Академический Документы
Профессиональный Документы
Культура Документы
Merced College
Central California
Community Colleges
Committed to Change
Copyright © 2013
Merced College, College of the Sequoias, and
Washington State University Energy Program
WSUEEP13-027
Publication Information
Document Credits
Project Director:
Alan Hardcastle, Ph.D.
Washington State University (WSU) Energy Program
(360) 956-2167, hardcast@wsu.edu
Disclaimer
This report was prepared as an account of work sponsored by an
agency of the United States Government. Neither the United States
Government nor any agency thereof, nor any of their employees,
makes any warranty, express or implied, or assumes any legal liabil-
ity or responsibility for the accuracy, completeness, or usefulness of
any information, apparatus, product, or process disclosed, or repre-
sents that its use would not infringe privately owned rights. Reference
herein to any specific commercial product, process, or service by trade
name, trademark, manufacturer, or otherwise does not necessarily
constitute or imply its endorsement, recommendation, or favoring by
the United States Government or any agency thereof. The views and
opinions of authors expressed herein do not necessarily state or reflect
those of the United States Government or any agency thereof.
Permission to Cite
General permission is granted for educators to photocopy and quote
limited material from this document for noncommercial instructional
or scholarly use. Permission must be sought from the copyright hold-
ers in order to charge for photocopies, to quote material in advertis-
ing, or to reprint substantial portions of the document in other
publications. Credit should always be given to the source of the
photocopies or quotes by citing a complete reference.
Acknowledgements
This document is the result of the collaborative efforts of industry, education
and government successfully working together through the Manufacturing
Maintenance Mechanic Skill Standards for Food Processing. A special thanks
to all who contributed, especially the employers and employees who partici-
pated in the advisory and focus groups. Their countless hours of work to
help produce the skill standards are greatly appreciated.
Thanks also to Merced College and the Clovis Center for providing meeting
facilities for Advisory Committee members, focus group participants, and
project staff, as well as Merced College’s Responsive Training Fund, College
II of the Sequoias’ Center for Applied Competitive Technologies, and the
Central Region Consortium for providing the facilitation services and meals
for the Advisory Committee members, focus group participants, and project
staff. Special thanks to the focus group participants, especially Preston Cary,
Sconza Candy Company; Richard Ulmer, Dole Packaged Food, LLC; and
Peter Xiong, The Wine Group, LLC for providing the workplace scenarios
included in the document. We also appreciate Bud Hendrickson, Dole
Packaged Food LLC; Stephanie Moreno, The Wine Group; and Tre Robinson,
Ruiz Foods for providing the Industry Perspectives included in the report.
Central California
Community Colleges
Committed to Change
V
Acronyms Used in this Publication
VI
Table of Contents
Publication Information............................................................................ I
For More Information.............................................................................. I
Document Credits................................................................................... I
Project Funding....................................................................................... I
Disclaimer............................................................................................... I
Permission to Cite..................................................................................... II
Acknowledgements................................................................................... II
Project Development and Coordination................................................. II
Advisory Committee..............................................................................III
Focus Group Participants........................................................................III
College Participants.............................................................................. IV
Business & Industry Participants............................................................ IV
Special Thanks....................................................................................... V
Acronyms Used in this Publication........................................................ VI
Industry Perspectives................................................................................ 1
Background................................................................................................ 5
National Context................................................................................... 6
What are Skill Standards?....................................................................... 6
Why are Skill Standards Important?........................................................ 7
The Benefits and Uses of Skill Standards................................................. 7
How Skill Standards Benefit Employers........................................... 7
How Skill Standards Benefit Labor Unions....................................... 8 VII
How Skill Standards Benefit Educators............................................ 8
How Skill Standards Benefit Government........................................ 9
How Skill Standards Benefit Students and Workers.......................... 9
Skill Standards to Training: A Continuous Development Process........... 10
A Model of Continuous Improvement for Economic Development....... 11
Using Skill Standards.................................................................... 11
Pyramid of Competencies............................................................. 12
Results ...................................................................................................... 17
Job Summary....................................................................................... 18
Competencies.............................................................................. 18
Definitions........................................................................................... 19
Critical Work Functions................................................................. 19
Employability Skills....................................................................... 19
Key Activities................................................................................ 19
Level of Importance...................................................................... 19
Performance Indicators................................................................. 19
Technical Skills, Knowledge, Abilities and Tools............................. 19
Theories, Concepts and Equipment...................................................... 20
Science and Engineering Theories and Concepts.......................... 20
Math for Maintenance Mechanics................................................ 21
Components and Equipment........................................................ 21
Mechanical Knowledge, Systems and Components...................... 22
Critical Work Functions.......................................................................... 23
A. Maintain a Safe, Healthy and Environmentally-Conscious
Work Environment........................................................................ 29
B. Maintain and Repair Plant Equipment........................................... 34
C. Install and/or Modify Equipment.................................................. 40
D. Communicate with Co-Workers to Promote Productivity
and Customer Responsiveness...................................................... 43
E. Adhere to Company and Regulatory Policies and Standards......... 48
F. Perform Technical and Administrative Duties................................ 51
G. Operate Auxiliary Equipment (e.g., Fork Lift, Aerial Lift)................ 55
Verification Survey Results.................................................................... 57
VIII Future of Food Manufacturing Maintenance Mechanics....................... 58
Maintenance mechanics will need to be able to
program CNC devices.................................................................. 58
Maintenance mechanics will need to know
computer-aided design................................................................ 58
Maintenance mechanics will need to be able to
program and maintain robots....................................................... 58
Maintenance mechanics will need to work collaboratively
in new ways................................................................................. 59
Integration............................................................................................... 69
Assessment and Certification: A Vital Connection................................. 70
Assessment Strategies.......................................................................... 70
List of Tables
Table 1. SCANS Skills................................................................................. 15
Table 2. Skill Standards for Food Manufacturing
Maintenance Mechanics............................................................... 24
Table 3. SCANS Survey Results................................................................... 26
Table 4. Primary Tasks and Functions Involved in Routine Scenario............ 63
Table 5. Primary Tasks and Functions Involved in Crisis Scenario................ 65
Table 6. Primary Tasks and Functions Involved in Long-Term Scenario....... 67
Table 7. Assessment Design....................................................................... 73
List of Figures
Figure 1. Sample Survey Questions from the Workplace
Standards Skill Inventory.............................................................. 16
Figure 2. Food Manufacturing Maintenance Mechanics:
Importance of Critical Work Functions.......................................... 57
Figure 3. Integrating Skill Standards............................................................ 71
IX
X
Industry Perspectives
1
One of the biggest challenges in manufacturing is
getting qualified maintenance candidates. There
are many candidates who apply, but most have
little experience and some are laid off operations
employees who have taken maintenance classes at the
local community/junior college. As employers, we struggle with how to assess
prospective employees and, due to the high demands of our current work-
force, have difficulty properly developing our current and future maintenance
workforce. Another trend is of aging workers who are not able to retire and have
limited computer knowledge, making it difficult for them to work with current
computerized maintenance systems.
The value I see with the development of the Food Manufacturers Maintenance
Skill Standards is that we have identified the skills that are important to all
manufacturers and it has allowed the colleges and manufacturing companies to
get on the same page as to what the needs are. Now that they are identified,
the challenge is to continue the partnership to ensure candidates get the proper
classroom knowledge and match it with appropriate work experience. The next
step will also include methods needed to assess and put together developmental
plans for current employees and future candidates.
Enjoy,
Bud Hendrickson
Sr. Maintenance Manager
Dole Packaged Food LLC
Atwater, CA
It is critical that industry and education work together
to define the skills, knowledge and abilities required for
individuals to succeed in the manufacturing workplace.
Although each employer is unique, there is a common-
ality about what students, job seekers and current
employees must know and be able to do to be a successful industrial mainte-
nance worker within the food manufacturing industry in the Central Valley. Ruiz
Foods, along with many other regional food manufacturers, participated in the
Skill Standards effort outlined in this report because we are dedicated to growing
the workforce of the Central Valley. Our participation allowed us to document
the skill needs required of our industry. This document will serve as a common
communication tool to colleges, high schools and training organizations to make
sure that their programs are up-to-date and will attract students to opportunities
in our industry.
Sincerely,
Tre Robinson
Maintenance Manager
Ruiz Foods
Dinuba, CA
I’ve been involved in the Manufacturing Cluster for the
Central Valley since 2004. This Skill Standards effort is
the most practical and headstrong movement that I have
either worked with or come across. My management team,
including maintenance managers at The Wine Group, are
excited about this effort and I am excited that we were involved. It is critical
that we, as employers, work cooperatively to guide the effort to improve the
workforce that we are recruiting. We need to utilize educational programs that
are practical for our industries. Partnering with education for future candidates
who are interested in the mechanical field will improve our retention and, thus,
our productivity.
With the aging of the workforce and the continued demand for skilled workers
in maintenance within the food manufacturing industry, it is critical that
manufacturers, colleges, workforce boards, and economic development agencies
are on the same page about the skills needed by our regional workforce. This
4 Skill Standards effort is set forth to systematically document the skills needed by
maintenance mechanics within food manufacturing in California’s Central Valley.
By documenting these skills, we are helping our training partners (colleges)
clearly understand our needs which will, in turn, give them the best data to
train the workforce we are seeking. This cooperative effort between education
and industry is a vision I have been striving for and hoping to achieve during
my involvement in regional manufacturing groups over the last 10 years. I am
pleased with the end-product of our efforts and hope you will find it valuable.
I also hope it will inspire you to work cooperatively in local/regional efforts to
strengthen partnerships among education, training and industry.
