guido walt slides workshop 2013
TRANSCRIPT
-
8/11/2019 Guido Walt Slides Workshop 2013
1/52
Competence development for Maintenance Techniciansand Maintenance Supervisors
Guido WaltWear-Management
Steering Committeeof the WorldMaintenance Forum
Convenor of CEN/TC
319 WG 9Qualification ofMaintenancePersonnel
Good Morning
Education and Training
-
8/11/2019 Guido Walt Slides Workshop 2013
2/52
1. Terms and definitions.
2. Tasks of Maintenance Technicians, Supervisors andEngineers.
3. Required competencies of Maintenance Technicians,
Supervisors and Engineers, based on maintenanceand companies objectives.
4. Skills and knowledge.
5. Learning outcomes a paradigm change.
6. Discussion and summary
Index
-
8/11/2019 Guido Walt Slides Workshop 2013
3/52
Projects:
prEN 15628 is a draft standard from CEN/TC 319.
VocTrainMaint was a Leonardo project running fromOctober 2009 to end of 2011 under the Lifelong
Learning Program and financially supported by theEuropean Commission(http://www.voctrainmaint.eu)
EURIAC is a Leonardo Project running from October2011 to September 2013 under the Lifelong LearningProgram and financially supported by the EuropeanCommission (http://www.euriac.eu).
1. Terms and definitions prEN 15628
-
8/11/2019 Guido Walt Slides Workshop 2013
4/52
Projects:
Pile Up is a Leonardo Project running from October2011 to September 2013 under the Lifelong LearningProgram and financially supported by the EuropeanCommission (http://www.pile-up.eu).
VEMT is a Leonardo Project running from October2012 to September 2014 under the Lifelong LearningProgram and financially supported by the European
Commission (http://www.validmaint.com).
1. Terms and definitions prEN 15628
-
8/11/2019 Guido Walt Slides Workshop 2013
5/52
International standards: Europe
ENV 13269: 2006 - Guideline on preparation ofmaintenance contracts
EN 13306: 2010 - Maintenance Terminology EN 13460: 2009 - Documents for Maintenance
EN 15331: 2009 - Criteria for design, managementand control of maintenance services for buildings
EN 15341: 2006 - Key Performance Indicators CEN/TR 15628: 2007 Qualification of Maintenance
personnel prEN 15628: 2012 Qualification of Maintenance
personnel
1. Terms and definitions prEN 15628
-
8/11/2019 Guido Walt Slides Workshop 2013
6/52
International standards: IEC TC 56
IEC 60300-1 - Dependability managementPart 1: Dependability management systems
IEC 60300-2 - Dependability managementPart 2: Guidelines for dependability management
IEC 60300-3-10 - Dependability managementPart 3-10: Application guide - Maintainability IEC 60300-3-14 - Dependability management
Part 3-14: Application guide - Maintenance and
maintenance support IEC 60300-3-16 - Dependability management (2007)
Part 3-16: Application guide - Guideline for thespecification of maintenance support services
1. Terms and definitions prEN 15628
-
8/11/2019 Guido Walt Slides Workshop 2013
7/52
Terms:
Competence
Knowledge
Skills
Level of qualification
Procedure
Qualification
1. Terms and definitions prEN 15628
-
8/11/2019 Guido Walt Slides Workshop 2013
8/52
Definitions:
Competence
The proven ability to use knowledge, skills and personal,social and/or methodological ability in work or study
situation and in professional and personal development.
Competence is described in terms of responsibility andautonomy.
1. Terms and definitions prEN 15628
-
8/11/2019 Guido Walt Slides Workshop 2013
9/52
Knowledge
The outcome of the assimilation of information throughlearning.
Knowledge is the body of facts, principles, theories andpractices that is related to a field of work or study.
1. Terms and definitions prEN 15628
-
8/11/2019 Guido Walt Slides Workshop 2013
10/52
Skills
The ability to apply knowledge and know-how to completetasks and solve problems.
Skills are described as cognitive (involving the use of logical,intuitive and creative thinking).
and / or
Skills are described as practical (involving manual dexterityand the use of methods, material, tools and instruments).
