2. 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.
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Performance Criteria Checklist 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. Feedback to trainees was provided.
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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 c. None of the above NTTATESDA QA SYSTEM
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Answer Key
Model Answer to Self- check On Learning Outcome 2 1. 2. 3. 4. 5.
b. Maintenance Program c. All of the above b. Plan, Do, Check and Act a. Manpower, Money.(Financial Resources), Methods and Systems b. User’s or Manufacturer’s Manuals
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INFORMATION SHEET NO. 5.2-1
Types of Maintenance Learning Objectives: 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. 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. A.
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1.
B.
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. 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
MAINTENANCE
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PLANNED
Preventive
Time-Based
Predictive
ConditionBased
UNPLANNED
Corrective
Controlled
Tag – Out Bill:
Emergency
Breakdow n
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 NTTATESDA QA SYSTEM
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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
SAMPLE TEMPLATE 3: TAG-OUT BILL LOG SERIA L
DANGER/CAUTION TAG-OUT INDEX AND RECORD AUDITS DATE TYPE DESCRIPTION DATE ISSUE ( Danger/Cauti (System Components, Test COMPLET D on) reference ,etc. ED
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01 02 03
1/2/10 2/24/1 0 6/5/10
Danger Warning Caution
Power switch under repair Transformer perimeter fence warning signs installation On-going grinding activity
Prepared by: ______________________ ______________ Trainer Supervisor
1/10/10 3/3/10 6/5/10
Approved: ______
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 Desktop Computer Type Equipment Computer 1 Code 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. NTTATESDA QA SYSTEM
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3. 4. 5. 6. 7.
Use the computer properly. Scan the computer and any removable devices regularly. Properly shut down the computer when not in use. Turn off the AVR/UPS after shutting down the computer. 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 • •
Facilities must be adequately illuminated, clean neat and dry. Keep the area organized so that there are no obstacle lying around on the floor.
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• • TIPS 1. 2. 3. 4. 5. 6.
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. IN PREPARING A CHECKLIST Keep it simple – one page per checklist. Follow a logical sequence. Use bullet enumerated points, if relevant. Consider the 5WH. Avoid making assumptions. 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. 1
Locatio n M 04
Eqpt. Qnt Title No. y G 1001 3 Pipeline Booster Pump
2
M04
G 1002 2
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Training Methodology I Maintain Training Facilities
Descriptio n Welrs Pumps Ltd. Size/Type OK Serial No. A11556-001 B11556-002 Brook Crompton Frame: 280th
Date Developed:
PO No. 10200 GO
Drawin g Ref. 02 1020 E
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
Prevention damage to environment
Prevention of failures, damages.
of the
PLANET Prevention of accidents (to save lives and limbs)
PROPERTIES PEOPLE
SAMPLE TEMPLATE 6 Area Section In-Charge NTTATESDA QA SYSTEM
/
:
INSPECTION REPORT
:
Practical Work Area / Computer Laboratory
:
IT Personnel (Name)
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FACILITY TYPE
INCIDENT
ACTION TAKEN
Printer – HP Overheating Deskjet 695C Monitor No. 1
of
PC Black out
Monitor No. 2
of
PC Static screen
Monitor No. 3
of
PC Half visibility
Sent to HP service center for repair Sent to computer technician Sent to computer technician
screen Sent computer technician
to
PROGRESS / REMARKS Cannot be repaired; replace printer Cannot be repaired; replace monitor Buy monitor parts and replace damaged parts Buy monitor parts and replace damaged parts
Reported by:
Date
Signature Over Printed Name
SAMPLE TEMPLATE 7 :
WORK REQUEST
WORK REQUEST Unit No.
Description: Compressor, instrumentation air, No. 1
5-20 Observation: V-BELTS WORN
Date Reported: Aug. 15, 2010 Reported by:
Should be replaced
Tonet
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Activity:
Date completed: Sign:
Spare parts used:
SAMPLE TEMPLATE 8 : Area Section
/
I
BREAKDOWN / REPAIR REPORT
:
Practical Work Area / Computer Laboratory
:
IT Personnel (Name)
NATURE OF BREAKDOWN Printer – HP Deskjet Overheating 695C FACILITY TYPE
RECOMMENDATION Sent to HP service center for repair
Reported by:
Date
Signature Over Printed Name
Sample Template 9 Area Section
/
:
Practical Work Area / Computer Laboratory
Area Section
/
:
IT Personnel (Name)
FACILITY TYPE Floor
: SALVAGE REPORT
Model
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RECOMMENDATION Store
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back-up Page 42 of 124
Speed Color Printer
cartridge for other floor model printer
Reported by:
Date
Signature Over Printed Name
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TASK SHEET NO. 5.2-1 On Learning Outcome 4 Module Title: Maintaining Training Facilities 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. Time Allotment: 30 mins. Materials and equipment needed: 1. Template #3 2. Sample template #3 3. TR/CBC 4. Inventory of Tools and Equipment 5. Laptop/PC 6. Bond paper, ball pen and pencil 7. Tag-out Bill documents and procedures Steps/Procedures: 1. Prepare all your reference materials and laptop/PC 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. 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
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? Did the trainer monitor the activities?
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TASK SHEET NO. 5.2-2 On Learning Outcome 4 Module Title: Maintaining Training Facilities 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: Materials and equipment needed: 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: 1. Prepare all your reference materials and laptop/PC 2. Fill up all items in Template 5. 3. Observe safety of tools and equipment. 4. 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
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. PPE condition was checked in accordance with the manufacturer’s instruction. The trainer monitors the activities.
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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 (Refer to LO1)
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TASK SHEET NO. 5.2-3 on Learning Outcome No.4 Module Title: Maintaining Training Facilities Learning Outcome: Maintain Training Equipment and Tools Task: Prepare an Inspection Report Learning Objectives: 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: Materials and equipment needed: 1. 2. 3. 4. 5. 6. 7.
