maintain training facilities

COMPETENCY BASED LEARNING MATERIAL

Sector : TVET

Qualification Title: TRAINING METHODOLOGY I

Unit of Competency: Maintain Training Facilities

Module Title: Maintaining Training Facilities

Technical Education & Skills Development AuthorityNATIONAL TVET TRAINERS ACADEMY

Marikina City

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Trainer’s Methodology IMaintain Training Facilities

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TRAINING METHODOLOGY 1

COMPETENCY-BASED LEARNING MATERIALS

No. Unit of Competency Module Title Code

1. Plan Training Session Planning Training Session

2. Facilitate Competency-Based Training

Delivering Competency-Based Training

3. Supervise Work-Based Learning

4. Conduct Institutional Assessment

Conducting Institutional Assessment

5. Maintain Training Facilities

Maintaining Training Facilities

6. Facilitate e-learning(Distance Education Mode)

Facilitating e- learning (Distance Education Mode)

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MODULE CONTENTS

MODULE 5 : MAINTAINING TRAINING FACILITIES

Learning Outcomes

Learning Content Progress Check

No.Training Duratio

n LO 1 Plan maintenance activities

Schedule of Maintenance

Information Sheet No. 5.1-1 Maintenance Program

Perform Task Sheet No.5.1-1 Prepare Equipment Maintenance Schedule

Perform Task Sheet No. 5.1-2 Prepare Maintenance Inspection Checklist

LO 2 Maintain training equipment and tools

Types of MaintenanceInformation 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)

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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 housekeeping 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

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b. OHS and Waste Management

Information Sheet No. 5.3-2 Occupational Health and Safety

Information Sheet No.5.3-3 Waste Management

Perform Task Sheet No. 5.3-3 Prepare Waste Segregation List

LO 4 Document maintenance inspections

Reporting and Documentation

Information Sheet No. 5.4-1 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 Sheets at the end of each section to test your own progress.

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.

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http://www.tesda.gov.ph/

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 activities2. Maintain training equipment and tools 3. Implement housekeeping activities4. 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 ACTIVITIESLearning Content Presentation Practice Feedback Resources Time

Scheduling maintenance Read Information Sheet No. 5.1-1 on Maintenance Program

Perform Task Sheet No. 5.1-1 Equipment Maintenance Schedule

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

Self- check

Make equipment maintenance schedule

Make Maintenance Inspection Checklist

Compare answer to self- check key answer

Compare your maintenance schedule to Sample Template

Compare your maintenance inspection checklist to Sample Template

Information Sheet No. 5.1- 1 Types of MaintenanceSelf- Check key answer

Task Sheet No. 5.1-1 Equipment Maintenance ScheduleSample template

Task Sheet No. 5.1-2 Maintenance Inspection ChecklistSample Template

LO 2 MAINTAIN TRAINING EQUIPMENT AND TOOLS

Learning Content Presentation Practice Feedback Resources Time

Identifying types of maintenance for equipment and tools

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

Self-check Compare answer to Self-check Answer Key

Information Sheet No. 5.2-1 on Types of MaintenanceSelf-check

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Self-check answer keyPreparing maintenance schedule and relevant documents

Read Information Sheet No. 5.2-1 on the preparation of maintenance schedule and relevant documents

Perform Task Sheet No. 5.2-1 Tag-out Bill

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

Perform Task Sheet No. 5.1-1 Equipment Maintenance Schedule (Refer to LO1)

Perform Task Sheet No. 5.1-2 on Maintenance

Self-check

Prepare TAG-OUT BILL of the particular tag-out equipment/ system/ test instruments activity in your workplace

Make Equipment Record w/ Code and Drawing

Make equipment maintenance schedule

Make Maintenance Inspection Checklist

Compare your answer to Self-check Answer Key

Compare your work to Sample Template

Compare your equipment record to Sample Template

Compare your maintenance schedule to Sample Template

Compare your maintenance inspection checklist to

Information Sheet No. 5.2-1 on the Preparation of Maintenance ScheduleSample template

Task Sheet No 5.2-1Sample Template

Task Sheet No. 5.2-2 Equipment Record w/ Code & Drawing ListSample template

Task Sheet No. 5.1-1 Equipment Maintenance ScheduleSample template

Task Sheet No. 5.1-2 Maintenance Inspection Checklist

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Inspection Checklist (Refer to LO1)

Perform Task Sheet No. 5.2-3 on making Inspection Report

Perform Task Sheet No. 5.2-4 on Work Request

Perform task Sheet No. 5.2-5 on Breakdown/Repair Report

Perform task Sheet No. 5.2-6 on Salvage Report

Make inspection report of your equipment and tools based on the result of inspection.

Make work request based on the inspection report

Make breakdown/ repair report based on the requested work

Make salvage report

Sample Template

Compare your inspection report to Sample Template

Compare your work request to Sample Template

Compare your breakdown/repair report to Sample Template

Compare your salvage report to Sample Template

Sample Template

Task Sheet No. 5.2-3 On Inspection reportSample Template

Task Sheet No. 5.2-4 on Work Request Sample Template

Task Sheet No. 5.2-5 Breakdown/Repair ReportSample template

Task Sheet No. 5.2-6 on Salvage ReportSample Template

LO 3. IMPLEMENT HOUSEKEEPING ACTIVITIES


Maintaining Read Information Sheet No.5.3- Self- check Compare your Information Sheet No. 5.3-

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Facilities 1 On 5S Housekeeping System

Perform Task Sheet No.5.3-1 Preparing Housekeeping Schedule

Perform Task Sheet No. 5.3-2 Preparing Housekeeping checklist

Read information Sheet No. 5.3-2 On Occupational Health and Safety

Make Housekeeping Schedule in your respective work area.