1. Terms and definitions prEN 15628
-
8/11/2019 Guido Walt Slides Workshop 2013
11/52
Levels of qualification
Maintenance Manager /Asset Manager
Management /Engineering training +work experience
Maintenance Supervisor /Engineer
Technically-basedtraining + workexperience
Maintenance Technician Specialist
Maintenance Technician
Vocational training II +work experience
Vocational training I
1. Terms and definitions prEN 15628
-
8/11/2019 Guido Walt Slides Workshop 2013
12/52
Procedure
Documents and instructions which indicate standardizedpractices, operational instructions and technical rules referredto the involved competence.
1. Terms and definitions prEN 15628
-
8/11/2019 Guido Walt Slides Workshop 2013
13/52
Qualification
A formal outcome of an assessment and / or validationprocess which is obtained when a competent body determinesthat an individual has achieved learning outcomes to given
standards.
1. Terms and definitions prEN 15628
-
8/11/2019 Guido Walt Slides Workshop 2013
14/52
2. Maintenance tasks prEN 15628
-
8/11/2019 Guido Walt Slides Workshop 2013
15/52
Economics :No task
Customer oriented tasks :Commissioned tasks
Process oriented tasks, related toRisks, steps, equipments, resources, monitoring, recording
Staff oriented tasks:
Team working and cooperation
Cooperation with external partners :Target oriented and safety-conscious cooperation
2.1. Maintenance Technician Specialists
-
8/11/2019 Guido Walt Slides Workshop 2013
16/52
Economics :Budget planning, cost monitoring, performance controlling
Customer oriented tasks :Ensure availability and compliance to schedules and quality
Process oriented tasks, related toRisks, job safety, safety culture, strategies implementation
Staff oriented tasks, related to
Leading, planning, assessments, training, responsibility
Cooperation with external partners :Coordinating, briefing, budget-, schedule-, quality control
2.2. Tasks of Maintenance Supervisors
-
8/11/2019 Guido Walt Slides Workshop 2013
17/52
Economics :Budget planning, cost management, Performance controlling
Customer oriented tasks :Ensure availability, quality, low costs, LCC, communication
Process oriented tasks :Establishing plant specific strategies, KPIs, SHE, Know-how
Staff oriented tasks :
Optimizing required work force and ensure qualification
Cooperation with external partners :Keeping good relations and erecting a network
2.3. Tasks of Maintenance Managers
-
8/11/2019 Guido Walt Slides Workshop 2013
18/52
3. Required competencies (prEN 15628)
-
8/11/2019 Guido Walt Slides Workshop 2013
19/52
Maintenance Technician Specialist :1. To perform or ensure safe execution of tasks
2. To act promptly in case of failure or malfunction
3. To perform or ensure proper execution of tasks
4. To ensure availability of supporting material
5. To coordinate / supervise onsite tasks
6. To ensure quality of maintenance tasks
7. To use and ensure the use of IT systems
3. Required competencies (prEN 15628)
-
8/11/2019 Guido Walt Slides Workshop 2013
20/52
Maintenance Supervisor :1. To ensure implementation of strategies / policies
2. To plan maintenance tasks
3. To organise maintenance resources (incl. personnel)
4. To ensure compliance with regulations (SHE)
5. To ensure and improve efficiency and effectiveness
6. To manage the performance of contractors
7. To communicate and fulfil entrepreneurial obligation