Template 6 Sample template 6 TR/CBC Maintenance Inspection Checklist Laptop/PC Ballpen Any Maintenance Inspection Manual/Instruction (if available)
Procedures: Prepare all your reference materials and laptop/PC. Fill up all items in Template 6 based on the Maintenance Inspection Checklist result. 3. Segregate and label inspected equipment. 4. Call your facilitator who will guide you and check your work after doing this activity. 1. 2.
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CRITERIA
Ye s
No
Full utilization of facilities and resources. All needed forms for the task were provided. Safety of tools and equipment was observed in accordance with the manufacturer’s instruction. PPE condition was checked in accordance with the manufacturer’s instruction. All needed manufacturer and instruction manual were provided.
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TASK SHEET NO. 5.2-4 On Learning Outcome 5 Module Title: Maintaining Training Facilities Learning Outcome: Maintain Training Equipment and Tools Task: Prepare a Work Request Learning Objectives: 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: Materials and equipment needed: 1. Template 7 2. Sample template 7 3. TR/CBC 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. 6. Call your facilitator who will guide you and check your work after doing this activity.
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CRITERIA
Ye s
No
Trainer oriented student about the task. All needed forms for the task were provided. Safety of tools and equipment was observed in accordance with the manufacturer’s instruction. PPE condition was checked in accordance with the manufacturer’s instruction. All needed manufacturer and instruction manual were provided. Full utilization of facilities and resources.
TASK SHEET NO. 5.2-5 On Learning Outcome 5 NTTATESDA QA SYSTEM
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Module Title: Maintaining Training Facilities Learning Outcome: Maintain Training Equipment and Tools Task: Prepare a Breakdown/Repair Report Learning Objectives: 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: Materials and equipment needed: 1. 2. 3. 4. 5. 6.
Template 8 Sample template 8 TR/CBC Equipment Record Laptop/PC 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. 6. Call your facilitator who will guide you and check your work after doing this activity.
Performance Criteria Checklist
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CRITERIA
Ye s
No
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? Was there a manufacturer and instruction manual provided?
TASK SHEET NO. 5.2-6 Module Title: Maintaining Training Facilities NTTATESDA QA SYSTEM
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Learning Outcome: Maintain Training Equipment and Tools Task: Prepare Salvage Report
Learning Objectives: 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. Time Allotment: 30 mins. Materials and equipment needed: 1. 2. 3. 4. 5. 6. 7.
Template # 9 Sample template #9 TR/CBC Inventory of Tools and Equipment Laptop/PC Pencil/Pen Manual of Procedures
Procedures: 1. Prepare all your reference materials and laptop/PC 2. Identify the same equipment you have chosen. Indicate the Property Number. 3. Fill up all items in Template #9. 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.
Performance Criteria Checklist CRITERIA
Ye s
No
Appropriate forms and records were provided. NTTATESDA QA SYSTEM
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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.
SELF-CHECK On Learning Outcome 2 Directions: Identify the term described by the sentence. Write your answer on the blank before the number. NTTATESDA QA SYSTEM
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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.
Answer Key NTTATESDA QA SYSTEM
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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
INFORMATION SHEET NO. 5.3-1
THE 5S HOUSEKEEPING SYSTEM
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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 standardized cleanup:
five
Japanese
words
that
described
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.
Seiri (Sort) Shitsuke (Self-Discipline)
Seiton (Systematize)
5S
Seiketsu (Sanitize)
Seiso (Sweep)
SEIRI (SORT) • TIDINESS, ORGANIZATION, • Taking out and disposing of unnecessary items. • Unneeded items are thrown away or disposed. NTTATESDA QA SYSTEM
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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 work routines. • PREPARE a Housekeeping Standard check list. Checklist should be very detailed and stringent. Remember that thoroughness is a requirement of EXCELLENCE. NTTATESDA QA SYSTEM
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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. NTTATESDA QA SYSTEM
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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. Sample Template 10 :
HOUSEKEEPING SCHEDULE
Sector
Information and Communications Technology
Qualification
PC Operation NCII
Section/Area
Practical Work Area / Computer Laboratory
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ACTIVITIES 1. Clean computers and printers 2. Clean computer tables and chairs 3. Arran ge table and chairs 4. Clean floor 5. Clean walls and windows 6. Dispo se waste
MANPOW ER
Schedule for the Month of ________________ I
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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. NTTATESDA QA SYSTEM
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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 : CHECKLIST Section/Area: In- Charge: YES
NO
HOUSEKEEPING INSPECTION
Practical work Area , Computer Laboratory
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?
Inspected by:
Date:
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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.
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TASK SHEET NO. 5.3-1 Module Title: Maintaining Training Facilities Learning Outcome: Implement Housekeeping Activities Task: Prepare a Housekeeping Schedule Learning Objectives: After reading the Information Sheet No. 5.3-1, Using the Blank Template, YOU MUST be able to prepare a Housekeeping Schedule for a chosen area/areas. Time Allotment: 30 mins. Materials and equipment needed: 1. Template # 10 2. Sample template #10 3. TR/CBC 4. Inventory of Tools and Equipment 5. Laptop/PC 6. Pencil/Pen 7. Bond Paper 8. Manual of Procedures 9. Schedule of Activities of the School/Center 10. Calendar Procedures: 1. Prepare all your reference materials and laptop/PC NTTATESDA QA SYSTEM
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Identify the area or location you have chosen. Fill up all items in Template #10. Tick the box corresponding to each given inspection area. 5. Call your facilitator who will guide you and check your work after doing this activity. 2. 3. 4.
Performance Criteria Checklist CRITERIA
Ye s
No
Did the trainer prepare the needed materials/equipment for the task? Was there a full utilization of work areas/resources? Is the safety of tools and equipment observed in accordance with the manufacturer’s instruction? Did the trainer provide feedback to trainees? Was there a manufacturer and instruction manual provided?