Sincerely,
Stephanie Moreno
HR Manager South Valley Operations
The Wine Group
Madera, CA
Background on the Skill
Standards Project
5
This project was a collaboration of Merced College, College of the Sequoias,
the Central Region Consortium, and the Central California Community
Colleges Committed to Change (C6) Consortium. The project goal was to
ensure that a standards-based approach will be used as a foundation for
defining competencies and measurable skills of maintenance mechanics in
food manufacturing companies, an occupation that is expected to change
significantly in the coming years. The standards also help to ensure that
proposed training and degree programs for maintenance mechanics
incorporate current foundational skills.
National Context
The National Skill Standards Board (NSSB) was established by Congress
in 1994 to encourage the creation and adoption of a national system of
voluntary skill standards that would enhance the ability of the U.S. to
compete effectively in a global economy. By the time the NSSB sunset in
2003, several national voluntary skill standards projects were developed
by various industries in full partnership with education, organized labor
and community-based organizations. The intent was to have voluntary
skill standards that are flexible, portable, and continuously updated and
improved.
Workers can accurately assess their skills against those required for career
advancement and plan effectively for their career pathways. They can
determine the skills and abilities needed for advancement or transfer within
industries, and determine the continuous learning and training they need to
upgrade their skills.
Step 4: Articulation
• Develop models to support the articulation of program outcomes and
competencies among academic and training systems.
• Establish articulation agreements among existing programs to ensure
portability of skills.
• Connect competencies and Certificates of Competence with
benchmark documentation to build national portability systems.
Pyramid of Competencies
The Pyramid of Competencies is a depiction of skill standards in three broad
skill categories.
• Tier I represents the broadest level of competencies, and is the set
12 of employability (SCANS) skills, knowledge, abilities and personal
qualities required of all workers to be successful in today’s workplace.
These are the universal skills that are needed to apply technical
knowledge and tools effectively.
• Tier II represents technical skills, knowledge and abilities common to
jobs within a cluster across all industries or industry sectors.
• Tier III represents industry-specific technical skills, knowledge and
abilities that are unique to individual jobs or clusters and are the most
prone to rapid change. For example, many workers need to upgrade
their skills based on sudden market shifts.
Skill Standards
Development Process
13
Advisory Committee and Initial Focus Group
An Advisory Committee consisting of food manufacturing managers and
leaders from firms throughout California’s Central Valley was convened by
Alan Hardcastle of the WSU Energy Program to provide oversight for this
project. The Advisory Committee nominated participants for the focus
group process.
The initial two-day focus group, led by Terryll Bailey of The Allison Group,
included nine experienced food manufacturing maintenance mechanics
representing different companies across California’s Central Valley. There
was broad diversity in terms of participants’ ages and years of experience in
the industry.
The first step in the focus group process was to identify the primary
functions and key activities that constitute the work of a competent, entry-
level maintenance mechanic. Working with a draft of sample critical work
functions, prepared from background research and input from the Advisory
Committee, the group revised and adapted functions and tasks to meet the
needs of maintenance mechanics throughout California’s Central Valley.
Participants freely made changes and recommendations, and crafted seven
critical work functions with correlating key activities.
Performance Criteria
The second step was to identify the performance indicators for each key
activity, answering the question: “How do you know when this is performed
14 well?” The group also identified the tools, knowledge and foundation skills
required to meet the performance criteria. The draft skill standards generated
through the focus group process were reviewed by members of the Advisory
Committee with respect to current industry trends and requirements.
Survey Verification
Third, a survey of SCANS* skills and personal qualities for maintenance
mechanics was administered to focus group members, and later to a larger
sample of maintenance mechanics from food manufacturers across the
region. A total of 107 SCANS competency surveys were returned; survey
results are provided on pages 26 to 28.
* SCANS are foundation employability skills required of workers in all occupations at varying levels
specific to their jobs. See: http://wdr.doleta.gov/SCANS/whatwork/
and feedback were compiled and analyzed, and a draft of the document was
reviewed by the Advisory Committee (see list of members on page III).
Personal Worksite
Basic Skills Thinking Skills
Qualities Competencies
Utilizing
Reading Creative Thinking Responsibility
Resources
Interpersonal
Writing Decision Making Self-Worth
Skills
Utilizing
Arithmetic Problem Solving Sociability
Information
Using
Speaking Knows/Learns Integrity/Honesty
Technology
Reasoning
Figure 1.
Sample Survey Questions from the
Workplace Standards Skill Inventory
16
Skill Standards
Results
17
Job Summary
Maintenance and repair of all plant equipment including, but not limited to,
electrical, pneumatic and hydraulic systems.
Competencies
• Able to use basic hand and power tools.
• Able to read blue prints and do layout work/sketches.
• Basic knowledge of gas, gas tungsten (TIG), gas metal (MIG) and arc
welding. Also able to use plasma cutter.
• Timely analysis and repair of all breakdowns in plants using basic
troubleshooting skills.
• Able to troubleshoot and wire a 3-phase motor.
• Able to troubleshoot and repair 110-volt and 24-volt control wiring.
• Able to rebuild centrifugal and positive displacement pumps.
• Ensure all safety procedures are followed according to company safety
policies.
• Computer literate and proficiency with email, word processor,
and computerized maintenance management system application
(CMMS-MP2).
• Demonstrate a high level of communication, cooperation and
teamwork with production operators to maintain and repair plant
equipment. Must treat production operators as a customer.
• Properly prioritize issues and take personal accountability to make
sure all repairs fit the core value of “excellence.”
• English skills must be proficient to understand, read, write and speak
18 English.
• Promote company culture.
• Each employee must know their role in the manufacture and
distribution of safe, wholesome and high-quality products because
food safety is a company-wide responsibility.
Minimum Qualifications
High school diploma or equivalent.
Physical Demands
The physical demands described here are representative of those that must
be met by an employee to successfully perform the essential functions of this
job. Reasonable accommodations may be made to enable individuals with
disability to perform the essential functions.
• Effectively handle lifting of various objects weighing up to 50 pounds.
Work Environment
The work environment characteristics described here are representative of
those an employee encounters while performing the essential functions of
the job. Reasonable accommodations may be made to enable individuals
with disabilities to perform the essential functions.
• The noise level in the work environment is very loud. Ear plugs are
provided for safety.
• Regular exposure to elements such as odor, noise, dust, heat, cold or
chemicals.
Definitions
The skill standards template beginning on page 29 contains the following
components.
Employability Skills are basic academic and personal skills that are needed
to build more advanced competencies. They are required by all workers to
obtain meaningful work and to participate in the modern workplace.
Key Activities are the tasks related to the critical work functions, composed
of work activities that are measurable and observable and that result in a
decision, product or service.
23
Table 2.
Skill Standards for Food Manufacturing Maintenance Mechanics
Critical Work
Key Activities
Functions
A. A1 A2
Maintain a Safe, Perform environmental Perform emergency drills
Healthy and and safety inspections and participate in emergency
Environmentally response teams
Conscious Work
Environment
B. B1 B2
Maintain and Repair Perform troubleshooting Perform preventive
Plant Equipment maintenance
C. C1 C2
Install and/or Support the installation, Assist with testing to
Modify Equipment move/removal, custom- ensure functionality after
24 ization or upgrade of installation, move/removal,
equipment customization or upgrade
D. D1 D2
Communicate with Fill out maintenance Participate in meetings and
Co-Workers to Promote and repair logs problem-solving groups
Productivity and
Customer Responsiveness
E. E1 E2
Adhere to Company and Comply with Adhere to site-specific work
Regulatory Policies and environmental practices and procedures,
Standards regulations and emergency response
and preparedness
F. F1 F2
Perform Technical and Maintain manual and Assist in training other
Administrative Duties electronic records, employees
databases and reports
G. G1 G2
Operate Auxiliary Inspect equipment Operate rolling/mobile
Equipment equipment
(e.g., Fork Lift, Aerial Lift)
Key Activities
A3 A4 A5
Identify, report Attend safety Reclaim, recycle
and take corrective meetings or dispose of
action on unsafe and fluids,
out-of-compliance refrigerants,
conditions and materials and
behaviors regarding waste
personal and food
safety, and environ-
mental/ regulatory
requirements.
B3 B4 B5 B6
Gather parts, Perform diagnostic Perform repairs Document
materials, tools and testing equipment mainte-
equipment nance & repair
C3
Fabricate parts or
components
25
D3 D4 D5
Communicate Suggest ways to Promote
job-specific needs prevent future teamwork and
equipment continuous
malfunction or improvement
improve equipment
performance
E3
Comply with safety
requirements and
standards
F3 F4
Perform Obtain and maintain
housekeeping proficiency in
current and new
technologies
Table 3.
SCANS Survey Results
Basic Skills
Demonstrates Identifies relevant details, facts,
specifications, follows set of
Effective Reading instructions and probes to gain
Strategies knowledge/information.
Demonstrates Records information accurately,
Effective Writing completes forms and writes simple
Strategies documents.
Demonstrates
Listens attentively and confirms and
Effective interprets communication.
Listening Skills
Demonstrates Communicates appropriate verbal/
non-verbal messages, presents basic
Effective ideas/information, explains concepts
Speaking Skills and actively participates in discussion.
26 Thinking Skills
Applies Creative Demonstrates creative
Thinking/ thinking process while problem solving
Generates Ideas and develops creative solutions.
Personal Qualities
Follows procedures and pays
attention to details, follows up on
Demonstrates
assigned tasks, works with minimal
Responsibility supervision, and demonstrates
initiative.
Maintains a positive self-image,
Demonstrates responds assertively, defends own
Belief in Self viewpoints, accepts constructive
Worth criticism, and accepts responsibility
for own behavior.