Make Housekeeping inspection checklist

Self-check

answer to Answer Key

Compare your answer to Sample Template

Compare your answer to Sample Template

Compare answer to Answer Key

1 On 5S Housekeeping SystemSelf- check Answer Key Sample Template

Task Sheet No. 5.3-1 On Preparing Housekeeping Schedule

Task Sheet No. 5.3-2 On Preparing Housekeeping Checklist

Sample TemplateInformation Sheet No.5.3-2 On Occupational Healthand SafetySelf-checkSelf –check Answer Key

Waste Management

Read Information Sheet No.5.3-3 on Waste Management

Self- check Compare answer to self-check

Information Sheet No.5.3-3 on Waste management

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Perform Task Sheet No. 5.3-3Preparing Waste Segregation List

Make waste segregation list

Answer Key

Compare answer to Sample Template

Self –check

Self-check answer key

Task Sheet No. 5.3-3 Preparing Waste Segregation listSelf-checkSelf –check Answer KeySample Template

LO 4 REPORT AND DOCUMENT MAINTENANCE PROCEDURES


Regular inspections in the work area

Read Information Sheet No. 5.5-1 on Reporting and Documentation Process

Self-check Compare answer to Self-check Answer Key

Information Sheet No.5.1-1 Reporting and Documentation Process

Self-check

Self-check Answer Key

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Document maintenance and repair activities

C. ASSESSMENT PLAN

Written Test: Self-Check

Performance Test: Institutional Assessment with Oral Questioning and Written Tests

D. TEACHER’S SELF-REFLECTION OF THE SESSION

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Competency Summary

UNIT OF COMPETENCY Maintain Training Facilities

MODULE TITLE Maintaining Training Facilities

MODULE DESCRIPTOR:

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

NOMINAL DURATION:

LEARNING OUTCOMES:

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

1. Plan maintenance activities

2. Maintain training equipment and tools

3. Implement housekeeping activities

4. Report and document maintenance procedures

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

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Training resources are identified and classified Proper inventory of training resources are properly listed Concerned department/personnel are informed on the schedule of work according

to standard operating procedure Regular inspection is applied according to procedures and standards Occupational Health and Safety and 5S procedures are applied in maintaining

facilities Disposal of waste and dangerous chemicals are based on Occupational Health and

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

procedures Tools and equipment are identified according to classification/specification and job

requirements Non- functional tools and equipment are segregated and labeled according to

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

instruction Conditions of PPE are checked in accordance with manufacturer’s instructions Regular inspections are recorded as per company practices Maintenance and repair activities are documented Documents are kept for future use

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Learning Outcome Summary

LO1. PLAN MAINTENANCE ACTIVITIES

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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

LO2 Maintain Training Equipment and Tools


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Different Types of maintenance are explained and identified Tools and equipment are identified according to classification/specification and job

requirements. Tools and equipment are tagged-out according to its condition. Non- functional tools and equipment are segregated and labeled according to

classification. Tools and equipment are maintained according to manufacturer’s manual. Safety of tools and equipment are observed in accordance with manufacturer’s

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

CONTENTS:

1. Types of Maintenance2. Executing Regular Maintenance Activities and Routine Servicing Repair3. Maintenance Procedures4. Responding to Failed or Unsafe Equipment5. Securing of Equipment and Tools6. Reporting of Complex Faults or Repair Requirements7. 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 Equipment and tools securing standards Manufacturer’s Instructions/Manual

METHODOLOGIES:


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ASSESSMENT METHOD:


LO3. IMPLEMENT HOUSEKEEPING ACTIVITIES


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

facilities.

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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:


LO4. REPORT AND DOCUMENT MAINTENANCE PROCEDURES


Regular inspections are recorded as per company practices Maintenance and repair activities are documented Documents are kept for future use

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CONTENTS:

Reporting and Documentation Process Types of Documents in the Maintenance of Facilities

CONDITIONS:

Participants must be provided with the following:

Regular inspection procedures and standards Organizational policies Procedures of keeping documents

METHODOLOGIES:


ASSESSMENT METHOD:


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Learning Experiences

Learning Outcome 1

PLAN MAINTENANCE ACTIVITIES

Learning Activities Special Instructions

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

Answer learning evaluation on Maintenance Program

Compare answers to Self- check Key Answer

Perform Task Sheet No. 5.1-1 Preparing Equipment Maintenance Schedule.

Answer learning evaluation on preparing Equipment Maintenance Schedule.

Compare answer with sample template for Equipment Maintenance Schedule

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

Answer learning evaluation on preparing Maintenance Inspection Checklist.

Compare answer with sample template for Maintenance Inspection Checklist

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Learning Experiences

Learning Outcome No.2

Maintain Training Equipment and Tools

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

Answer learning evaluation on Types of Maintenance

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

Answer learning evaluation on Preparing Tag Out Bill

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

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

Perform Task Sheet No. 5.1-1 Preparing Equipment Maintenance Schedule (Refer to LO1)

Answer learning evaluation Preparing Equipment Maintenance Schedule

Compare answers to Self- check Key Answer

Compare your work to sample template for Tag Out Bill.