3. Required competencies (prEN 15628)
-
8/11/2019 Guido Walt Slides Workshop 2013
21/52
10 main skills needed for Maintenance professionals -answered by 16 Maintenance Managers (CH)
3. Required competencies (VocTrainMaint)
1 Method and processes2 Repair techniques and methods
3
4
Fault finding techniques
Preventive activities56
Condition based maintenanceReliability
789
10
Maintenance Concepts/MethodologiesMeasurementsMaintainabilityDocumentation
-
8/11/2019 Guido Walt Slides Workshop 2013
22/52
Ranking of max. training pay back answered by 18experienced Maintenance Supervisor (CH)
12
ReliabilityCondition based maintenance
3 Fault finding techniques
45 MaintainabilityDocumentation
67
Preventive activitiesMethods and processes
89
10
Repair techniques and methodsMaintenance Concepts / MethodologiesGuiding, control, analysis of work performed
3. Required competencies (VocTrainMaint)
-
8/11/2019 Guido Walt Slides Workshop 2013
23/52
Relevant competences and skills for MaintenanceTechnician Specialists and Maintenance Supervisors
8 answers (CH)Structure / OrganizationWork Planning/SchedulingTeam Working/ Commcation
English LanguageInformation TechnologyTraining and InstructionsQuality AssuranceEnvironmentAutomationOccupational Health / Safety
Technician148
3758678
Supervisor688
7868678
3. Required competencies (VocTrainMaint)
-
8/11/2019 Guido Walt Slides Workshop 2013
24/52
Relevant competences and skills for MaintenanceTechnician Specialists and Maintenance Supervisors
8 answers (CH)Objectives-Policies-StrategiesConcepts and MethodologiesRestoration Techniques
TerminologyPartnering and ContractingLaws and RegulationsCondition Based MaintenanceFault Finding TechniquesContinuous ImprovementDocumentation
Technician138
367
5.5767
Supervisor88
5.5
8887788
3. Required competencies (VocTrainMaint)
-
8/11/2019 Guido Walt Slides Workshop 2013
25/52
Relevant competences and skills for MaintenanceTechnician Specialists and Maintenance Supervisors
7 answers (CH)Energy Efficiency &Sustainable Technology
Materials Technology (8answers)Heating/Climate/Cooling/Ventilation
Disposal ManagementContingency Management
Technician
0
7
2
32
Supervisor
5
4
4
45
3. Required competencies (VocTrainMaint)
-
8/11/2019 Guido Walt Slides Workshop 2013
26/52
Relevant competences and skills for MaintenanceTechnician Specialists
7 answers (CH)Mechanical competenciesBasics in mechanicsIndustrial Hydraulic Systems
Industrial Pneumatic SystemsBearingsRepair Welding / CoatingNone Destructive Testing
Heat TreatmentVibration TechniquesTribology
Knowledge
77
7776
777
Skills
67
7722
167
3. Required competencies (VocTrainMaint)
-
8/11/2019 Guido Walt Slides Workshop 2013
27/52
Relevant competences and skills for MaintenanceTechnician Specialists
7 answers (CH)Electrical / electroniccompetences
Basics in Electro techniques
Power distributionSafety system
ElectronicsProgrammingInstrumentation & Robotics
Knowledge
7
67
645
Skills
6
44
545
3. Required competencies (VocTrainMaint)
-
8/11/2019 Guido Walt Slides Workshop 2013
28/52
Relevant competences and skills in Automation64 questionnaires were answered correctly sent-in from:
Switzerland 25, Finland 13, Denmark 5, Sweden 3,
Slovakia 3, Netherlands 2, Hungary 2, Germany 1, Italy 1,France 1, Poland 1, Portugal 1, Czech Republic 1, Brazil 1,China 1, Morocco 1, Peru 1, Saudi Arabia 1.