Interpersonal Skills
Actively participates in team activi-
ties, volunteers for special tasks,
Participates as
demonstrates commitment, works
Team Member to improve team skills and encour-
ages/supports team members.
Models proper performance/
Teaches attitudes, conducts task-specific
Others training and coaches others to
apply related concepts.
Responds to customer needs and
Serves
demonstrates sensitivity to
Customers customer concerns and interests
Adheres to standards, encourages
Exhibits others to adopt new concepts,
Leadership demonstrates commitment to
excellence and leads by example.
Understands negotiation process,
Negotiates
identifies conflicts and
Agreements demonstrates composure.
Understands the legal aspects of
Works with discrimination, respects the rights
Diversity of others and demonstrates
awareness of diversity.
28 Understanding / Management of Systems
Use of Technology
Selects Knows available technology and
Appropriate understands requirements of the
Technology task and technological results.
Understands technology
Applies applications, follows proper
Technology to procedures, understands the opera-
Task tion and manipulates technology
for desired results.
Follows specified maintenance,
Maintains/ identifies and corrects malfunc-
Troubleshoots tions, troubleshoots failures,
Technology and evaluates performance of
technology.
Food Manufacturing Maintenance Mechanics
Critical Work Function:
A. Maintain a Safe, Healthy and Environmentally
Conscious Work Environment
Key Activity
A1. Perform environmental and safety inspections
Performance Indicators – Employability Skills –
Technical Knowledge –
How do we know when the task SCANS Skills and
Skills, Abilities, Tools
is performed well? Foundational Abilities
• Reference is made to technical • Knowledge of food manufac- • Records information accurately,
manuals during the course of turing terminology including completes forms and writes
inspections. tools, equipment and systems. simple documents.
• Checklists and procedures are • Knowledge of food safety • Selects data relevant to
followed. and sanitation policies and the task, identifies the
• The environment is scanned procedures and use of safety need for data and predicts
for hazardous conditions. equipment. outcomes.
• Documentation is complete • Knowledge of the components • Records information accurately,
and accurate and submitted and processes utilized in a safe completes forms and writes
to appropriate personnel in a work environment. simple documents.
timely manner. • Knowledge of typical • Translates blueprints, drawings
• Personal protective equipment hazards. and diagrams; applies
(PPE) is worn as required. • Ability to identify and appropriate principles to the
• Visual inspections are use personal protective situation; and utilizes previous
conducted correctly and in a equipment. training/experience to predict
timely manner. • Knowledge of procedures outcomes.
• Inspections occur within for storing hazardous • Starts on time, efficiently
required frequency materials. manages time, prioritizes daily
specifications. • Knowledge of documentation tasks, and monitors/adjusts 29
• Food safety policies procedures. task sequence.
are adhered to (Good • Knowledge of procedures for
Manufacturing Practices) visual inspection.
according to company, • Knowledge of required
customer and U.S. Department frequency for inspections.
of Agriculture (USDA) • Knowledge of food safety
guidelines. policies, Good Manufacturing
• Safety and environmental Practices and company,
testing equipment is properly customer and USDA guide-
calibrated/certified and used lines, including material safety
correctly. data sheets (MSDSs) and their
• Spill Prevention Control and locations.
Countermeasures (SPCC) plans • Knowledge of calibration
are up to date. procedures for safety and
• Spill remediation supplies environmental testing
and kits are inspected and equipment and ability to
maintained. determine if it is certified.
• Knowledge of procedures for
using safety and environmental
testing equipment.
• Knowledge of SPCC plans and
requirements.
• Knowledge of contents of spill
remediation supplies and kits.
Food Manufacturing Maintenance Mechanics
Critical Work Function:
A. Maintain a Safe, Healthy and Environmentally
Conscious Work Environment – Continued
Key Activity
A2. Perform emergency drills and participate in
emergency response teams
Performance Indicators – Employability Skills –
Technical Knowledge –
How do we know when the task SCANS Skills and
Skills, Abilities, Tools
is performed well? Foundational Abilities
• Training and certification • Ability to obtain and maintain • Listens attentively and confirms
on relevant emergency, first certifications on respirators and interprets communication.
aid and CPR procedures are and other emergency response • Actively participates in team
complete and up to date. equipment. activities, volunteers for
• Emergency response complies • Knowledge of procedures to special tasks, demonstrates
with company and regulatory use emergency equipment. commitment, works to
policies and procedures. • Knowledge of emergency improve team skills and
• PPE is used as required. policies and procedures. encourages/supports team
• Knowledge of emergency members.
responses. • Understands system organi-
• Knowledge of emergency zation/ hierarchy and follows
personnel, phone numbers procedures.
and address/locations within • Translates blueprints, drawings
facilities. and diagrams; applies
• Knowledge of guidelines for appropriate principles to the
and how to use PPE. situation; and utilizes previous
training/experience to predict
outcomes.
30
Food Manufacturing Maintenance Mechanics
Critical Work Function:
A. Maintain a Safe, Healthy and Environmentally
Conscious Work Environment – Continued
Key Activity
A3. Identify, report and take corrective action on unsafe and
out-of-compliance conditions and behaviors regarding personal
and food safety, and environmental / regulatory requirements.
Performance Indicators – Employability Skills –
Technical Knowledge –
How do we know when the task SCANS Skills and
Skills, Abilities, Tools
is performed well? Foundational Abilities
• Conditions that present a • Knowledge of plant equipment • Translates blueprints, drawings
threat to health, safety and the and processes. and diagrams; applies
environment are identified, • Ability to identify an unsafe appropriate principles to the
reported to appropriate condition. situation; and utilizes previous
parties, and documented • Knowledge of the training/experience to predict
promptly. components, conditions and outcomes.
• Corrective actions are procedures utilized in a safe • Communicates appropriate
identified, and documentation working environment. verbal/non-verbal messages,
is completed once corrective • Knowledge of the conse- presents basic ideas/
actions are taken. quences of safety situations information, explains concepts
• Appropriate parties are such as systems under pressure and actively participates in
consulted about corrective and stored energy systems vs. discussion.
actions. low risk maintenance items. • Records information
• Corrective actions are taken • Knowledge of documentation accurately, completes forms
promptly according to procedures and reporting and writes simple documents.
company procedures. requirements for unsafe and • Identifies the problem,
• Follow-up procedures are out of compliance conditions, analyzes possible causes/ 31
followed. behaviors and environmental/ reasons, generates/evaluates
• Food safety policies regulatory requirements. solutions and devises/imple-
are adhered to (Good • Knowledge of procedures for ments plan of action.
Manufacturing Practices) taking corrective actions. • Maintains a positive self-image,
according to company, • Knowledge of Good responds assertively, defends
customer and USDA Manufacturing Practices and own viewpoints, accepts
guidelines. company, customer and USDA constructive criticism, and
policies and guidelines for accepts responsibility for own
food safety policies. behavior
Food Manufacturing Maintenance Mechanics
Critical Work Function:
A. Maintain a Safe, Healthy and Environmentally
Conscious Work Environment – Continued
Key Activity
A4. Attend safety meetings.
Performance Indicators – Employability Skills –
Technical Knowledge –
How do we know when the task SCANS Skills and
Skills, Abilities, Tools
is performed well? Foundational Abilities
• Meetings are attended in an • Knowledge of company • Actively participates in team
effective and focused manner procedures and standards. activities, volunteers for
with full participation. • Knowledge of meeting/ special tasks, demonstrates
• Information regarding safety is training protocols. commitment, works to
accurately given and received. • Knowledge of work area safety improve team skills and
• Information regarding unsafe requirements. encourages/supports team
behavioral/ work practices • Knowledge of food manufac- members.
and/or work areas is accurately turing plant terminology. • Listens attentively and confirms
given and received. • Knowledge of work and interprets communication.
• Issues are accurately discussed environment and safety • Responds appropriately to
and solutions are defined. policies. others, takes active interest
• Communication is respectful • Knowledge of company safety in and willingly helps others,
and without discrimination. program. and modifies behavior to
• Follow-up on assigned safety environment.
tasks is completed. • Communicates appropriate
• Safety needs are commu- verbal/non-verbal messages,
nicated effectively and in a presents basic ideas/
timely manner. information, explains concepts
and actively participates in
32 discussion.
• Maintains a positive self-image,
responds assertively, defends
own viewpoints, accepts
constructive criticism and
accepts responsibility for own
behavior.
• Understands the legal aspects
of discrimination, respects the
rights of others and demon-
strates awareness of diversity.
Food Manufacturing Maintenance Mechanics
Critical Work Function:
A. Maintain a Safe, Healthy and Environmentally
Conscious Work Environment – Continued
Key Activity
A5. Reclaim recycle or dispose of fluids, refrigerants,
materials and waste.
Performance Indicators – Employability Skills –
Technical Knowledge –
How do we know when the task SCANS Skills and
Skills, Abilities, Tools
is performed well? Foundational Abilities
• Fluids, refrigerants, materials • Knowledge of laws, regula- • Follows procedures and pays
and waste that can be tions and company policies attention to details, follows
reclaimed are correctly regarding reclaiming, up on assigned tasks, works
identified. recycling and disposal of with minimal supervision, and
• Proper recycling, reclaiming fluids, refrigerants, materials demonstrates initiative.
and disposal procedures and waste. • Maintains self-control, accepts
are followed. • Knowledge of guidelines for responsibility for own behavior,
• Hazardous materials regula- and how to use PPE. accepts constructive criticism
tions are followed. • Ability to discern fluids, and sets well-defined/realistic
• No fluids are spilled or refrigerants, materials and goals.
fluid spills are handled in waste that can be reclaimed • Uses materials in a safe and
accordance with food safety and recycled. efficient manner, and acquires
guidelines. • Knowledge of recycling, and distributes supplies and
• Safety procedures are followed reclaiming and disposal equipment.
in accordance with company procedures and locations.
policies and procedures. • Knowledge of hazardous
• All laws and regulations and materials regulations.
company policies are followed
and compliance requirements
33
met regarding reclaiming,
recycling and disposal of fluids,
refrigerants, materials and
waste.