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TASK SHEET NO. 5.3-1 Module Title: Maintaining Training Facilities Learning Outcome: Implement Housekeeping Activities Task: Prepare a Housekeeping Checklist Learning Objectives: After reading the Information Sheet No. 5.3-1, using the Blank Template, YOU MUST be able to prepare a Housekeeping Checklist for a chosen area/areas. Time Allotment: 30 mins. Materials and equipment needed: 1. Template # 11 2. Sample template #11 3. TR/CBC 4. Inventory of Tools and Equipment 5. Laptop/PC 6. Pencil/Pen 7. Bond Paper 8. Manual of Procedures 9. Schedule of Activities of the School/Center Procedures: 1. Prepare all your reference materials and laptop/PC 2. Identify the area or location you have chosen. NTTATESDA QA SYSTEM
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Fill up all items in Template #11. Tick the box corresponding to each given inspection area. 5. Call your facilitator who will guide you and check your work after doing this activity. 3. 4.
Performance Criteria Checklist CRITERIA
Ye s
No
Did the trainer prepare the needed materials/equipment for the task? Was there a full utilization of work areas/resources? Is the safety of tools and equipment observed in accordance with the manufacturer’s instruction? Did the trainer provide feedback to trainees? Was there a manufacturer and instruction manual provided?
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SELF- CHECK On Learning Outcome No.3
Instruction: Encircle the correct answer. 1. Arrangement or organization of necessary item in good order to use. a) Seiso/Sweep b) Seiton,systematize c) Seiketsu/standardize 2.
Taking out and disposi9ng of unnecessary items. a) Seiton/Systematize b) Seiso/Sweep c) Seiri/Sort
3. Keeping rhe workplace as well as neat. a) Seiso/Sweep b) Seiketsu/Standardize c) Seiton/Systematize 4. Doing things spontaneously without being told. a) Seiri /Sort b) Seiton/Systematize c) Shitsuke/Self-discipline 5. Maintaining the workplace in high standard housekeeping. a) Shitsuke/Self-discipline b) Seiketsu/Standardize c) Seiton/Systematize NTTATESDA QA SYSTEM
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Answer Key
Model Answers to Self-Check On Learning Outcome No.3 1. 2. 3. 4. 5.
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b. Seiton/Systematize c. Seiri/Sort a. Siso/Sweep c. Shitsuke/Self –discipline b. Seiketsu/Standardize
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INFORMATION SHEET NO. 5.3-2 OCCUPATIONAL HEALTH and SAFETY (OH&S) Learning Objectives: After reading this INFORMATION SHEET, YOU MUST be able to understand the importance of Occupational Health and Safety in your workplace. Definition of Terms: Safety – The freedom from danger, injury or damage. Occupational health and safety (OH&S) – is a crossdisciplinary area concerned with protecting the safety ,health and welfare of people engaged in work or employment. As a secondary effect, OHS may also protect co –workers, family members, employers, customers, supplies, nearby communities, and other members of the public who are impacted by the workplace environment. 1. 2.
Since 1950, the International Labour Organization (ILO) and the World Health Organization (WHO have shared a common definition of occupational health. It was adopted by the joint ILO/WHO Committee on Occupational Health at its first session in 1950 and revised at its twelfth session in 1995. The definitions reads: “ Occupational health should aim at: the promotion and maintenance of the highest degree of physical, mental and social well-being of workers in all occupations; the prevention among workers of departures from health caused by their working conditions; the protection of workers in their employment from risks resulting from factors adverse to health; the placing and maintenance of the worker in an occupational environment adapted to his physiological and psychological capabilities; and, to summarize, the adaptation of work to man and each man to his job.” The reasons for establishing good occupational safety and health standards are frequently identified as: • Moral-An employee should not have to risk injury at work, nor should others associated with the work environment. NTTATESDA QA SYSTEM
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Economic- Many governments realize that poor occupational safety and health performance results in cost to state (e.g. through social security payments to the incapacitated, cost for medical treatment, and the lost of “employability” of the worker). Employing organizations also sustain costs in the event of an incident at work ( such as legal fees, fines, compensatory damages, investigation times , lost production, lost goodwill from the workforce, from customers and from the wider community). • Legal – Occupational safety and health requirements maybe reinforced in civil law and/ or criminal law, it is accepted that without the “ encouragement” of potential regulatory action or litigation, many organizations would not act upon their implied moral obligations. •
Occupational health and safety specialists and technicians, also known as safety and health practitioners or occupational health and safety inspectors, help prevent harm to workers, , property, the environment and general public. They promote occupational health and safety within organizations in many ways, such as by advising management pon how to increase worker productivity through raising morale and reducing absenteeism, turnover, and equipment downtime while securing savings on insurance premiums, workers compensation benefits, and litigation expenses. ( industrial engineers, including health and safety, have similar goals, See the section on engineers elsewhere in the Handbook.) Occupational health and safety specialists analyze work environments and design programs to control, eliminate, and prevent disease or injury caused by chemical ,physical, radiological, and biological agents or ergonomic factors that involve the impact of equipment design on a worker’s comport or fatigue. They may conduct inspections and inform the management of a business which areas may not be in compliance with state and federal laws or employer policies, in order in order to gain their support for addressing these areas. They advise management on the cost and effectiveness of safety and health programs. OHS in Relation to Waste Management and Disposal of Dangerous Chemicals Infectious waste can be divided into three primary groups. These include:
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Liquid waste such as blood, other bodily fluids or culture media which is known or suspected to be contaminated with a disease agent. 2. Soft materials such as dressings, bandages, bedding, toweling etc. that are saturated to the point that they are capable of releasing blood, body fluids or other potentially infectious materials when handled and compressed. 3. Any object commonly referred to as sharp, that has been contaminated with blood, body fluids or other infectious agent which could penetrate the skin or could do so if broken. Example of sharps waste include: broken glass ,pipettes (glass and hard plastic) ,scalpel blades and lancets. 1.