3. Required competencies (EURIAC)
Programmable Logic Controllers, PLC systems Fault finding in PLC controlled systemsInstrumentation & Robotics Motors, driver units and servo techniquesMachine safety system General safety rules and basic safety systems Safety systems with active components
-
8/11/2019 Guido Walt Slides Workshop 2013
29/52
Facility Management: 7 answers (KSA, CH, DK, FI, HU)Relevant competences and skills in Automation
Programmable Logic Controllers, PLC systems Fault finding in PLC controlled systems
Instrumentation & Robotics
Inputs and outputs (sensors and switches) Motors, driver units and servo techniques
Machine safety system General safety rules and basic safety systems Safety systems with active components Safe PLC systems
3. Required competencies (EURIAC)
-
8/11/2019 Guido Walt Slides Workshop 2013
30/52
Hospitals: 6 answers (CH)Relevant competences and skills in Automation
Programmable Logic Controllers, PLC systems Fault finding in PLC controlled systems
Instrumentation & Robotics
Inputs and outputs (sensors and switches) Motors, driver units and servo techniques
Machine safety system General safety rules and basic safety systems Safety systems with active components Risk analyses
3. Required competencies (EURIAC)
-
8/11/2019 Guido Walt Slides Workshop 2013
31/52
Chemical, Petrochemical: 6 answers (BR, CN, IT, CH)Relevant competences and skills in Automation
Programmable Logic Controllers, PLC systems Fault finding in PLC controlled systems
Instrumentation & Robotics Inputs and outputs (sensors and switches) Motors, driver units and servo techniques
3. Required competencies (EURIAC)
-
8/11/2019 Guido Walt Slides Workshop 2013
32/52
Food industry: 7 answers (CH; DK, FI, PE)Relevant competences and skills in Automation
Programmable Logic Controllers, PLC systems Fault finding in PLC controlled systemsInstrumentation & Robotics Motors, driver units and servo techniques
Machine safety system General safety rules and basic safety systems Safety systems with active components Risk analysesPeripherals Pneumatics
3. Required competencies (EURIAC)
-
8/11/2019 Guido Walt Slides Workshop 2013
33/52
4. Skills and knowledge (Pile Up)
-
8/11/2019 Guido Walt Slides Workshop 2013
34/52
4. Skills and knowledge (Pile Up)
Competence
The proven ability to use knowledge, skills and personal, social and/or methodological ability
Competence is described in terms of responsibility andautonomy.
-
8/11/2019 Guido Walt Slides Workshop 2013
35/52
Process industryOperator: Knowledge for participating in maintenance
and repairs
1. To explain about different maintenance strategies2. To explain equipment manuals3. To know the working regulations4. To understand and explain the working principles of
equipment (like pumps, valves, measure & controlequipment, seals, piping)
5. To understand the principles of electricity in relation tosafety
4. Skills and knowledge (Pile Up)
-
8/11/2019 Guido Walt Slides Workshop 2013
36/52
Process industryOperator: Practical skills for participating in
maintenance and repairs
1. To recognise, explain unsafe or critical situations andmention possible measures
2. To perform and monitor minor repair and maintenancework according audited procedures on mechanical,electrical and instrument field
3. To assist and cooperate with maintenance personnel
4. To organise and use tools for doing proper and safemaintenance work5. To monitor the use of reliable equipments and working
methods during maintenance work
4. Skills and knowledge (Pile Up)
-
8/11/2019 Guido Walt Slides Workshop 2013
37/52
Process industryOperator: Competencies for participating in
maintenance and repairs
1. To instruct a team on all necessary work stepsautonomously
2. To assume responsibility of his/her own safety and of ateam
3. To coordinate his/her own work schedule and the scheduleof a team concerning
4. To report on the state of maintenance in the plantautonomously and proactively5. To Propose improvements
4. Skills and knowledge (Pile Up)
-
8/11/2019 Guido Walt Slides Workshop 2013
38/52
5. Learning outcomes
-
8/11/2019 Guido Walt Slides Workshop 2013
39/52
5. Learning outcomes
A paradigm change
Structure of learning outcomes
1. Unit of learning outcomes2. Title of the unit3. Prerequisites
4. Worktasks5. Learning Outcomes
Knowledge Skills - Competence
6. Reference to National Qualification7. Assessments
-
8/11/2019 Guido Walt Slides Workshop 2013
40/52
5. Learning outcomes
Exemple: Unit of learning outcomes in automation forthe Maintenance Personnel (from the EURIAC project):(http://www.euriac.eu/Downloads/Units%20of%20L
O_EURIAC_DRAFT.pdf)
-
8/11/2019 Guido Walt Slides Workshop 2013
41/52
5. Learning outcomes
Index: Learning outcomes for Maintenance Technicians(Pile Up project draft 2012) Mechanical Non Destructive Testing (NTD) Electrical General tasks Reporting Personal competencies Health, safety, environment
-
8/11/2019 Guido Walt Slides Workshop 2013
42/52
5. Learning outcomes
Assessments
Knowledge and practical skills:
Theoretical test Multiple choice
Example VEMT:Questions : MachiningGrinding with CBN and diamond wheels
Competencies Observation Standardized interviews
-
8/11/2019 Guido Walt Slides Workshop 2013
43/52
6. Discussion and summary
-
8/11/2019 Guido Walt Slides Workshop 2013
44/52
6. Discussion and summary
Competence of the Maintenance Staff
Task-related competence
- Skills- Knowledge
+The proven ability to use knowledge,skills and personal, social and/ormethodological abilities
=
Responsibility and Autonomy !