• Appropriate PPE equipment
is worn.
• Information regarding
problems with fluid,
refrigerant, material and
waste reclamation, recycling
and disposal locations is
communicated to appropriate
personnel effectively and in a
timely manner.
Food Manufacturing Maintenance Mechanics
Critical Work Function:
B. Maintain and Repair Plant Equipment
Key Activity
B1. Perform troubleshooting
Performance Indicators – Employability Skills –
Technical Knowledge –
How do we know when the task SCANS Skills and
Skills, Abilities, Tools
is performed well? Foundational Abilities
• Blueprints and schematics are • Knowledge of the system and • Identifies the problem,
consulted as necessary. plant equipment, and how it analyzes possible causes/
• Information about the nature interacts with other systems reasons, generates/evaluates
and possible causes of failure and sequence of operations. solutions and devises/imple-
is systematically gathered • Knowledge of and ability to ments plan of action.
through visual inspection, perform diagnostic tests, use • Identifies the problem,
experience, operator test equipment and interpret applies principles to process/
feedback, observation of plant the output. procedure, extracts infor-
equipment during operation • Knowledge of basic trouble- mation/data and uses logic to
and disassembly of plant shooting processes and proce- draw conclusions.
equipment, as appropriate. dures such as visual inspection, • Identifies system discrepancies,
• Proper diagnostic tests experience, operator feedback monitors and adjusts system
and root cause analysis are and observation of plant performance and trouble-
performed and repeated equipment during operation shoots system malfunction/
as necessary and solutions and disassembly. failure.
correctly identified. • Knowledge of root cause • Listens attentively, and
• Diagnosis is timely and analysis and ability to diagnose confirms and interprets
effective. problems and identify their communication.
• Troubleshooting processes solutions. • Demonstrates creative thinking
and outcomes are properly • Ability to access and read process while problem
34 documented in accordance equipment logs and histories solving and develops creative
with company procedures. to gain knowledge of typical solutions.
• Manufacturer’s performance problems, symptoms and • Follows specified maintenance,
specifications are used when causes. identifies and corrects
evaluating plant equipment • Ability to execute isolation malfunctions, troubleshoots
performance. procedures. failures, evaluates performance
• Procedures for isolating • Ability to read blueprints and of technology.
problems are initiated schematics. • Utilizes mathematical formulas
correctly and followed through • Knowledge of multiple trades and processes, summarizes
completely. and crafts and their functional and translates mathematical
• Proper procedures and precau- boundaries and nomenclature. data.
tions are followed with respect • Ability to read and understand • Recognizes job tasks and may
to food safety in accordance manufacturer’s specifications distribute work assignments
with customer, company and manuals. and match talent to positions.
and USDA specifications and • Knowledge of and ability to
regulations. apply customer, company and
• Trades and craft boundaries are USDA food safety specifications
adhered to where applicable. and regulations.
• Issues are escalated in • Knowledge of food-compliant
accordance with company maintenance materials and
policies and procedures. processes.
• Knowledge of escalation
procedures.
Food Manufacturing Maintenance Mechanics
Critical Work Function:
B. Maintain and Repair Plant Equipment – Continued
Key Activity
B2. Perform preventive maintenance (PM)
Performance Indicators – Employability Skills –
Technical Knowledge –
How do we know when the task SCANS Skills and
Skills, Abilities, Tools
is performed well? Foundational Abilities
• Safety procedures (including • Knowledge of food • Identifies relevant details, facts,
lockout tagout) are followed manufacturing equipment, specifications; follows set of
and proper PPE is worn or components, processes and instructions and probes to gain
used. sequence of operations. knowledge/ information.
• PM sheet guides and proce- • Ability to read and interpret • Recognizes accuracy of
dures are completely followed. manufacturer’s specifications, information, provides accurate
• Maintenance job is recommendations and PM communication, interprets
documented and verified sheets. information and prepares basic
according to company • Ability to identify tolerances summaries.
procedure. within the PM. • Records information
• Required maintenance • Knowledge of tools and accurately, completes forms
is performed correctly, equipment used for PM. and writes simple documents.
completed on time and meets • Knowledge of hazardous • Follows procedures and pays
the required frequency. materials and waste recycling, attention to details, follows
• Suggestions to revise reclaiming and disposal laws; up on assigned tasks, works
maintenance plan are made regulations; and relevant with minimal supervision and
to appropriate personnel company policies and demonstrates initiative.
effectively and in a timely procedures. • Maintains self-control, accepts
manner. • Knowledge of PM require- responsibility for own behavior,
• Food safety is maintained ments and frequency. accepts constructive criticism
according to customer, • Knowledge of PM documen- and sets well-defined/realistic 35
company and USDA specifica- tation procedures. goals.
tions and regulations. • Knowledge of company safety • Follows specified maintenance,
• Equipment is properly policies and procedures, identifies and corrects malfunc-
calibrated. including lockout tagout tions, troubleshoots failures,
• Hazardous materials and waste concepts and procedures. and evaluates performance of
are recycled, reclaimed and/or • Ability to use PPE. technology.
disposed of in accordance with • Knowledge of and ability to • Performs basic computations
all applicable laws, regulations apply customer, company and and measurements, performs
and company policies and USDA food safety specifications measurements and predicts
procedures. and regulations. arithmetic results.
• Tests for functionality and • Knowledge of food-compliant
safety of plant equipment and maintenance materials and
systems are completed and processes.
documented in accordance • Ability to calibrate equipment.
with all applicable laws, regula- • Knowledge of cyber security
tions and company policies procedures.
and procedures. • Knowledge of tests for
• PM projects or tasks are functionality and safety of
coordinated with operators plant equipment and system;
and other production staff. and related laws, regulations,
policies and procedures.
• Ability to interact with
operators and other
production staff.
Food Manufacturing Maintenance Mechanics
Critical Work Function:
B. Maintain and Repair Plant Equipment – Continued
Key Activity
B3. Gather parts, materials, tools and equipment
Performance Indicators – Employability Skills –
Technical Knowledge –
How do we know when the task SCANS Skills and
Skills, Abilities, Tools
is performed well? Foundational Abilities
• Tools, parts, materials and • Knowledge of tool termi- • Translates blueprints, drawings
equipment are located in a nology and the locations of and diagrams; applies
timely manner. tools, parts, materials and appropriate principles to the
• If a part is not available, equipment. situation, and utilizes previous
follow-up occurs to ensure • Knowledge of tools such as training/experience to predict
that adequate supplies are hand tools and precision outcomes.
maintained. measuring tools. • Uses materials in a safe and
• Calibration and certification • Knowledge of different efficient manner, and acquires
of tools is ensured where types of materials used in and distributes supplies and
applicable. maintenance, parts and their equipment.
• Tool box is properly stocked. application. • Identifies relevant details, facts
• Tools and equipment are • Ability to inspect and calibrate and specifications; follows set
checked to insure they are in tools, determine whether of instructions; and probes to
safe and proper working order. certifications are current, and gain knowledge/information.
• Procedures regarding submit nonfunctional tools for • Understands decision-making
nonfunctioning tools and repair. process, analyzes situation/
equipment are followed. • Ability to plan and organize information and considers
• Recommendations for acqui- relevant materials and tools risks/implications.
sition of new tools are made to prior to job site work. • Utilizes mathematical formulas
appropriate personnel. • Ability to use prior documen- and processes, summarizes
36 • Tools are returned to the tation for planning and and translates mathematical
proper location in accordance organizing work. data.
with company procedures. • Ability to anticipate new • Understands technology
• Where required, tool boxes, equipment, tools and applications, follows proper
tools and parts are properly requisitions needed to perform procedures, understands the
sanitized. necessary work and improve operation and manipulates
• Paperwork for all required efficiency and safety. technology for desired results.
permits is correctly filled • Knowledge of established • Follows specified maintenance,
out, posted and turned in, policies and procedures identifies and corrects malfunc-
and required equipment is regarding tools, parts, tions, troubleshoots failures,
assembled at the work site. materials and equipment. and evaluates performance of
• Knowledge of sanitation technology.
requirements and procedures
for tools, tool boxes and parts.
• Knowledge of permits
required, and the associated
procedures and equipment
required for each permit.
Food Manufacturing Maintenance Mechanics
Critical Work Function:
B. Maintain and Repair Plant Equipment – Continued
Key Activity
B4. Perform diagnostic testing
Performance Indicators – Employability Skills –
Technical Knowledge –
How do we know when the task SCANS Skills and
Skills, Abilities, Tools
is performed well? Foundational Abilities
• All required test equipment is • Knowledge of plant equipment • Knows available technology
identified and located. being tested and location of and understands requirements
• Test equipment is used information about equipment of the task and technological
correctly. and the characteristics/condi- results.