Liquid or Special waste-Determination and disposal are coordinated by the Department of Environment Health and safety in accordance with local, state and federal regulations. Liquid or special wastes include but is not limited to: • Bacteriocidal or sanitizing solutions • Concrete and asphalt sealants • Degreasing agents • Floor sealers, waxes and strippe4rs • Heating or air – conditioning treatment solutions • Lubrication oils • Paints, latex and oil- based • Related paint products thinners, solvent and strippers • Pesticide or herbicide products • Sludge wastes, including cooling tower sludge • Vehicles maintenance fluids • Water treatment solutions Radioactive Waste- Determination and disposal are coordinated by the Radiation Safety Office in accordance with local, state and federal regulations. Radioactive waste includes, but is not limited to: • General laboratory refuse (e.g. , glassware, paper, etc.) that is contaminated with radioactive materials. • Liquid wastes which includes a radioactive material component, and • The remains of animals that contain radioactive materials as a result of administration of such material for research.
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Radioactive waste is required to be labeled in accordance with procedures established by the radiation safety office and typically exhibits the universal radiation precaution symbol for radiation. Hazardous or Chemical Waste- Determination and disposal are coordinated by the Department of Environment Health and Safety in accordance with local, state and federal regulations. Hazardous or chemical waste includes but is not limited to any stock chemical or chemical reagent that may inhibit one or more of the following physical hazards. Corrosivity- The material has a pH , whether acidic or basic, that will corrode steel or injure human tissue. This includes materials with a pH less than 5 or greater than 10, regardless of strength of the acid or base. • Ignatibility- The material presents a significant fire hazard at room temperature. • Reactivity- The material reacts violently with water, forms potentially explosive mixtures with water ,generate toxic gases, vapors or fumes when mixed with waste, or is unstable and can undergo a violent physical change. • Toxicity- The materials exhibits a significant characteristic or toxicity to human health or the environment. •
GOOD OH&S PRACTICE Disaster Plan There should be plan in place to deal with any emergency. The nature of emergency can vary from fire and chemical spills, and all the obvious hazard that these present, to power and water failures that can lead to unsafe working conditions. Training and Providing Relevant Information Awareness of the problems and positive approach to prevention is the key to good OH&S practice. Many accidents and injuries can be avoided by providing staff with appropriate training. Up to date information regarding safe work practices, equipment safety and chemical information should be readily available in the workplace. Much of this information is available as poster and charts. The benefits of this can be seen in staff morale, productivity and the NTTATESDA QA SYSTEM
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quality of work. Other benefits can be seen in terms of reduced in insurance premium, compensations and rehabilitation claims. Work and Storage areas With the safety of material in mind, work and storage areas should be designed, constructed, and equipped to ensure that there is minimum risk to archive material or staff. Work and storage areas must be kept free of food and drinks, harmful contaminants, pollutants or vermin and harmful radiation. Exits, passageway, stairs and equipment access areas should be kept clear of obstruction; including stored materials or materials and equipment in use. Obstruction can be potential hazard. Near MISS and Hazardous Incidents and Accident Investigation Near misses and hazardous incidents are those in which no one gets hurt and where no material or equipment is damage, but have the potential to cause damage or harm. Step should be taken to eliminate causes as soon as possible, and while rectifying initial problem ensures that is does not create a danger to anyone else. Regular safety inspections of a workplace can help to ensure that wherever possible accidents are prevented from occurring. It is very useful to develop a safety check list that is appropriate to the workplace. Supervisors should be trained to understand and recognize the occupational health and safety risk and needs in the area they are responsible for. This will enable them to fulfill their duty in regard to accidents are work related accidents which results in serious injury. An incident is any non-work related fatality which occurs on work premises. Dangerous are occurrences are occurrences which may not necessarily result in injury but which endanger the health and safety of an employee at a workplace, and arise from operations which are carried out in the workplace. Records of reports and witness statements of notifiable accidents, incidents and dangerous occurrences will need to be preserved in the event of future claims or litigation. There are also valuable in identifying hazard and improvements that may still be needed to prevent further accidents. First Aid
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First Aid Officers are responsible for taking positive action to prevent further injury to staff, to render fist aid treatment in accordance with their approved training, and to keep record of treatment provided. First Aid Officers are also responsible for ensuring that the first aid box in their workplace is kept fully stock and accessible, and for ensuring that the rest room or first aid room is kept in good condition. OH&S LEGISLATION AND POLICIES BOOK FOUR OF THE LABOR CODE OF THE PHILIPPINES pertains to the HEALTH, SAFETY , ANDSOCIAL WELFARE of employees in the workplace. The acts listed below have introduced significant changes to the health and safety and social welfare benefits of all workers. Thus,relevant provisions of these laws are included under BOOK 4 of the Labor Code. Republic Act No.8282 or the ‘ Social Security System Act of 1997” Republic Act No.8291 ‘Government Service Insurance System (GSIS) Act of 1997” • Republic Act No.7699 or the “Limited Portability Scheme,” Republic Act No.7875, or the “ National Health Insurance Act 1995,” • Republic Act No. 7742,” or the “ or the “ Pag-ibig Fund,” • Republic Act No, 8425,”” or the ‘Social Reform and Poverty Alleviation Act”. These are number of policies that pertain to the occupational health and safety of people in the workplace. These policies are promulgated by Occupational Health and Safety Center (OHSC) under the office of the Department of Labor and Employment. Among 5these policies are: • •
•
• • • • • • •
National Workplace Policy cy on STD/HIV/AIDS Implementing Rules and Regulations on STD/HIV/AIDS List of Hazardous Work of Children Safety in the Co0nstruction Industry Substance/Drug Abuse Policy for Tuberculosis Control in the Philippines Department Order 47-03: Guidelines on SARS Prevention and Control in the Workplace.
Ways to learn and understand SAFETY • Accidental Experience. Experience which were Date Developed: NTTATraining Methodology I TESDA Maintain Training Facilities QA Developed by: SYSTEM
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•
Safety Education. A method which makes us aware of dangerous situations Avoid accidents or injury.