[Recommendation 2008 / C 111/01/CE of the European Parliament and the Councilof 23 April 2008]
-
8/11/2019 Guido Walt Slides Workshop 2013
45/52
Maintenance:
- Industrial Maintenance
- Maintain Infrastructure
- Building Maintenance
- Hospital Engineering
- Cultural Heritage
- After Sales Services
6. Discussion and summary
6 i i d
-
8/11/2019 Guido Walt Slides Workshop 2013
46/52
Excellence in Maintenance includes:
- Maintenance Policies in line with Corporate Strategies
- Support, Processes, Tools
- Organizational Models - IEC standards Risk Assessment
- KPIs (Availability, Maintainability, OEM, SHE and Quality)
- Continuous Improvement (TPM)
- Compliance with the Budget
6. Discussion and summary
6 Di i d
-
8/11/2019 Guido Walt Slides Workshop 2013
47/52
Leadership is based on:
Communication to
- the Executive Management
- Communication to Staff and other Business Units
Compliance with
- Relevant Laws
- Operational Instructions and the current State of the Art
6. Discussion and summary
6 Di i d
-
8/11/2019 Guido Walt Slides Workshop 2013
48/52
Duties and Tasks oriented Maintenance:
Clear descriptions of maintenance duties / tasks are a must.
Preparation: Analysis of the tasks Procurement of necessary equipments / resources; Selection of the appropriate working method; Preparation of the required documentation
Implementation: Execution of the commissioned activities; Implementation of activity recording and transfers; Assure a clear and transparent documentation.
6. Discussion and summary
6 Discussion and summary
-
8/11/2019 Guido Walt Slides Workshop 2013
49/52
Structure of the Maintenance Staff:
Three levels are currently implemented world-wide:
Maintenance Manager /Asset Manager
Engineering training + workexperience
Maintenance Engineer /Supervisor
Technically-based training +work experience
Maintenance Technician
Specialist
Vocational training + work
experience
6. Discussion and summary
6 Discussion and summary
-
8/11/2019 Guido Walt Slides Workshop 2013
50/52
Competence development for Maintenance staff:
CEN/TC 319 Maintenance Focus: Qualification
CEN/TR 15628: 2007 -Maintenance Qualification ofMaintenance personnel
Upgrading to a EuropeanStandard EN 15628
Leonardo de Vinci projects Focus: Learning outcomes
Maintenance Manager EuroMaint (2006 to 2008)
Maintenance Engineer /
Supervisor
VocTrainMaint
(2009 to 2011)
Maintenance Technician EURIAC + Pile Up(2011 to 2013)
6. Discussion and summary
6 Discussion and summary
-
8/11/2019 Guido Walt Slides Workshop 2013
51/52
Validation and Qualification ofMaintenance staff:
Key points:
- Internal Partnership (Quality Circle, TPM, ..)- Competent Maintenance Personnel- Qualified Maintenance Suppliers
- Team working / Communication (TPM)
Leadership is measured by
- Validation of Maintenance Personnel- Assessing the Performance- Qualification of Maintenance Suppliers
6. Discussion and summary
Focus on Leadership - The Global Trends
-
8/11/2019 Guido Walt Slides Workshop 2013
52/52
The 2nd World Maintenance Forum04 06 September 2013Palazzo dei Congressi, Lugano, Switzerland
I hope to meet youin Switzerland.
Thank you for youkind attention.
Guido Waltworld-maintenance.comwear-management.ch
Focus on Leadership - The Global Trends