• Testing procedures are tions of normal operations. • Understands technology
gathered from company or • Knowledge of location and applications, follows proper
technical manuals. proper operation of test procedures, understands the
• Calibration and certification equipment. operation and manipulates
of test equipment is ensured • Knowledge of functions of test technology for desired results.
where applicable. equipment. • Identifies relevant details, facts
• Tests are conducted in • Ability to calibrate test and specifications; follows set
accordance with company, equipment and determine of instructions; and probes to
customer and USDA specifica- whether certifications are gain knowledge/information.
tions and regulations. current. • Identifies the problem,
• Test results are compared • Knowledge of baseline applies principles to process/
with baseline operating data operating data of the plant procedure, extracts infor-
of the plant equipment, equipment. mation/data and uses logic to
and anomalies are corrected • Knowledge of test result draw conclusions.
or referred to appropriate documentation procedures. • Selects appropriate categories
personnel or departments. • Knowledge of electronics for information, interprets
• Test results are properly including analog, digital and information and applies 37
documented and filed. logic theory. processes to new information.
• Safety procedures and regula- • Knowledge of the manufac- • Starts on time, efficiently
tions are completely followed. turing process and how testing manages time, prioritizes daily
• Sights, sounds, feel and smell impacts food safety. tasks and monitors/adjusts task
of plant equipment is used • Knowledge of food-compliant sequence.
to verify that it is operating maintenance materials and • Follows specified maintenance,
normally. processes. identifies and corrects malfunc-
• Ability to perform diagnostic tions, troubleshoots failures,
testing with no adverse impact and evaluates performance of
on food safety. technology.
• Knowledge of tests that put
the manufacturing process at
risk.
• Knowledge of when to make
corrections and when to refer
problems to other individuals
or departments.
• Knowledge of company,
customer and USDA
specifications and regulations
regarding diagnostic testing.
• Knowledge of safety proce-
dures and regulations.
• Ability to identify plant
equipment malfunctions using
technical indicators, gauges
and human sensory inputs
(sight, sound, smell, feel).
Food Manufacturing Maintenance Mechanics
Critical Work Function:
B. Maintain and Repair Plant Equipment – Continued
Key Activity
B5. Perform repairs
Performance Indicators – Employability Skills –
Technical Knowledge –
How do we know when the task SCANS Skills and
Skills, Abilities, Tools
is performed well? Foundational Abilities
• Work is performed safely in • Ability to track how compo- • Starts on time, efficiently
accordance with company nents and equipment are manages time, prioritizes daily
policies and procedures disassembled so they can be tasks, and monitors/adjusts
(including lockout tagout) and correctly put back together. task sequence.
in accordance with all applicable • Knowledge of safe work • Identifies relevant details, facts
laws and regulations. practices with respect to repairs, and specifications; follows set
• Repair procedures are followed. including lockout tagout. of instructions; and probes to
• During repair process, plant • Knowledge of company policies gain knowledge/information.
equipment is thoroughly and procedures regarding • Records information
inspected to identify other documentation and safety. accurately, completes forms
repair needs. • Knowledge of technical and writes simple documents.
• Where appropriate, repair plan requirements for specifications • Uses materials in a safe and
and job safety/hazard analysis of parts to be repaired and efficient manner, and acquires
are effectively communicated manufacturer’s recommended and distributes supplies and
to appropriate personnel in a procedures. equipment.
timely manner. • Knowledge of plant equipment • Follows procedures and pays
• Replaced parts are properly function, purpose within attention to details, follows
disposed of or refurbished and the system, and sequence of up on assigned tasks, works
returned to service. operations and how they affect with minimal supervision and
• Repairs are conducted and other plant systems demonstrates initiative.
38 documented in accordance with • Knowledge of plant equipment • Recognizes job tasks and may
company, USDA and industry inspection procedures. distribute work assignments
regulations, and in such a way • Knowledge of proper disposal and match talent to positions.
as to minimize negative impact and refurbishing procedures for
on product flow and food safety parts and components.
and quality. • Knowledge of and ability to
• Equipment is properly calibrated apply customer, company and
and certifications are current. USDA food safety specifications
• Components are correctly and regulations.
programmed, integrated into • Knowledge of food-compliant
the plant system and backed up, maintenance materials and
and all security procedures are processes.
followed. • Ability to identify unacceptable
• Hazardous materials and waste product.
are recycled, reclaimed and/or • Ability to calibrate tools and
disposed of in accordance with determine whether certifications
all applicable laws, regulations are current.
and company policies and • Ability to program components,
procedures. integrate them into the plant
• Tests for functionality and safety system and execute backup
of plant equipment and systems protocols.
are completed and documented • Knowledge of cyber security
in accordance with all applicable procedures.
laws, regulations and company • Knowledge of tests for
policies and procedures. functionality and safety of
• All documentation is completed plant equipment and system;
and submitted in accordance and related laws, regulations,
with company policies and policies and procedures.
procedures.
Food Manufacturing Maintenance Mechanics
Critical Work Function:
B. Maintain and Repair Plant Equipment – Continued
Key Activity
B6. Document equipment maintenance and repair
Performance Indicators – Employability Skills –
Technical Knowledge –
How do we know when the task SCANS Skills and
Skills, Abilities, Tools
is performed well? Foundational Abilities
• Documentation is performed • Knowledge of documentation • Identifies the problem,
according to company and policies and procedures. applies principles to process/
department policies and • Ability to input relevant and procedure, extracts infor-
procedures. accurate data into manual and mation/data and uses logic to
• Documents and appropriate electronic systems. draw conclusions.
files are input into database, • Understanding of how • Records information
filed or distributed to correct documentation and proce- accurately, completes forms
parties. dures affect critical operations and writes simple documents.
• Preventive maintenance and timelines. • Selects data relevant to the
schedule is properly adjusted • Ability to report findings and task, identifies the need for
to reflect repairs made. make recommendations based data and predicts outcomes.
• Documentation is accurate, on documented history and • Selects appropriate categories
legible and complete and is findings. for information, interprets
completed in a timely manner. • Understanding of the information and applies
• Documentation is under- operational system and how processes to new information.
standable and succinct. equipment maintenance issues
can adversely impact opera-
tions, food safety and food
quality.
• Ability to use correct
terminology.
39
Food Manufacturing Maintenance Mechanics
Critical Work Function:
C. Install and/or Modify Equipment
Key Activity
C1. Support the installation, move/removal, customization or
upgrade of equipment
Performance Indicators – Employability Skills –
Technical Knowledge –
How do we know when the task SCANS Skills and
Skills, Abilities, Tools
is performed well? Foundational Abilities
• Installation, move/removal, • Knowledge of safety • Identifies relevant details, facts
customization or upgrade of regulations, requirements and specifications; follows set
plant equipment is performed and policies regarding of instructions; and probes to
safely, including lockout plant equipment, including gain knowledge/information.
tagout, and in accordance lockout tagout concepts and • Recognizes accuracy of
with all applicable laws and procedures. information, provides accurate
regulations. • Ability to implement and communication, interprets
• Plan of action is followed. follow a plan of action. information and prepares basic
• Installation, move/removal, • Ability to suggest modification summaries.
customization or upgrade of to plans of action as needed. • Follows procedures and pays
plant equipment is completed • Knowledge of the system attention to details, follows
to specification and in a timely and equipment, and how it up on assigned tasks, works
manner. interacts with other systems. with minimal supervision and
• Proper procedures and precau- • Ability to understand and demonstrates initiative.
tions are followed with respect follow vendors’ equipment • Actively participates in team
to food safety in accordance requirements and activities, volunteers for
with customer, company recommendations. special tasks, demonstrates
and USDA specifications and • Knowledge of plant equipment commitment, works to
regulations. installation, move/removal, improve team skills and
40 customization or upgrade encourages/supports team
procedures. members.
• Knowledge of vendor, • Adheres to standards,
equipment and system encourages others to adopt
terminology. new concepts, demonstrates
• Ability to understand as-built commitment to excellence and
and layout diagrams and leads by example.
blueprints. • Translates blueprints/drawings/
• Knowledge of procedures and diagrams, applies appropriate
precautions with respect to principles and theories to
food safety. situations and utilizes previous
• Knowledge of food-compliant training/experience to predict
maintenance materials and outcomes.
processes. • Understands the legal aspects
• Knowledge of customer, of discrimination, respects the
company and USDA specifica- rights of others and demon-
tions and regulations. strates awareness of diversity.
Food Manufacturing Maintenance Mechanics
Critical Work Function:
C. Install and/or Modify Equipment – Continued
Key Activity
C2. Assist with testing to ensure functionality after installation,
move/removal, customization or upgrade
Performance Indicators – Employability Skills –
Technical Knowledge –
How do we know when the task SCANS Skills and
Skills, Abilities, Tools
is performed well? Foundational Abilities
• Prior to starting the test, • Knowledge of testing • Identifies relevant details, facts
communications are made to procedures and parameters and specifications; follows set
appropriate parties regarding and company policies and of instructions; and probes to
the test. procedures. gain knowledge/information.
• Testing is performed in • Knowledge and application • Identifies system discrepancies,
accordance with company, of relevant safety policies monitors and adjusts system
equipment manufacturer and procedures, including performance, and trouble-
and industry protocols lockout tagout concepts and shoots system malfunction/
(including lockout tagout) and procedures. failure.
procedures. • Knowledge of submittal • Understands decision-making
• Test procedures and results procedures for test results. process, analyzes situation/
are properly documented and • Ability to input test results information and considers
submitted. manually and electronically. risks/implications.
• Test equipment is checked, • Knowledge of test equipment • Suggests system modifications/
calibrated and used properly. calibration and use. improvements and determines
• Proper procedures and precau- • Knowledge of food-compliant system components to be
tions are followed with respect maintenance materials, improved.
to food safety in accordance precautions and processes. • Performs basic computations
with customer, company • Knowledge of customer, and measurements, performs
and USDA specifications and company and USDA specifica- measurements, and predicts 41
regulations. tions and regulations. arithmetic results.
• Understands technology
applications, follows proper
procedures, understands the
operation and manipulates
technology for desired results.