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

Compare your work to sample template for Equipment Maintenance Schedule.

Perform Task Sheet No. 5.1-2 Preparing Maintenance Inspection Checklist (Refer to LO1)

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Answer learning evaluation on Maintenance Inspection Checklist

Perform Task Sheet No. 5.2-3 Preparing Inspection Report

Answer learning evaluation on Inspection Report

Perform Task Sheet No. 5.2-4 Preparing Work Request

Answer learning evaluation on Work Request

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

Answer learning evaluation on Breakdown/Repair Report

Perform Task Sheet No. 5.2-6 Preparing Salvage Report

Answer learning evaluation on Salvage Report

Compare your work to sample template for Maintenance Inspection Checklist.

Compare your work to sample template for Inspection Report.

Compare your work to sample template for Work Request.

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

Compare your work to sample template for Salvage Report.

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LEARNING EXPERIENCES


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.

Answer learning evaluation on Preparing Housekeeping Schedule.

Compare your Housekeeping Schedule to sample template.

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

Answer learning evaluation on Preparing Housekeeping Checklist

Compare your answers to Sample template

Read Information Sheet No. 5.3-2 on Occupational Health and Safety

Answer learning evaluation on Occupational Health and Safety

Compare your answers to Self-check key answer.

Read Information Sheet No. 5.3-3 on Waste Management.

Compare your answers to Self-check key answer

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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

.

Compare your Waste Segregation list to Sample template.

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LEARNING EXPERIENCES


DOCUMENT MAINTENANCE INSPECTION

Read Information Sheet No. 5.4-1 on Reporting and Documentation Process

Answer learning evaluation on Reporting and Documenting Process

Compare answers to Self-check answer key.

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INFORMATION SHEET NO.5.1-1

MAINTENANCE PROGRAM

Learning Objectives: After reading this INFORMATION SHEET, YOU MUST be able to understand the Quality Management Cycle ( QMC), Maintenance programming and scheduling.

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.

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The following diagram is the Shewhart cycle (PDCA) for quality improvements. Made popular by Dr. Deming.

The Quality Management Cycle(delete)

The philosophy is to keep improving the quality of an organization. It is defined by the four key steps:

Plan: Design and revised business process components to improve results.

Do: Implement the plan and measure its performance Check: Assess the measurements and report the results to decisions

makers Act: Decides on changes needed to improve the process.

The consolidation phase enables the organization to take stock of what has been taking place and to ensure made to processes that require

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PLAN PLAN

DO IMPLEMENT

CHECK ASSESS/CORRECT

ACT SUSTAIN

=

==

=

documentation (both to allow processes to be repeatable and to facilitate recognition of the achievement of some form of quality standard).

B. QMC IN THE MAINTENANCE PROGRAM

The philosophy of the Quality Management Cycle can be applied in the Maintenance Program of an organization. The first step of the Quality Management cycle in maintenance is to Plan by preparing all the details of the maintenance program. Then DO, wherein the organization implements the methods and strategies of maintenance based on the maintenance schedule. Then CHECK , here the organization regular inspects equipment to determine if the required maintenance procedures are conducted .Finally ACT, here the organization acts on the result of the inspection conducted

1. Plan. Here in this stage an organization must be able to prepare a good maintenance program which will define the standards for Best Management Practices. The maintenance program must clearly answer the question on WHY,WHO,WHAT,WHEN, WHERE and HOW.

WHO WHY

WHAT How

WHERE WHEN

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Facilities Maintenance

Why Maintain?

1. General Objective:

To maintain the optimum condition of physical facilities at acceptable levels and minimum cost to satisfy the expected demands of TVET programs and activities.

2. Specific Objectives:

To extend the useful life of physical facilities To assure the operational readiness of installed equipment and maximum

possible return on investments. To properly discard hazardous wastes To ensure the safety of personnel using the facilities, physical properties and

the environment.

What can we gain from maintaining our facilities?

Ensured SAFE environment Improve MORALE of human resources Reduced operational COST Increased PRODUCTION Prolonged LIFE facilities Prompt DELIVERY of services/ product

WHO?

Who will manage the activities? Who will monitor and evaluate the operations? Who will prepare the maintenance schedule? Who will implement the program? Who will keep the records? Who will conduct inspection? Who will certify and accept the work? Who will prepare the report?

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In- charge of inventory, data base, procurement

and reporting, FINANCIAL MANAGEMENT AND

AVAILABILITY

Administrative Officer

Team Manager

Plans, directs. Monitors and evaluates team

operation.

Area Head(Equipment & Service Vehicles)

Area Head(Ecology)

Area Head(Structures&

Grounds)

Tools and Equipment

Service VehiclesFormulates, Schedules,

Supervises/implements and inspect all unit of activities

Building/s

Electrical

Water/Plumbing

Communication

What, Where, When?

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

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

How to maintain?

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

Manpower Money (Financial Resources) Methods and System Machines (Facilities) Materials and Supplies

2. DO. Here in this stage the organization through the clearly identified Maintenance Program, must be able to practice the Methods and System defined in order to meet the standards (measurable performance levels of maintenance execution) established.