Blank space for OHS & SAFETY
Genesis 43:9 I myself will guarantee his safety; you can hold me personally responsible for him. If I don’t bring him back to you and set him here before you. I will bear the blame before you all my life. OBJECTIVE OF THE OHS STANDARD To protect working man against the dangers of injury, sickness or death through safe and healthful working conditions, thereby assuring the conservation of valuable manpower resources and the prevention of loss or damage to lives and properties.
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PERSONAL RESPONSIBILITIES FOR SAFETY • • • • • • •
Observe all precautions related to your work. Report unsafe conditions or any equipment or materials you think might be unsafe. Warn others of hazards. Report any injury or ill health. Wear protective clothing. Be safety conscious. Always inspect equipment and associated attachments for damage before using.
SAFETY PRECAUTIONS • • • •
Concerning Facilities Facilities must be adequately illuminated, clean, neat and dry. Keep the area organized so that there are no obstacles lying around the floor. The equipment and the floor area around the equipment must be free from dust and any chipping. Workbenches must be strong and sturdy, and their surfaces treated with nonskid materials.
Concerning people When working wear appropriate protective clothing properly. Never remove safety devices or safety covers from equipment. Be careful of high voltage .Never touch switches with wet hands. Should an accident occur, It should be reported immediately to proper authority no matter how trivia. INFORMATION SHEET NO. 5.3-3 • • • •
WASTE MANAGEMENT Learning Objectives: After reading this information Sheet, YOU MUST be able to understand the importance of Waste Management Definition of Terms Ecological Waste Management- The proper handling of the things we throw away in a manner that does not harm anyone or anything, be it human, animal or the environment.
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Waste Management is the collection, transport, processing, recycling or disposal of waste materials, usually ones produced by human activity, in an effort to reduce their effect on human health or local aesthetics or amenity. A sub focus in recent decades has been to reduce the effect of waste materials on the enviro0nment and to recover resources from them. Waste management can involve solid, liquid or gaseous substances with different methods and fields of expertise for each. The waste hierarchy refers to the “3 Rs” Reduce . reuse and recycle. Which classify waste management strategies according to their desirability in terms of waste minimization. The waste hierarchy remains the cornerstone of most waste minimization strategies. The aim of waste hierarchy is to extract the maximum practical benefit from products and to generate the minimum amount of waste. Presidential Decree ( PD ) 1152, “ The Philippines Environment Code,” Which took effect in 1997, provides a basis for an integrated waste management regulation starting from waste source to methods of disposal. PD 1152 has further mandated specific guidelines to manage municipal wastes (solid and liquid), sanitary landfill and incineration, and disposal sites in the Philippines. In 1990, the Philippines Congress enacted the toxic Substances, Hazardous and Nuclear Wastes Control Act, commonly known as Republic Act (RA) 6969. A law designed to respond to increasing problems associated with toxic chemicals and hazardous and nuclear wastes. RA 6969 mandates control and management of import, manufacturer. Process, distribution, use, transport, treatment, and disposal of toxic substances and hazardous and nuclear wastes in the country. The Act seeks to protect public health and the environment from unreasonable risk posed by these substances in the Philippines. Apart from the basic policy rules and regulations of RA 6969, hazardous waste management must also comply with the requirements of other specific environmental laws, such as PD 934 (Pollution Control Law), PD 1586 (Environmental Impact Assessment System Law), RA 8749 (Clean Air Act ) and RA 9003 (Ecological Solid Waste Management Act) and their implementing rules and regulations.
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Segregated Waste = Resources Mixed Waste = Garbage To reduce waste…
SEGREGATE
Recycle NonBiodegradable
Compost Biodegradable
SAMPLE WASTE SEGREGATION LIST
Every area in our workplace generate waste. It is part of every worker’s responsibility to make the workplace not only clean but also sanitized and free from any hazards. It is also the company’s task to develop a system to identify the waste generated in the area and considers the ways of their proper disposal. Hence, a waste segregation list must be put together and implemented.
Below is sample Waste Segregation list of the Practical Work Area/ Computer Laboratory
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Sample Template No. 12 :
Section / Area
GENERATED / ACCUMULATED WASTE
WASTE SEGREGATION LIST
Practical Work Area / Computer Laboratory
WASTE SEGREGATED METHOD RECYCLE
1. Paper
COMPOST
DISPOSE
/
2. Pens
/
3.
/
Diskette/Dis cs
SAMPLE WASTE SEGREGATION LIST
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Learning Outcome: Implement Housekeeping Activities Task: Prepare a Waste Segregation List Learning Objectives: After reading the Information Sheet No. 5.3-3, Using the Blank Template, YOU MUST be able to prepare a Waste Segregation List. Time Allotment: 30 mins. Materials and equipment needed: 1. Template # 12 2. Sample template #12 3. TR/CBC 4. Inventory of Tools and Equipment 5. Laptop/PC 6. Pencil/Pen 7. Bond Paper 8. Manual of Procedures 9. Schedule of Activities of the School/Center 10. Calendar Procedures: 1. Prepare all your reference materials and laptop/PC 2. Identify the area or location you have chosen. 3. Fill up all items in Template #12. 4. Tick the box corresponding to each given inspection area. 5. Call your facilitator who will guide you and check your work after doing this activity.
Performance Criteria Checklist CRITERIA
Ye s
No
Materials/equipment was prepared. NTTATESDA QA SYSTEM
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PPE condition was checked in accordance with the manufacturer’s instruction Appropriate forms and records were provided. Full utilization of areas/resources. Manufacturer and instruction manual was provided.
SELF-CHECK On Learning Outcome 3
Instruction: Encircle the correct answer. NTTATESDA QA SYSTEM
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1.
It is a cross- disciplinary area concerned with protecting the safety, health and welfare of people engaged in work or employment. a) Occupational Health and Safety b) International Labor Organization
2. They analyze work environments and design programs to control, eliminate, and prevent disease or injury caused by chemical, physical, radiological, and biological agents or ergonomic factors that involved the impact or equipment design on a worker’s comfort or fatigue. a) Occupational health and safety technicians b) Occupational health and safety specialists c) Health physicists 3.