• Follows specified maintenance,
identifies and corrects
malfunctions, troubleshoots
failures, evaluates performance
of technology.
Food Manufacturing Maintenance Mechanics
Critical Work Function:
C. Install and/or Modify Equipment – Continued
Key Activity
C3. Fabricate parts or components
Performance Indicators – Employability Skills –
Technical Knowledge –
How do we know when the task SCANS Skills and
Skills, Abilities, Tools
is performed well? Foundational Abilities
• Work is performed safely, and • Knowledge of the purpose and • Identifies relevant details, facts
PPE is used in accordance proper functionality of plant and specifications; follows set
with company policies and equipment and systems. of instructions; and probes to
procedures. • Knowledge of fabrication gain knowledge/information.
• Proper tools and materials are equipment, tools and • Utilizes mathematical formulas
used correctly. processes. and processes, and summarizes
• Where applicable, specifica- • Ability to design, produce and translates mathematical
tions are written in accordance and fit fabricated parts and data.
with industry standards. components to existing or new • Demonstrates creative-thinking
• Measurements and quantity equipment. process while problem
estimates are accurate. • Knowledge of layout solving and develops creative
• Documentation is completed techniques and procedures. solutions.
accurately and submitted • Ability to read blueprints and • Understands decision-making
according to procedure, as schematics. process, analyzes situation/
required. • Knowledge of safety standards, information and considers
• Fabricated parts and compo- PPE and how to use it, permits, risks/implications.
nents are designed and tested and permit processes and • Knows available technology
to ensure they are functional, requirements. and understands requirements
aesthetically acceptable • Ability to measure accurately. of the task and technological
and conform to design • Ability to estimate quantities results.
42 specifications. and write specifications. • Understands technology
• All required permits are • Knowledge of documentation applications, follows proper
completed, posted and requirements and procedures. procedures, understands the
turned in, and all associated • Knowledge of materials such operation and manipulates
equipment is assembled. as hardware, lubricants, technology for desired results.
cutting fluids and fasteners, • Uses materials in a safe and
metals, plastics, and fittings. efficient manner and acquires
• Knowledge of functionality and distributes supplies and
testing procedures and equipment.
equipment.
Food Manufacturing Maintenance Mechanics
Critical Work Function:
D. Communicate with Co-Workers to Promote
Productivity and Customer Responsiveness
Key Activity
D1. Fill out maintenance and repair logs
Performance Indicators – Employability Skills –
Technical Knowledge –
How do we know when the task SCANS Skills and
Skills, Abilities, Tools
is performed well? Foundational Abilities
• Status reports are clearly • Knowledge of plant • Records information
communicated from shift to equipment, system and accurately, completes forms
shift. maintenance terminology. and writes simple documents.
• Documentation is performed • Knowledge of status reports • Selects data relevant to the
according to company and and repair logs. task, identifies the need for
department policies and • Knowledge of documentation data and predicts outcomes.
procedures. policies and procedures. • Demonstrates honesty and
• Documents and appropriate • Ability to use internal company trustworthiness, accepts
files are input into database, computer maintenance responsibility for own behavior,
filed or distributed to correct management system. and recommends ethical
parties. course of action.
• Documentation is accurate, • Identifies system discrepancies,
legible and complete, and is monitors and adjusts system
completed in a timely manner. performance, and trouble-
• Documentation is under- shoots system malfunction/
standable and succinct. failure.
• Communicates appropriate
verbal/non-verbal messages,
presents basic ideas/ 43
information, explains concepts
and actively participates in
discussion.
• Understands computer
operation, performs basic
data entry, locates and
retrieves information, and uses
integrated/multiple software.
• Selects appropriate categories
for information, interprets
information and applies
processes to new information.
Food Manufacturing Maintenance Mechanics
Critical Work Function:
D. Communicate with Co-Workers to Promote Productivity and
Customer Responsiveness – Continued
Key Activity
D2. Participate in meetings and problem-solving groups
Performance Indicators – Employability Skills –
Technical Knowledge –
How do we know when the task SCANS Skills and
Skills, Abilities, Tools
is performed well? Foundational Abilities
• Meetings are attended with • Meetings are attended with • Identifies the problem,
active participation and with active participation and with analyzes possible causes/
adequate preparation. adequate preparation. reasons, generates/evaluates
• Information is accurately given • Information is accurately given solutions and devises/imple-
and received. and received. ments plan of action.
• Questions are asked and • Questions are asked and • Actively participates in team
answered in a courteous and answered in a courteous and activities, volunteers for
respectful manner. respectful manner. special tasks, demonstrates
• Issues are accurately and • Issues are accurately and commitment, works to
thoroughly discussed and thoroughly discussed and improve team skills and
solutions are defined. solutions are defined. encourages/supports team
• Communication is respect- • Communication is respect- members.
fully performed without fully performed without • Translates blueprints/drawings/
discrimination. discrimination. diagrams, applies appropriate
principles and theories to
situations, and utilizes previous
training/experience to predict
outcomes.
• Responds appropriately to
44 others, takes active interest
in and willingly helps others,
and modifies behavior to
environment.
• Listens attentively and confirms
and interprets communication.
• Understands decision-making
process, analyzes situation/
information and considers
risks/implications.
• Understands the legal aspects
of discrimination, respects the
rights of others and demon-
strates awareness of diversity.
• Communicates appropriate
verbal/non-verbal messages,
presents basic ideas/
information, explains concepts
and actively participates in
discussion.
Food Manufacturing Maintenance Mechanics
Critical Work Function:
D. Communicate with Co-Workers to Promote Productivity and
Customer Responsiveness – Continued
Key Activity
D3. Communicate job-specific needs
Performance Indicators – Employability Skills –
Technical Knowledge –
How do we know when the task SCANS Skills and
Skills, Abilities, Tools
is performed well? Foundational Abilities
• On-the-job issues and concerns • Knowledge of operators/other • Communicates appropriate
are discussed with appropriate production staff and business verbal/non-verbal messages,
parties. needs. presents basic ideas/
• Communication demonstrates • Knowledge of the roles and information, explains concepts
knowledge of operators and responsibilities of company and actively participates in
other production staff and personnel and departments. discussion.
business needs. • Knowledge of industry, plant, • Selects data relevant to the
• Communication is clear and company, equipment, safety, task, identifies the need for
relevant to the situation. regulatory, maintenance, repair data and predicts outcomes.
• Communication is made in a and personnel terminology. • Understands system organi-
timely and accurate manner to zation/hierarchy and follows
the correct parties. procedures.
• Records information
accurately, completes forms
and writes simple documents.
• Responds to customer needs
and demonstrates sensitivity
to customer concerns and
interests.
• Follows procedures and pays
45
attention to details, follows
up on assigned tasks, works
with minimal supervision, and
demonstrates initiative.
• Recognizes job tasks, and may
distribute work assignments
and match talent to positions.
Food Manufacturing Maintenance Mechanics
Critical Work Function:
D. Communicate with Co-Workers to Promote Productivity and
Customer Responsiveness – Continued
Key Activity
D4. Suggest ways to prevent future equipment malfunction or
improve equipment performance
Performance Indicators – Employability Skills –
Technical Knowledge –
How do we know when the task SCANS Skills and
Skills, Abilities, Tools
is performed well? Foundational Abilities
• Suggestions are made to • Knowledge of scheduling • Communicates appropriate
adjust maintenance scheduling and maintenance plans and verbal/non-verbal messages,
or maintenance plan based challenges. presents basic ideas/
on evidence from the last • Knowledge of the needs information, explains concepts
preventive maintenance for of operators and other and actively participates in
the plant equipment. production staff discussion.
• Communication is clear and • Knowledge of plant equipment • Records information
relevant to the situation. and repair histories. accurately, completes forms
• Communication is made in a • Knowledge of industry, plant, and writes simple documents.
timely and accurate manner to company, equipment, safety, • Suggests system modifications/
the correct parties. regulatory, maintenance, repair improvements and determines
• Suggestions take the internal and personnel terminology. system components to be
needs of operators and other • Knowledge of the roles and improved.
production staff into account. responsibilities of company • Follows procedures and pays
personnel and departments. attention to details, follows
• Knowledge of how mainte- up on assigned tasks, works
nance procedures affect critical with minimal supervision and
46 operations and timelines. demonstrates initiative.
• Translates blueprints/drawings/
diagrams, applies appropriate
principles and theories to
situations and utilizes previous
training/experience to predict
outcomes.
• Maintains a positive self-image,
responds assertively, defends
own viewpoints, accepts
constructive criticism, and
accepts responsibility for own
behavior.
• Understands negotiation
process, identifies conflicts and
demonstrates composure.
Food Manufacturing Maintenance Mechanics
Critical Work Function:
D. Communicate with Co-Workers to Promote Productivity and
Customer Responsiveness – Continued
Key Activity
D5. Promote teamwork and continuous improvement
Performance Indicators – Employability Skills –
Technical Knowledge –
How do we know when the task SCANS Skills and
Skills, Abilities, Tools
is performed well? Foundational Abilities
• Supervisor and co-workers • Knowledge of company • Adheres to standards,
are kept informed of events, policies, goals and targets. encourages others to adopt
requests and problems in the • Ability to determine when and new concepts, demonstrates
plant. how to consult with supervisor commitment to excellence and
• Company policies, goals and and co-workers. leads by example.
targets are clearly communi- • Knowledge of industry, • Demonstrates honesty and
cated and supported. facility/plant, agency, system, trustworthiness, accepts
• Information is accurately given, plant equipment, scientific, responsibility for own behavior,
received and understood and technical, tool, safety and and recommends ethical
is appropriate to the situation personnel terminology. course of action.
and timely. • Ability to locate and use • Models proper performance/
• Oral and written commu- communications devices such attitudes, conducts task-
nication is concise and as telephones, radios, public specific training and coaches
courteous. address systems, email and others to apply related
• Proper terminology is used to mobile devices. concepts.
communicate with team and • Ability to identify and report • Recognizes accuracy of
other personnel. problems. information, provides accurate
• Input is given to promote • Ability to interact with communication, interprets
teamwork and continuous operators and other information and prepares basic
improvement. production staff. summaries.