5S

Preventive Maintenance Corrective Maintenance

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

SAMPLE EQUIPMENT MAINTENANCE SCHEDULE

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Maintenance Methods and System

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

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

SAMPLE TEMPLATE NO. 2 EQUIPMENT MAINTENANCE SCHEDULE

EQUIPMENT TYPE Desktop Computer

EQUIPMENT CODE LWKS 1

LOCATION Practical Work Area / Computer Laboratory

ACTIVITIES MANPOWER

Schedule for the Month of_____________

Daily

Every Other Day

Weekly

Every 15th

Day

Monthly

Remarks

1. Clean computers and printers

IT Personnel x

2.Check computer for viruses

IT Personnel X

3. Clean computer peripherals

IT Personnel x

4. Check electric and computer connections

IT Personnel x

5.Turn off unit when not in use or at the end of the day.

IT Personnel x

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3. CHECK. To determine if the maintenance program is implemented according to what is planned, an assessment must be done. The result of the assessment will then be recorded and recorded to the proper authorities for the immediate action.

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

SAMPLE EQUIPMENT INSPECTION CHECKLIST

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

Sample Template No. 3 : MAINTENANCE INSPECTION CHECKLIST

Equipment Type : Desktop ComputerProperty Code :Number : Computer 1 / 1001ALocation : Practical Work Area / Computer Laboratory

YES NO INSPECTION ITEMS√ 1. Are the peripherals (keyboard, mouse, etc.) returned to their

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

√ 3. Is the computer unit in good working condition?√ 4. Is the equipment arranged for the purpose of safety and ease

in maintenance?√ 5. Is the auto- voltage regulator (AVR) and/or UPS turned off

when not in use√√?√ 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


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 #12. Sample template # 13. TR/CBC4. Inventory of Tools and Equipment5. Laptop/PC

Procedures:

1. Prepare all your reference materials and laptop/PC2. 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 Yes NoTrainees were oriented about the taskMaterials and equipment are providedSafety of tools and equipment were observed in accordance with the manufacturer’s instructionPPE condition was checked in accordance with the manufacturer’s instructionThe performance of the trainees were evaluated based on Performance CriteriaFeedback to trainees was provided.

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Learning Outcome: Prepare Schedule of Maintenance

Task: Prepare Maintenance Inspection Checklist


After reading the information Sheet No. 5.1-2, YOU MUST be able to Prepare an inspection Checklist on the same equipment you have chosen in Task Sheet No. 5.1-1.



1 Template #22 Sample template #23 TR/CBC4 Inventory of Tools and Equipment5 Laptop/PC

Procedures:

1. Prepare all your reference materials and laptop/PC2. 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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CRITERIA Yes NoTrainees 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 Scheduleb. Maintenance Programc. None of the above

2. What can we gain from maintaining our facilities?a. Improve morale of human resourcesb. Reduced operation costc. 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 Checkb. Plan, Do, Check and Actc. None of the above

4. The best reference for the proper use and maintenance of an equipment is the:a. Maintenance programb. User’s or Manufacture’s manualsc. 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 Systemsb. Machines (Facilities), Mechanical, Moneyc. None of the above

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Answer Key

Model Answer to Self- check On Learning Outcome 2

1. b. Maintenance Program2. c. All of the above3. b. Plan, Do, Check and Act4. a. Manpower, Money.(Financial Resources), Methods and Systems5. b. User’s or Manufacturer’s Manuals

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INFORMATION SHEET NO. 5.2-1

Types of Maintenance


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

Contents:Types of maintenanceTag-Out Bill

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

contents).2. To assure the optimum availability of installed equipment for protection (or

service) and obtain the maximum possible return of investment.3. To ensure operational readiness of all equipment required for emergency use.4. To ensure the safety of personnel using facilities.

DEFINITION OF TERMS:

Maintenance - work that is done regularly to keep equipmen ,building and grounds in good condition and working order.

A. Planned Maintenance – Work activities are performed as scheduled/ expected. Work is based- on pre- conceived/ planned activities.

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

1. Preventive Maintenance - Maintenance performed to PREVENT or FIND failures BEFORE they develop into a breakdown.

Time- Based Maintenance – based on calendar days or running hours or usage. (Inspection, cleaning, lubrication, programmed replacement and repairs). Example: Change oil every months or every 5,000 km.

Conditioned- Based Maintenance – visual monitoring and condition monitoring technique (temperature, hydraulic fluid wear, surface condition, crack, leaks, vibration, corrosion/erosion, electric insulation, etc.)

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1. Predictive Maintenance – Maintenance performed at a predetermined periods when the maintenance activity is most cost effective and before the equipment fails.

2. Corrective Maintenance - Maintenance performed to CORRECT or REPAIR a failure. Controlled Maintenance – Condition improvement/enhancement of

equipment.Example: Engine overhaul. Also referred to as Proactive Maintenance – maintenance performed to stabilize the reliability of machines or equipment. Breakdown Maintenance – Repair done when the equipment fails while

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

B. Unplanned Maintenance – Maintenance performed unexpectedly.B.1. Emergency – maintenance performed to put the item on hand IMMEDIATELY to avoid serious consequences, i.e. Loss of production, disrupted schedule, extensive damage to assets, idle workers or for safety reasons

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

DIAGRAM 1

Types of Maintenance

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PreventivePreventive

MAINTENANCEMAINTENANCE

PLANNEDPLANNED UNPLANNED

CorrectiveCorrective EmergencyEmergency

Time-BasedTime-Based Condition-BasedCondition-Based Controlled Breakdown

PredictivePredictive

Tag – Out Bill:

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

Purposes of Tag-Out Bill

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

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

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

Tag – Out Bill on:

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

Preventive MaintenancePower 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

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.