They are responsible for taking positive action to prevent further injury to staff to render first and treatment in accordance with their approved training, and to keep a record of treatment provided. a) Supervisors b) Health and safety specialists c) First aid officers
4. This refers to the 3Rs which classify waste management strategies according to their desirability in terms of waste minimization. a) Waste hierarchy b) Waste management c) Waste Segregation 5.
It is the collection, transport, processing, recycling or disposal of waste materials usually ones produced by human activity, in an effort to reduce their effect on human health or local aesthetics or amenity. a) Waste hierarchy b) Waste management c) Waste segregation
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Model Answer to Self- Check On Learning outcome 3 1. 2. 3. 4. 5.
a. Occupational Health and Safety b. Occupational Health and Safety specialists c. First aid officers Waste hierarchy Waste management
INFORMATION SHEET NO. 5.4-1
REPORTING AND DOCUMENTATION PROCESS Learning objective: NTTATESDA QA SYSTEM
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After reading this INFORMATION SHEET , YOU MUST be able to understand the process of reporting and documenting maintenance activities. Definition of Terms Planning involves the selection of objectives and the determination of the policies, programs, and procedures to be used for the achievement of the selected objectives. Scheduling is a method of planning that cites specific objectives to be accomplished in relation to time…Inherent maintenance program is the use of schedules to delineate when specific types of maintenance are to be performed….The major thrust of work scheduling is to improve the efficiency of the maintenance department. Responsibilities that are normally assigned to the maintenance department are the health and safety of the public and employees, minimization of downtime hours on production or building equipment, housekeeping and keeping the general appearance of the facilities presentable. The ultimate goal should be to optimize the use of every maintenance dollar spent in achieving the assigned mission. Reports that lead to the identification of work pertains to how a maintenance department determines requirements for craft labor hours…. The various methods of identifying work are: •
• • • • • • •
complaints emergency service calls foreman’s inspection manufacturer and safety standards periodic maintenance inspection by craftsmen an inspection group formalized planning
Periodic maintenance is preferred over preventive maintenance because a comprehensive program encompasses maintenance operations that go beyond the prevention of equipment breakdown. Properly planned, a periodic maintenance program can effectively identified who, what, when, where, why, and how specific repetitive operations are to be performed . . . expand a system to schedule repetitive inspection and NTTATESDA QA SYSTEM
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maintenance of building equipment, utility distribution systems, janitorial services, groundskeeping and gardening activities, and the painting of buildings. A specific work order is prepared to accomplish each of these types of periodic maintenance system. Where several kinds of maintenance are required for a given item, a separate schedule is established for each operation. For example, a machine tool may have separate schedules for lubrication, electrical checks, mechanical checks, and tolerance checks. For each of these activities, a separate work order is generated at the prescribed time and distributed to the appropriate craft skill. A historical record is a basic component of any maintenance system. “All maintenance and repair activity of an equipment item should be reported for inclusion in an historical record. A single record that contains the complete maintenance history of the item, including preventive maintenance, breakdown, repair, and rebuild data should be maintained. The minimal information required to establish a record in a system should consist of the following four items: • • •
•
an identification number for the piece of equipment or work activity (What) the location of the maintenance work (Where) a determination of what operations are to be performed and how often (Why, when, and How) a judgment as to what craft skills is required to perform the operation (Who)
Inspection would involved periodic inspection of equipment to insure safe and proper operation, assuring that periodic maintenance is performed, control of the quality of the work accomplished by maintenance craftsmen ,inspection of materials and parts received from vendors, and examination of items removed during repair or overhaul operations to determine the feasibility of repair. Maintenance would consist of the lubricating, adjusting, and routine replacement usually classified as preventive maintenance. It would also include work necessary to restore equipment to operation on a quick-fix basis in the event of a breakdown.
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Repair would consist of replacing parts to restore a piece of equipment to full operating condition, and to alleviate undesirable conditions found during periodic maintenance or breakdown. Overhaul would involve the reconditioning of equipment: teardown, replacement, reassembly, and testing. Construction and rehabilitation would consist of building, modifying, and restoring structures. Housekeeping would cover those janitorial and groundskeeping activities necessary to provide clean and orderly facilities an d grounds. Salvage would involve the reclamation and disposition of surplus material and scrap. Organizing in a maintenance department is the grouping of activities necessary to achieve the mission of the department and the assignment of each group to supervisor. In its purest form, organization by operation would consist of separate group ( or individual ) for inspection, maintenance, repair, overhaul, construction, housekeeping and salvage. Examples of Building Equipment Building equipment which are scheduled for periodic maintenance are: 1. Heating, ventilating, and air conditioning system : • Air handling fans and motors • Condensing unit – pumps and fan motor • Hot water boilers • Boiler pumps and motors • Air filters • Water circulation pumps and motors 2. Domestic water system: • Hot water boilers • Hot water circulation pumps and motors • Chilled drinking water system pumps and motors • Urinal flushing system 3.
Fire protection and safety system:
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• Emergency lighting system • Fire detection devices and alarms 4. Internal transport systems: • Elevators • Escalators • Dumbwaiters • Compressed air door system pumps and motors 5. Electrical distribution systems: • Lighting and ballasts • Panels and breakers • Transformer Rationale in Reporting and Documentation The reason for the reporting and documentation process is to collect data that can be used to optimized efficiency and enable cost- effective decisions and actions. For quality, a Documented Procedures Manual in the Reporting and Maintenance of Facilities, is suggested. Reporting Process Based on the inspection report, undertake the following: 1. Analyze inspection report; 2. Investigate condition of facilities based on the inspection report and in conformance with the standard; 3. Prepare repair improvement schedule to correct malfunctions and damage ((if any); 4. Install continues maintenance on facilities. Documentation Process 1. Collecting data shall be the first job to be accomplished. 2. Data collected shall be used as reference for technical information or as a basis to structure the equipment and facilities inventory. 3. The inventory shall be used as one of the bases in planning the maintenance of equipment and facilities as well as in documenting of procedures. NTTATESDA QA SYSTEM
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Types of Documents in the Maintenance of Facilities 1. Equipment and Facilities Inventory. This can also be called construction or engineering documents which shows: o Comprehensive list of equipment/facilities with corresponding number and description o Functional relations between equipment/areas housed by each building o Geographical position/location of equipment and facilities (includes shop layout and vicinity maps) 2. Technical Documentation. maintenance.