47
• Operators and production staff • Responds to customer needs
are contacted to obtain input and demonstrates sensitivity
on maintenance issues. to customer concerns and
interests.
• Maintains a positive self-image,
responds assertively, defends
own viewpoints, accepts
constructive criticism and
accepts responsibility for own
behavior.
• Understands the legal aspects
of discrimination, respects the
rights of others and demon-
strates awareness of diversity.
Food Manufacturing Maintenance Mechanics
Critical Work Function:
E. Adhere to Company and Regulatory
Policies and Standards
Key Activity
E1. Comply with environmental regulations
Performance Indicators – Employability Skills –
Technical Knowledge –
How do we know when the task SCANS Skills and
Skills, Abilities, Tools
is performed well? Foundational Abilities
• Environmental regulations are • Knowledge of procedures to • Demonstrates honesty and
supported and followed. prevent or reduce emissions trustworthiness, accepts
• Non-compliant conditions are and spills. responsibility for own behavior,
reported to proper personnel • Knowledge of Hazardous and recommends ethical
and authorities in accordance Materials (HAZMAT) proce- course of action.
with all applicable laws, regula- dures information. • Identifies relevant details, facts
tions and company policies. • Knowledge of emergency and specifications; follows set
• Procedures to prevent policies and procedures and of instructions; and probes to
non-compliant conditions are ability to use emergency gain knowledge/information.
implemented in an effective equipment. • Identifies the problem,
manner. • Knowledge of PPE applies principles to process/
requirements. procedure, extracts infor-
• Knowledge of regulations mation/ data and uses logic to
protecting the environment. draw conclusions.
• Knowledge of reporting • Follows procedures and pays
procedures. attention to details, follows
up on assigned tasks, works
with minimal supervision, and
48 demonstrates initiative.
Food Manufacturing Maintenance Mechanics
Critical Work Function:
E. Adhere to Company and Regulatory
Policies and Standards – Continued
Key Activity
E2. Adhere to site-specific work practices and procedures, and
emergency response and preparedness.
Performance Indicators – Employability Skills –
Technical Knowledge –
How do we know when the task SCANS Skills and
Skills, Abilities, Tools
is performed well? Foundational Abilities
• Site-specific work practices • Knowledge of site-specific • Identifies relevant details, facts
and procedures are thoroughly work practices and procedures. and specifications; follows set
followed. • Knowledge of emergency of instructions; and probes to
• Emergency response and response and preparedness. gain knowledge/information.
preparedness procedures are • Selects appropriate categories
followed. for information, interprets
information and applies
processes to new information.
• Selects data relevant to the
task, identifies the need for
data and predicts outcomes.
• Maintains a positive self-image,
responds assertively, defends
own viewpoints, accepts
constructive criticism and
accepts responsibility for own
behavior.
• Starts on time, efficiently 49
manages time, prioritizes daily
tasks and monitors/adjusts task
sequence.
Food Manufacturing Maintenance Mechanics
Critical Work Function:
E. Adhere to Company and Regulatory
Policies and Standards – Continued
Key Activity
E3. Comply with safety requirements and standards.
Performance Indicators – Employability Skills –
Technical Knowledge –
How do we know when the task SCANS Skills and
Skills, Abilities, Tools
is performed well? Foundational Abilities
• Safety and OSHA • Knowledge of site-specific • Identifies relevant details, facts
(Occupational Safety and work practices and procedures. and specifications; follows set
Health Administration) • Knowledge of emergency of instructions; and probes to
regulations are supported and response and preparedness. gain knowledge/information.
followed. • Selects appropriate categories
• Mandatory safety training for information, interprets
is attended with active information and applies
participation. processes to new information.
• Potential job hazards are • Selects data relevant to the
accurately identified and task, identifies the need for
clearly discussed with all data and predicts outcomes.
appropriate personnel. • Maintains a positive self-image,
• Safety violations are reported responds assertively, defends
to appropriate personnel own viewpoints, accepts
in a timely manner and in constructive criticism and
accordance with company accepts responsibility for own
policies. behavior.
• Cooperation with safety • Starts on time, efficiently
50 department or other personnel manages time, prioritizes daily
is provided in an effective tasks and monitors/adjusts task
manner. sequence.
Food Manufacturing Maintenance Mechanics
Critical Work Function:
F. Perform Technical and Administrative Duties
Key Activity
F1. Maintain manual and electronic records, databases and reports.
Performance Indicators – Employability Skills –
Technical Knowledge –
How do we know when the task SCANS Skills and
Skills, Abilities, Tools
is performed well? Foundational Abilities
• Records and reports are • Knowledge of policies and • Understands computer
accurate and are filed in requirements regarding operation, performs basic
proper locations. records, databases and reports. data entry, locates and
• Records and reports are • Knowledge of data-upload retrieves information, and uses
submitted in a timely manner procedures and locations. integrated/multiple software.
to appropriate personnel and • Knowledge of company • Identifies relevant details, facts
departments. policies, procedures and and specifications; follows set
• Records and reports are kept protocols with respect to of instructions; and probes to
up to date. security and use of computers gain knowledge/information.
• Records and reports are and mobile devices. • Records information
maintained in accordance accurately, completes forms
with company and regulatory and writes simple documents.
policies. • Selects data relevant to the
• Security and retention task, identifies the need for
protocols are accurately data and predicts outcomes.
followed. • Selects appropriate categories
• Data files are correctly for information, interprets
uploaded to server, intranet information and applies
or other designated archive processes to new information. 51
location.
• PCs and mobile devices are
used in a secure and prudent
manner in accordance
with company policies and
procedures.
Food Manufacturing Maintenance Mechanics
Critical Work Function:
F. Perform Technical and Administrative Duties – Continued
Key Activity
F2. Assist in training other employees.
Performance Indicators – Employability Skills –
Technical Knowledge –
How do we know when the task SCANS Skills and
Skills, Abilities, Tools
is performed well? Foundational Abilities
• Mentoring / training provided • Knowledge of company, • Communicates appropriate
is accurate, relevant and industry and regulatory verbal/non-verbal messages,
timely. terminology. presents basic ideas/
• Questions are answered in • Ability to identify and support information, explains concepts
a courteous and respectful trainee’s needs. and actively participates in
manner. • Knowledge of subject matter discussion.
• Communication is appropriate (such as manufacturing plant • Responds appropriately to
and proper terminology is equipment, maintenance others, takes active interest
used. requirements, how to use in and willingly helps others,
• Receptivity and support are tools). and modifies behavior to
provided to all trainees to help • Ability to demonstrate environment.
them advance. approved company • Models proper performance/
• Proficiency in subject matter is techniques, practices and attitudes, conducts task-
maintained. procedures. specific training and coaches
• Company goals are supported others to apply related
through effective mentorship. concepts.
• Adheres to standards,
encourages others to adopt
new concepts, demonstrates
commitment to excellence and
52 leads by example.
• Maintains a positive self-image,
responds assertively, defends
own viewpoints, accepts
constructive criticism, and
accepts responsibility for own
behavior.
• Understands the legal aspects
of discrimination, respects the
rights of others and demon-
strates awareness of diversity.
• Understands negotiation
process, identifies conflicts and
demonstrates composure.
Food Manufacturing Maintenance Mechanics
Critical Work Function:
F. Perform Technical and Administrative Duties – Continued
Key Activity
F3. Perform housekeeping.
Performance Indicators – Employability Skills –
Technical Knowledge –
How do we know when the task SCANS Skills and
Skills, Abilities, Tools
is performed well? Foundational Abilities
• Materials are kept in a safe • Knowledge of proper cleaning, • Follows procedures and pays
manner. organizing and storage attention to details, follows
• Unsafe conditions are procedures. up on assigned tasks, works
identified and reported • Ability to perform inspection of with minimal supervision and
promptly. tools, materials and equipment demonstrates initiative.
• Workstation/work area and/ (restock, recycle or repair). • Maintains self-control, accepts
or shop are clean and clear of • Knowledge and ability to responsibility for own behavior,
safety hazards. identify and report or correct accepts constructive criticism
• All appropriate safety for unsafe conditions. and sets well-defined/realistic
equipment is present and in • Understanding of house- goals.
proper working order. keeping protocols and • Starts on time, efficiently
• Housekeeping protocols are requirements. manages time, prioritizes daily
followed. • Knowledge of hazardous tasks and monitors/adjusts task
• Tools and equipment are material laws, rules and sequence.
cleaned, returned to proper regulations. • Adheres to standards,
location and tagged if broken. • Ability to identify nonfunc- encourages others to adopt
• All hazardous materials tional tools for repair, and new concepts, demonstrates
procedures are followed in knowledge of communications commitment to excellence
accordance with applicable and tagging requirements for and leads by example.
laws and regulations. nonfunctioning tools.
• Knowledge of safety 53
equipment and its proper
working order.
Food Manufacturing Maintenance Mechanics
Critical Work Function:
F. Perform Technical and Administrative Duties – Continued
Key Activity
F4. Obtain and maintain proficiency in current
and new technologies.