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Example of Tag Out Bill

SAMPLE TEMPLATE 3: TAG-OUT BILL

DANGER/CAUTION TAG-OUT INDEX AND RECORD AUDITSLOG

SERIALDATE

ISSUEDTYPE

( Danger/Caution)DESCRIPTION

(System Components, Test reference ,etc.

DATECOMPLETED

01 1/2/10 Danger Power switch under repair 1/10/1002 2/24/10 Warning Transformer perimeter fence

warning signs installation3/3/10

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

Prepared by: Approved:______________________ ____________________ Trainer Supervisor

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I. PREVENTIVE MAINTENANCE

Preventive Maintenance of Machines / Facilities

Coverage:

Structure and Surroundings Included services Tools and Equipment Vehicles

Preventive Maintenance of Materials and Supplies

Office Training

Sample Template 4 : OPERATION OF EQUIPMENT

Equipment Type Desktop ComputerEquipment Code Computer 1Location Practical Work Area / Computer LaboratoryOperation Procedures :

1. Check power cords and cables. Check connections.2. Turn on AVR/UPS and then turn on the computer.3. Use the computer properly.4. Scan the computer and any removable devices regularly.5. Properly shut down the computer when not in use.6. Turn off the AVR/UPS after shutting down the computer.7. Return the mouse and keyboard to their proper place after use.

SAFETY

The freedom from danger, injury or damage. According to Japanese Standard, an addition to 5S is Safety, thus 5S will become 5S +

1Ways to learn and understand SAFETY

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

any chipping. Workbenches must be strong and sturdy, and their surfaces treated with non-skid

materials.

TIPS IN PREPARING A CHECKLIST1. Keep it simple – one page per checklist.2. Follow a logical sequence.3. Use bullet enumerated points, if relevant.4. Consider the 5WH.5. Avoid making assumptions.6. From each item in your checklist, other items will naturally originate from it.

SAMPLE TEMPLATE 5: EQUIPMENT RECORD W/ CODE AND DRAWING LIST

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EQUIPMENT RECORD W/ CODE AND DRAWING

No. Location Eqpt. No.

Qnty Title Description PO No. Drawing Ref.

1 M 04 G 1001 3 Pipeline Booster Pump

Welrs Pumps Ltd. Size/Type OK Serial No. A11556-001 B11556-002

10200 GO

02 1020 E

2 M04 G 1002 2 Motor Brook Crompton Frame: 280th

10200 GO

02 1021 E

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

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SAMPLE TEMPLATE 6 : INSPECTION REPORT

Area / Section : Practical Work Area / Computer Laboratory

In-Charge : IT Personnel (Name)

FACILITY TYPE INCIDENT ACTION TAKENPROGRESS /

REMARKSPrinter – HP Deskjet 695C

Overheating Sent to HP service center for repair

Cannot be repaired; replace printer

Monitor of PC No. 1 Black out Sent to computer technician

Cannot be repaired; replace monitor

Monitor of PC No. 2 Static screen Sent to computer technician

Buy monitor parts and replace damaged parts

Monitor of PC No. 3 Half screen visibility Sent to computer technician

Buy monitor parts and replace damaged parts

Reported by: Date

Signature Over Printed Name

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Prevention of damage to the environment

Prevention of accidents (to save lives and limbs)

Prevention of failures, damages.

PLANET

PEOPLE

PROPERTIES

SAMPLE TEMPLATE 7 : WORK REQUEST

WORK REQUEST

Unit No.5-20

Description:Compressor, instrumentation air, No. 1

Observation:V-BELTS WORN Date Reported:

Aug. 15, 2010Should be replaced Reported by:

TonetActivity: Date completed:

Sign:Spare parts used:

SAMPLE TEMPLATE 8 : BREAKDOWN / REPAIR REPORT


I : IT Personnel (Name)

FACILITY TYPE NATURE OF BREAKDOWN RECOMMENDATION

Printer – HP Deskjet 695C Overheating Sent to HP service center for repair

Reported by: Date


Sample Template 9 : SALVAGE REPORT


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Area / Section : IT Personnel (Name)

FACILITY TYPE PART ID RECOMMENDATION

Floor Model – High Speed Color Printer

Ink Cartridge Store as back-up cartridge for other floor model printer

Reported by: Date


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TASK SHEET NO. 5.2-1 On Learning Outcome 4


Learning Outcome: Maintain Training Equipment and Tools

Task Title: Prepare Tag-out Bill

Learning Objective:

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



1. Template #32. Sample template #33. TR/CBC4. Inventory of Tools and Equipment5. Laptop/PC6. Bond paper, ball pen and pencil7. Tag-out Bill documents and procedures

Steps/Procedures:

1. Prepare all your reference materials and laptop/PC2. 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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CRITERIA Yes NoDid 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: Prepare an Equipment Record with Code and Drawing


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

Time Allotment:


1. Template 52. Sample template 53. TR/CBC4. Invoice/Acceptance Report5. Previous inventory report (if available)6. Laptop/PC7. Ballpen8. Any Manual/Instruction for Recording (if available)

Procedures:

1. Prepare all your reference materials and laptop/PC2. 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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CRITERIA Yes NoThe 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



Task: Prepare an Inspection Report


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

Time Allotment:


1. Template 62. Sample template 63. TR/CBC4. Maintenance Inspection Checklist5. Laptop/PC6. Ballpen7. Any Maintenance Inspection Manual/Instruction (if available)

Procedures:

1. Prepare all your reference materials and laptop/PC.2. Fill up all items in Template 6 based on the Maintenance Inspection

Checklist result.3. Segregate and label inspected equipment.4. Call your facilitator who will guide you and check your work after doing this

activity.