Any
document
useful
for
o Mechanical, electrical, architectural, plumbing and equipment plans o List of components and spare parts of each equipment o Parts and functions of areas housed in each building including ducting, if any. o Equipment user manuals with details of the functions, operations, etc. o Work and repair manuals for each equipment or any document explaining how it can be repaired o Maintenance manuals Equipment and Facilities History • •
Information on life of equipment (date of installation/construction, repairs/replacements, refurbishment, etc.) Information in cost of equipment and construction/improvement of facilities (considering also the cost of repairs whether major or minor)
Monitoring, Recording and Reporting 1.
The Trainer shall maintain and keep a complete set of the following documents for each equipment and facility:
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• • •
Inventory Technical information, and Operation and maintenance manuals
2. The following records shall also be maintained and filed in complete sets: • • •
Inspection record Breakdown record, and Repair and maintenance record
3. Records shall be arranged according to: • • • •
Number of breakdowns Maintenance cost Repair and maintenance details, and Material consumption
4. All other information concerning equipment and facilities effectiveness interventions shall be recorded accordingly. 5. All information concerning any operation intervention shall be recorded for monitoring and reporting purposes. 6. Then information necessary for the documentation of works shall be as follows: • • • • •
Maintenance listing Manpower utilization Work backlog Material cost Cost analysis
Storing Documents 1. Available documents must be kept-up-to-date 2. Each document must have a title and a control internal number 3. The list shall mention where certain documents are, considering that not all documents are always in the maintenance division (location and responsible personnel
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SELF-CHECK On Learning Outcome 5 Directions: Choose a best answer for each number. 1. The ultimate goal of the maintenance department would include (a) Optimized the used of every peso spent in achieving the assign tasks/mission. (b)The health and safety of the public and employees (c) Housekeeping and keeping general appearance of the facilities presentable 2. A historical record (a) Is the same as a work order (b)Should contain all maintenance and repair activity of an equipment item (c) Can be disposed of as soon as the work required is accomplished 3. Inspection would involve (a) Periodic inspection of equipment for insure safe and proper operation (b) Control of the quality of work accomplished by maintenance craftsmen (c) All of the above 4. Maintenance would consists of the following except: (a) Lubricating, adjusting, and replacement usually classified as preventive maintenance (b)Replacing parts to restore a piece of equipment to full operating condition (c) Work necessary to restore equipment to operation on quick-fix basis in the event of breakdown. NTTATESDA QA SYSTEM
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5. Building equipment which are scheduled for periodic maintenance includes, among others, HVAC System, Fire and Safety Systems, except (a) Internal transport systems (b)Domestic water system (c) External electrical system
Model Answer to Self- Check 1. 2. 3. 4. 5.
(a) optimize the use of every peso spent in achieving the assigned tasks/mission (b) should contain all maintenance and repair activity of the equipment item. (c) All of the above. (b) replacing parts to restore a piece of equipment to full operating condition. (c) External electrical system
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Blank Template 1 : EQUIPMENT MAINTENANCE SCHEDULE Equipment Type
:
Property Code / Number
:
Location
: Schedule for the Month of _________________
ACTIVITIE S
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Responsi ble person
Daily
Ever y othe r Day
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Week ly
Every 15th Day
Date Developed:
Monthl y
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Remarks
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Prepared by:
Noted:
_____________________ Trainer
_________________ Supervisor
Blank Template 2:
MAINTENANCE INSPECTION CHECKLIST Equipment Type Property Number
Code
: /
:
Location
:
In - Charge
:
YE S
NO
INSPECTION ITEMS Are the equipment peripherals returned to their places? Is the equipment unit turned off when not in used? Is the equipment in good working conditions? Is the equipment unit arranged for the purpose of safety And ease in maintenance? Write additional Inspection items:
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Prepared by:
Noted:
_____________________ Trainer
_________________ Supervisor
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Blank Template No. 3 : TAG-OUT BILL LOG SERIA L
DANGER/CAUTION TAG-OUT INDEX AND RECORD AUDITS DATE TYPE DESCRIPTION DATE ISSUE ( Danger/Cauti (System Components, Test COMPLET D on) reference ,etc. ED
Prepared by: ______________________ ______________ Trainer Supervisor
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Approved: ______
Date Developed:
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Blank Template No. 4
: OPERATION OF EQUIPMENT
Equipment Type Equipment Code Location Operation Procedures :
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Blank Template No. 5:
EQUIPMENT RECORD W/ CODE AND DRAWING N o.
Locatio n
Eqpt. No.
Qty
Title
Descriptio n
PO No.
Drawin g Ref.
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INSPECTION REPORT Inspection Report # _____
Property ID Number Descriptive Name Location Findings:
Recommendation:
Inspected by:
Reported to:
Date :
Date
Blank Template No. 7 NTTATESDA QA SYSTEM
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WORK REQUEST Unit No.
Description:
5-20 Observation:
Blank Template No. 8
BREAKDOWN / REPAIR REPORT NTTATESDA QA SYSTEM
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Breakdown / Repair Report # _____ Property Number Descriptive Name Location
ID
Findings:
Recommendation:
Inspected by:
Reported to:
Date :
Date
Assigned to :
Received Assignment:
Assigned by:
Assignee:
Date :
Date
Subsequent Taken:
Action Recommendation:
By:
Reported to:
Date :
Date
Blank Template No. 9
SALVAGE REPORT NTTATESDA QA SYSTEM
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Salvage Report # _____
Property ID Number Descriptive Name Model Number
Inspection Rpt. # Date:
Serial Number:
Location Salvageable Parts Descriptive Name
Part Number
Quantity
Inspected by:
Reported to:
Date :
Date
Recommendatio n
Approved by:
Blank Template No. 10 NTTATESDA QA SYSTEM
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HOUSEKEEPING SCHEDULE Qualificati on
:
Station
Area Section
/
:
Tools / Eqpt.