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CRITERIA Yes NoFull 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: Prepare a Work Request


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

Time Allotment:


1. Template 72. Sample template 73. TR/CBC4. Inspection Report or Breakdown/Repair Report5. Laptop/PC6. 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 Yes NoTrainer 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.

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Task: Prepare a Breakdown/Repair Report


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

Time Allotment:


1. Template 82. Sample template 83. TR/CBC4. Equipment Record5. Laptop/PC6. 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.

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CRITERIA Yes NoDid 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?

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Task: Prepare Salvage Report


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



1. Template # 92. Sample template #93. TR/CBC4. Inventory of Tools and Equipment5. Laptop/PC6. Pencil/Pen7. Manual of Procedures

Procedures:

1. Prepare all your reference materials and laptop/PC2. 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.

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CRITERIA Yes NoAppropriate forms and records were provided.The condition of PPE was checked in accordance with the manufacturer’s instruction.The safety of tools and equipment were observed in accordance with the manufacturer’s instruction.Feedback was provided to trainees.Activities were monitored.

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Directions: Identify the term described by the sentence. Write your answer on the blank before the number.

____________1. Work that is done regularly to keep equipment, building and grounds in good condition.____________ 2. Work activities are performed as schedule/ expected. Work is based- on pre-conceived/planned activities. ____________ 3. Maintenance performed unexpectedly.____________ 4. Maintenance performed at a predetermined periods when the maintenance activity is most cost effective and before the equipment fails.____________ 5. Condition improvement/enhancement of equipment.____________ 6. Repair done when the equipment fails while in operation.____________ 7. A system of documents being applied to warm or let you know whether something in your workplace should either be operated with extra care or left alone.____________ 8. Based on calendar days or running hours or usage (Inspection, cleaning, lubrication, programmed replacements and repairs).____________ 9. Visual monitoring and condition monitoring technique (temperature, hydraulic fluid, wear, surface condition, crack, leaks, vibration, corrosion/erosion, electric insulation etc.).____________ 10. Maintenance performed to PREVENT or FINDS failures BEFORE they develop into a breakdown.

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Answer Key

Model answer to Self-check on Learning Outcome 4

1. Maintenance2. Planned Maintenance3. Unplanned Maintenance4. Predictive Maintenance5. Controlled Maintenance6. Breakdown Maintenance7. Tag-Out Bill8. Timed-Based Maintenance9. Condition- Based- Maintenance10.Preventive Maintenance

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THE 5S HOUSEKEEPING SYSTEM

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

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

Definition of Terms:

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

5S means good housekeeping and workplace organization.

5S

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Seiri(Sort)

Shitsuke(Self-Discipline)

Seiton(Systematize) Seiketsu

(Sanitize)

Seiso(Sweep)

SEIRI (SORT) TIDINESS, ORGANIZATION, Taking out and disposing of unnecessary items. Unneeded items are thrown away or disposed. 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.

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

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1. Keep it simple – one page per checklist2. Follow a logical sequence3. Use bullet enumerated points, if relevant4. Avoid making assumptions5. 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. 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.

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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

ACTIVITIES MANPOWER

Schedule for the Month of ________________

I 2 3 4 5 6 7 8 910

11

12

13

14

15

1. Clean computers and printers

Utility Personnel

2. Clean computer tables and chairs

Utility Personnel

3. Arrange table and chairs

Utility Personnel

4. Clean floor Utility

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Personnel5. Clean walls and

windowsUtility

Personnel

6. Dispose waste Utility Personnel

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.

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

Sample Template 11 : HOUSEKEEPING INSPECTION CHECKLIST

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

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YES NO INSPECTION ITEMS

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

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

3. Is the computer unit in working condition?4. Are all areas well lighted and ventilated?

5. Is the equipment arranged for the purpose of safety and ease in maintenance?

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

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

8. Is the computer unit free from any virus?

Inspected by: Date:

SECURITY POLICIES AND PROCEDURES

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 PropertyKeep 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

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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.



Learning Outcome: Implement Housekeeping Activities

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Task: Prepare a Housekeeping Schedule


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.



1. Template # 102. Sample template #103. TR/CBC4. Inventory of Tools and Equipment5. Laptop/PC6. Pencil/Pen7. Bond Paper8. Manual of Procedures9. Schedule of Activities of the School/Center10. Calendar

Procedures:

1. Prepare all your reference materials and laptop/PC2. Identify the area or location you have chosen. 3. Fill up all items in Template #10. 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.


CRITERIA Yes NoDid 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

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manufacturer’s instruction?Did the trainer provide feedback to trainees?Was there a manufacturer and instruction manual provided?




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Task: Prepare a Housekeeping Checklist


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.



1. Template # 112. Sample template #113. TR/CBC4. Inventory of Tools and Equipment5. Laptop/PC6. Pencil/Pen7. Bond Paper8. Manual of Procedures9. Schedule of Activities of the School/Center

Procedures:


activity.


CRITERIA Yes NoDid 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

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manufacturer’s instruction?Did the trainer provide feedback to trainees?Was there a manufacturer and instruction manual provided?

SELF- CHECK On Learning Outcome No.3

Instruction: Encircle the correct answer.

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a) Seiso/Sweepb) Seiton,systematizec) Seiketsu/standardize

2. Taking out and disposi9ng of unnecessary items.

a) Seiton/Systematizeb) Seiso/Sweepc) Seiri/Sort

3. Keeping rhe workplace as well as neat.

a) Seiso/Sweepb) Seiketsu/Standardizec) Seiton/Systematize

4. Doing things spontaneously without being told.a) Seiri /Sortb) Seiton/Systematizec) Shitsuke/Self-discipline

5. Maintaining the workplace in high standard housekeeping.

a) Shitsuke/Self-disciplineb) Seiketsu/Standardizec) Seiton/Systematize

Answer Key

Model Answers to Self-Check On Learning Outcome No.3

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1. b. Seiton/Systematize2. c. Seiri/Sort3. a. Siso/Sweep4. c. Shitsuke/Self –discipline5. b. Seiketsu/Standardize


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.

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Definition of Terms:

1. Safety – The freedom from danger, injury or damage.2. Occupational health and safety (OH&S) – is a cross-disciplinary 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.

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.

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

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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:

1. 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.

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

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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.

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.

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Training and Providing Relevant InformationAwareness 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 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.

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First Aid

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.

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Ways to learn and understand SAFETY

Accidental Experience. Experience which were caused by accidents. 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

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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.

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 non- skid

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.

Remember:

Segregated Waste = ResourcesMixed Waste = Garbage

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To reduce waste…

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

Sample Template No. 12 : WASTE SEGREGATION LIST

Section / Area Practical Work Area / Computer Laboratory

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RecycleNon-

Biodegradable

SEGREGATE

Compost Biodegradable

GENERATED / ACCUMULATED WASTE

WASTE SEGREGATED METHOD

RECYCLE COMPOST DISPOSE

1. Paper /

2. Pens /

3. Diskette/Discs /

SAMPLE WASTE SEGREGATION LIST




Task: Prepare a Waste Segregation List


After reading the Information Sheet No. 5.3-3, Using the Blank Template, YOU MUST be able to prepare a Waste Segregation List.

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1. Template # 122. Sample template #123. TR/CBC4. Inventory of Tools and Equipment5. Laptop/PC6. Pencil/Pen7. Bond Paper8. Manual of Procedures9. Schedule of Activities of the School/Center10. Calendar

Procedures:


activity.


CRITERIA Yes NoMaterials/equipment was prepared.PPE condition was checked in accordance with the manufacturer’s instructionAppropriate forms and records were provided.Full utilization of areas/resources.Manufacturer and instruction manual was provided.

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Instruction: Encircle the correct answer.

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 Safetyb) 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

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agents or ergonomic factors that involved the impact or equipment design on a worker’s comfort or fatigue.a) Occupational health and safety techniciansb) Occupational health and safety specialistsc) 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) Supervisorsb) Health and safety specialistsc) 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 hierarchyb) Waste managementc) 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 hierarchyb) Waste managementc) Waste segregation

Answer Key

Model Answer to Self- Check On Learning outcome 3

1. a. Occupational Health and Safety2. b. Occupational Health and Safety specialists3. c. First aid officers4. Waste hierarchy5. Waste management

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REPORTING AND DOCUMENTATION PROCESS

Learning objective:

After reading this INFORMATION SHEET , YOU MUST be able to understand the process of reporting and documenting maintenance activities.

Definition of Terms

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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 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.

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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.

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.

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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: 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

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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.

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 buildingo Geographical position/location of equipment and facilities (includes shop

layout and vicinity maps)

2. Technical Documentation. Any document useful for maintenance.

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o Mechanical, electrical, architectural, plumbing and equipment planso List of components and spare parts of each equipmento 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 repairedo 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:

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:

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Maintenance listing Manpower utilization Work backlog Material cost Cost analysis

Storing Documents

1. Available documents must be kept-up-to-date2. Each document must have a title and a control internal number3. The list shall mention where certain documents are, considering that not all

documents are always in the maintenance division (location and responsible personnel


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

presentable2. A historical record

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(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.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. (a) optimize the use of every peso spent in achieving the assigned tasks/mission2. (b) should contain all maintenance and repair activity of the equipment item.3. (c) All of the above.4. (b) replacing parts to restore a piece of equipment to full operating condition.

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5. (c) External electrical system

Blank Template 1 :

EQUIPMENT MAINTENANCE SCHEDULE

Equipment Type :

Property Code / Number :

Location :

ACTIVITIES Responsible person

Schedule for the Month of _________________Daily Every

other Day

Weekly Every 15th

Day

Monthly Remarks

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Prepared by: Noted:

_____________________ _________________ Trainer Supervisor

Blank Template 2:

MAINTENANCE INSPECTION CHECKLIST

Equipment Type :

Property Code / Number :

Location :

In - Charge :

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YES 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:

Prepared by: Noted:

_____________________ _________________ Trainer Supervisor

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Blank Template No. 3 : TAG-OUT BILL

DANGER/CAUTION TAG-OUT INDEX AND RECORD AUDITSLOG

SERIALDATE

ISSUEDTYPE

( Danger/Caution)DESCRIPTION

(System Components, Test reference ,etc.