In Charge
-
:
Servic es
ACTIVITIES
Responsib Schedule for the Month of _________________ Week Every le Daily Every Month Remarks Person
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other Day
ly
15th Day
Date Developed:
ly
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Blank Template No. 11 HOUSEKEEPING INSPECTION CHECKLIST
Qualification
:
Area / Section
:
In - Charge
:
YES
NO
CRITERIA 1. 2. 3. 4. 5. 6. 7. 8. 9. 10 . 11 . 12 . 13 . 14 . 15 .
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16 .
Blank Template No 12 WASTE SEGREGATION LIST
Qualificatio n Area Section In - Charge
: /
: :
GENERAL / ACCUMULATED WASTES
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WASTE SEGREGATION METHOD Recycle Compose Dispose
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TM 1 INSTITUTIONAL COMPETENCY ASSESSMENT INSTRUMENT In Maintaining Training Facilities
EVIDENCE PLAN NTTATESDA QA SYSTEM
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1. *Plan and prepares maintenance work schedule in accordance with machine/equipment operating time/condition 2. *Records regular inspection of tools, equipment, and other facilities as per company practices. 3. *Documents maintenance and repair activities. 4. *Disseminates information with other concerned department or personnel on the schedule of work. 5. *Performs housekeeping based on work requirement. 6. Communicates effectively with others if needed in order to ensure safe and effective maintenance operation. 7. *Incorporates safety practices in line with work requirements.
Written Test
The evidence must show that the candidate….
QuestioningOral
PROGRAM : TM 1 Unit of Competency : Maintain Training Facilities Ways in which evidence will be collected:
X
X X
X
X X X
X
8. *Knows and applies regular inspection according to procedures and standards.
X X X
9. *Knows and applies OH & S & 5S procedures. 10. *Disposes waste and dangerous chemicals based on OH&S procedures. 11. Identifies faults and problems in line with Maintenance and repair requirements. 12. Identifies and secures tools, equipment, materials & supplies according to job requirements and manufacturer’s procedures.
X X X X
13. *Segregates and labels non-functional tools and equipment
X
14.
*Checks the condition of PPE.
X
15.
*Keeps documents for future used.
X
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Note: *Critical aspects of competency
Rating Sheet for Oral Questioning / Interview Name: ____________________________________ Module Title: Maintenance of Training Facilities Time: 15 mins. Rating: ______ QUESTIONS Oral Interview (open-ended questions) on the following:
Rating Max. Point
1. Why we need to maintain training facilities? 2. As a CBT Facilitator, how do you prepare your plan in the maintenance of equipment? 3. What is the rationale in reporting and documenting the maintenance of facilities?
Actual Score
25 15 10
TOTAL MAX. POINTS/SCORE
ORAL QUESTIONING: Percentage Wt. 60% Oral Q. Rating = Actual Score x 100 x 60%/Max. Score The candidate’s Oral Questioning Rating was: ______ points
General Comments (Strengths/improvement needed)
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Competent
Not Competent
Signature:
Checked by:
___________________
_________________
Trainer
Facilitator
WRITTEN TEST NAME:_______________________________ Module Title: Maintaining Training Facilities Direction: Choose the best answer for each number. Time Duration: 15mins. NTTATESDA QA SYSTEM
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1. What can we gain from maintaining our facilities? a. Improve morale of human resources b. Reduced operation cost c. All of the above 2. 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 3.
What type of maintenance that performed unexpectedly? a. Unplanned Maintenance b. Planned maintenance c. Predicted maintenance d. Breakdown maintenance
4. It is 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. a. Maintenance b. Tag-out Bill c. System Procedures d. Warning System 5. Inspection would involve a. Periodic inspection of equipment to insure safe and proper operation b. Control of the quality of work accomplished by maintenance craftsman c. All of the above 6. Scheduling is a method of planning that a. Cites specific objectives to be accomplished in relation to time. b. Specifies the work, assignment distributed in relation to skills. NTTATESDA QA SYSTEM
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c. Defines work per employee in relation to place. 7.
A historical record is: a. The same as a work order b. Contain all maintenance and repair activity of an equipment item. c. Dispose as soon as the work required is accomplished.
8. Salvage would involve a. Overhaul or the reconditioning of equipment b. The reclamation and disposition of surplus materials and scrap c. Repair to full operating condition 9. Housekeeping would cover a. Repair or replacing parts to restore a piece of equipment b. Construction and rehabilitation of buildings c. Those janitorial and grounds keeping activities 10.
Periodic maintenance a. Is the same as preventive maintenance b. Encompasses maintenance operations that go beyond the prevention of equipment breakdown. c. Is the result of combining preventive maintenance with corrective maintenance.
WRITTEN TEST: Percentage Wt. 40% Written Test = Total Score x 100 x 40%/Max. Score The participant’s written Test Rating was: ______ points
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FINAL RATING = Written Test + Oral Q Rating
General Comments (Strengths/improvement needed)
Competent
Not Competent
Signature:
Checked by:
___________________
_________________
Trainer
Facilitator
References/Further Reading
Web Pages 1. www.works.com.my/cw/downloads_asap NTTATESDA QA SYSTEM
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2.www.fda.go/Science Research/Field Science 3.www.tesda.gov.ph
Published Books 1. Heintzelman, John E. The Complete Handbook of Maintenance Management by Prentice hall Inc., c. 1976
Unpublished Materials 1. TESDA Equipment Maintenance Management System, NITVET-FEMD, Taguig, MM 2. TM 1 Learning Modules, TESDA, Taguig City
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