DATECOMPLETED

Prepared by: Approved:______________________ ____________________ Trainer Supervisor

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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

No. Location Eqpt. No.

Qty Title Description PO No. Drawing Ref.

Blank Template No. 6

INSPECTION REPORT

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Inspection Report # _____

Property ID NumberDescriptive NameLocation

Findings: Recommendation:

Inspected by: Reported to:

Date : Date


WORK REQUEST

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Unit No.5-20

Description:

Observation:


BREAKDOWN / REPAIR REPORT

Breakdown / Repair Report # _____

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Property ID Number

Descriptive NameLocation

Findings: Recommendation:

Inspected by: Reported to:

Date : Date

Assigned to : Received Assignment:

Assigned by: Assignee:

Date : Date

Subsequent Action Taken: Recommendation:

By: Reported to:

Date : Date


SALVAGE REPORT

Salvage Report # _____

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Property ID Number Inspection Rpt. #

Date:

Descriptive NameModel Number Serial Number:Location

Salvageable Parts

Descriptive Name Part Number Quantity Recommendation

Inspected by: Reported to: Approved by:

Date : Date


HOUSEKEEPING SCHEDULE

Qualificatio : Station

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n

Area / Section

: Tools / Eqpt.

In - Charge : Services

ACTIVITIESResponsible

Person

Schedule for the Month of _________________Daily Every

other Day

Weekly Every 15th

Day

Monthly Remarks


HOUSEKEEPING INSPECTION CHECKLIST

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Qualification :

Area / Section :

In - Charge :

YES NO CRITERIA

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

Blank Template No 12

WASTE SEGREGATION LIST

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Qualification :

Area / Section :

In - Charge :

GENERAL / ACCUMULATED WASTESWASTE SEGREGATION METHOD

Recycle Compose Dispose

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TM 1

INSTITUTIONAL COMPETENCY

ASSESSMENT INSTRUMENT

In

Maintaining Training Facilities

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EVIDENCE PLAN

PROGRAM : TM 1Unit of Competency : Maintain Training FacilitiesWays in which evidence will be collected:

The evidence must show that the candidate….

Ora

l Que

stion

ing

Writt

en T

est

1. *Plan and prepares maintenance work schedule in accordance with machine/equipment operating time/condition

X X

2. *Records regular inspection of tools, equipment, and other facilities as per company practices.

X

3. *Documents maintenance and repair activities. X X4. *Disseminates information with other concerned department or

personnel on the schedule of work.X

5. *Performs housekeeping based on work requirement. X6. Communicates effectively with others if needed in order to ensure

safe and effective maintenance operation.X X

7. *Incorporates safety practices in line with work requirements. X

8. *Knows and applies regular inspection according to procedures and standards.

X

9. *Knows and applies OH & S & 5S procedures. X10. *Disposes waste and dangerous chemicals based on OH&S

procedures.X

11. Identifies faults and problems in line with Maintenance and repair requirements.

X

12. Identifies and secures tools, equipment, materials & supplies according to job requirements and manufacturer’s procedures.

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 RatingOral Interview (open-ended questions) on the following:

Max. Point Actual Score

1. Why we need to maintain training facilities? 252. As a CBT Facilitator, how do you prepare your plan in the

maintenance of equipment?15

3. What is the rationale in reporting and documenting the maintenance of facilities?

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:_______________________________


Direction: Choose the best answer for each number.

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Time Duration: 15mins.

1. What can we gain from maintaining our facilities?a. Improve morale of human resourcesb. Reduced operation costc. 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 Actc. None of the above

3. What type of maintenance that performed unexpectedly?a. Unplanned Maintenanceb. Planned maintenancec. Predicted maintenanced. 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. Maintenanceb. Tag-out Billc. System Proceduresd. Warning System

5. Inspection would involve a. Periodic inspection of equipment to insure safe and proper

operationb. Control of the quality of work accomplished by maintenance

craftsmanc. All of the above

6. Scheduling is a method of planning that a. Cites specific objectives to be accomplished in relation to time.

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b. Specifies the work, assignment distributed in relation to skills.c. Defines work per employee in relation to place.

7. A historical record is:a. The same as a work orderb. Contain all maintenance and repair activity of an equipment item.c. Dispose as soon as the work required is accomplished.

8. Salvage would involvea. Overhaul or the reconditioning of equipmentb. The reclamation and disposition of surplus materials and scrapc. Repair to full operating condition

9. Housekeeping would covera. Repair or replacing parts to restore a piece of equipmentb. Construction and rehabilitation of buildingsc. Those janitorial and grounds keeping activities

10. Periodic maintenance a. Is the same as preventive maintenanceb. 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

FINAL RATING = Written Test + Oral Q Rating

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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

2.www.fda.go/Science Research/Field ScienceNTTA-TESDA

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http://www.fda.go/Science

http://www.works.com.my/cw/downloads_asap

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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maintain training facilities

Documents

facilities training

module training

training equipment

training materials

training facilitiesdate

tvet training methodology

training methodology

drawingperform task