Performance Indicators – Employability Skills –
Technical Knowledge –
How do we know when the task SCANS Skills and
Skills, Abilities, Tools
is performed well? Foundational Abilities
• Technical trainings and • Ability to access information • Identifies relevant details, facts
working demonstrations on continuous learning and specifications; follows set
are attended with full opportunities. of instructions; and probes to
participation. • Knowledge of location of gain knowledge/ information.
• Initiative is demonstrated food manufacturing plant • Selects data relevant to the
to participate in continuous equipment instruction manuals task, identifies the need for
learning opportunities. and how to use them. data and predicts outcomes.
• Initiative is demonstrated • Ability to obtain and maintain • Understands computer
to recommend and request required certifications. operation, performs basic
training opportunities from data entry, locates and
management and gain retrieves information, and uses
knowledge on an individual integrated/multiple software.
basis. • Suggests system modifications/
• All required certifications are improvements and determines
kept up to date. system components to be
improved.
• Knows available technology
and understands requirements
of the task and technological
54 results.
• Demonstrates creative thinking
process while problem
solving and develops creative
solutions.
Food Manufacturing Maintenance Mechanics
Critical Work Function:
G. Operate Auxiliary Equipment (e.g., Fork Lift, Aerial Lift)
Key Activity
G1. Inspect equipment.
Performance Indicators – Employability Skills –
Technical Knowledge –
How do we know when the task SCANS Skills and
Skills, Abilities, Tools
is performed well? Foundational Abilities
• Pre start-up checks/inspections • Knowledge of equipment • Translates blueprints, drawings
are thoroughly performed. function and use. and diagrams; applies
• The correct checklists are • Knowledge of approved appropriate principles to the
efficiently located and used company and manufacturers’ situation; and utilizes previous
properly. inspection procedures, training/experience to predict
• Equipment is signed off specifications, checklists and outcomes.
and sheets are submitted in sign-offs, including OSHA • Selects data relevant to the
accordance with company (U.S. Occupational Safety and task, identifies the need for
procedures. Health Administration) and data and predicts outcomes.
• Proper tools are used and Cal-OSHA. • Records information
measurements are accurate. • Ability to use proper tools for accurately, completes forms
• Safety procedures are inspection and to measure and writes simple documents.
followed. accurately. • Identifies relevant details, facts
• Inspection documentation is • Ability to accurately complete and specifications; follows set
filled out completely and in a inspection documentation of instructions; and probes to
timely manner. manually and electronically. gain knowledge/information.
• Equipment malfunctions and • Knowledge of inspection • Demonstrates honesty and
readiness are communicated results and equipment trustworthiness, accepts
to appropriate personnel terminology. responsibility for own behavior, 55
effectively and in a timely • Ability to identify equipment and recommends ethical
manner. malfunctions. course of action.
• Communicates appropriate
verbal/non-verbal messages,
presents basic ideas/
information, explains concepts
and actively participates in
discussion.
• Follows procedures and pays
attention to details, follows
up on assigned tasks, works
with minimal supervision, and
demonstrates initiative.
• Identifies system discrepancies,
monitors and adjusts system
performance, and trouble-
shoots system malfunction/
failure.
Food Manufacturing Maintenance Mechanics
Critical Work Function:
G. Operate Auxiliary Equipment (e.g., Fork Lift, Aerial Lift) – Continued
Key Activity
G2. Operate rolling/mobile equipment.
Performance Indicators – Employability Skills –
Technical Knowledge –
How do we know when the task SCANS Skills and
Skills, Abilities, Tools
is performed well? Foundational Abilities
• Proper endorsement, licensing • Knowledge of and ability to • Selects data relevant to the
and authorization require- obtain licenses, certifications task, identifies the need for
ments are met. and authorizations. data and predicts outcomes.
• Equipment is operated safely, • Knowledge of safe equipment • Identifies relevant details, facts
in accordance with all appli- operation and manufacturers’ and specifications; follows set
cable laws and regulations. specifications. of instructions; and probes to
• Proper training and • Knowledge of company and gain knowledge/information.
certification for operating and OSHA/Cal-OSHA safety regula- • Demonstrates honesty and
rigging has been obtained. tions, policies and processes, trustworthiness, accepts
• Rigging requirements are and equipment operation responsibility for own behavior,
followed. procedures. and recommends ethical
• Lift plans are followed. • Knowledge of and ability course of action.
• Gauges and indicators fall to apply proper rigging • Identifies the problem,
within normal operating techniques. applies principles to process/
parameters. • Ability to understand and procedure, extracts infor-
• Sights, sounds, feel and smell implement a lift plan. mation/ data and uses logic to
of equipment is used to verify • Ability to identify equipment draw conclusions.
that equipment is operating malfunctions using technical • Understands system organi-
normally. indicators and gauges, and zation/hierarchy and follows
56 • Malfunctions are noted or human sensory inputs (sight, procedures.
reported and corrective actions sound, smell, feel). • Follows procedures and pays
are initiated • Knowledge of company attention to details, follows
• Safety regulations are followed policies and procedures for up on assigned tasks, works
in accordance with all appli- reporting and correcting with minimal supervision, and
cable laws and regulations. equipment malfunctions. demonstrates initiative.
Verification Survey Results
Figure 2 shows the average importance and standard deviation (variation)
among each function, rated on a scale from 1 (not important) to 5 (critical).
These results generally verify that the critical work functions included in the
skill standards document are relevant to the industry at large. The results
show that Critical Work Function B, Maintain and Repair Equipment, had
the highest average score (4.277) among all critical work functions. The
lowest-rated critical work function was Critical Work Function G, Operate
Auxiliary Equipment (3.429).
The standard deviation scores for all items show a modest variation among
respondents. It should be noted that all critical work functions had scores
considerably above 3.25, which confirms that respondents view all six of
the critical work functions as important or very important to the work of
maintenance mechanics.
Figure 2.
Food Manufacturing Maintenance Mechanics:
Importance of Critical Work Functions
57
Future of Food Manufacturing Maintenance Mechanics
The process of creating the 2013 skill standards for food manufacturing
maintenance mechanics underscored how ongoing modernization of the
manufacturing industry will alter the skill requirements and expectations of
those mechanics in the future.
Manufacturing facilities and plants have changed a great deal in the past
decade. Information technologies are being integrated into manufacturing,
which increases the use of computers to monitor and control manufacturing
processes and equipment. Today, this means an increase in devices such
as robotics and computer numerical control (CNC) machines. This is
compounded by innovations in technology such as rapid prototyping (3-D
printing) and implementation of virtual environments. The equipment
in use today in food manufacturing plants, as well as equipment that will
come on line in the near future, requires a more technically oriented skill
set for maintenance and repair mechanics. Some have coined the phrase
“Maintenance Technician” to describe this specialization in maintenance.
59
60
Food Processing
Maintenance Mechanics
Scenarios
61
Routine Scenario
I start the day with a turn-over meeting, in which we receive information
passed down from the technicians and mechanics at the end of the previous
shift. I refer to the log book, where work completed during that shift is
documented, including preventive maintenance (PM), events and issues of
the day. The log also provides notes of upcoming work.
I then perform rounds to conduct system checks and make sure machines
have the proper settings and are operating correctly. I record machine data,
file documentation and communicate with other maintenance mechanics
and production personnel about machine operation.
Once rounds are complete, I consult the scheduled work orders and see
that a gearbox rebuild is next on the list. I gather the personal protective
equipment (PPE) so I can perform the job safely. Then I refer to the
manuals and schematic to determine the parts needed, and I make sure I
have collected the parts and tools required for the job. I double check the
specifications and procedures as I perform the gearbox rebuild. I take the old
parts and waste material (oil) to the disposal site and document the work
completed and the disposal procedures that were followed.
I return to the scheduled work orders and the next one up is to perform a PM
oil change. I use the manual to locate the specifications for the correct type
and amount of oil. I perform lockout/tagout and make sure I have the proper
PPE so I can perform the work safely. Once the oil change is complete, I test
62 the equipment to make sure it is operating properly according to company
and manufacturer specifications. I dispose of the waste following the proper
protocols and document the work performed and the disposal processes.
The end of my shift has arrived. I make sure all the work I performed is
documented and attend a turn-over meeting to clearly communicate
information about the plant equipment, parts or personnel needs to the
next shift of mechanics.
Critical Work
Key Activities
Functions
A. A1 A2 A3 A4 A5
Maintain a Safe, Perform environmental Perform emergency drills Identify, report Attend safety Reclaim, recycle
Healthy and and safety inspections and participate in emergency and take corrective meetings or dispose of
Environmentally response teams action on unsafe and fluids, refrig-
Conscious Work out-of-compliance erants, materials
Environment conditions and and waste
behaviors regarding
personal and food
safety, and environ-
mental/ regulatory
requirements.
B. B1 B2 B3 B4 B5 B6
Maintain and Repair Perform troubleshooting Perform preventive Gather parts, Perform diagnostic Perform repairs Document
Plant Equipment maintenance materials, tools and testing equipment mainte-
equipment nance & repair
C. C1 C2 C3
Install and/or Support the installation, Assist with testing to Fabricate parts or
Modify Equipment move/removal, custom- ensure functionality after components
ization or upgrade of installation, move/removal,
equipment customization or upgrade
D. D1 D2 D3 D4 D5
Table 4.
Communicate with Fill out maintenance and Participate in meetings and Communicate Suggest ways to Promote
Co-Workers to Promote repair logs problem-solving groups job-specific needs prevent future teamwork and
Productivity and equipment continuous
Customer Responsiveness malfunction or improvement
Routine Scenario
improve equipment
performance
E. E1 E2 E3
Adhere to Company and Comply with environ- Adhere to site-specific work Comply with safety
Regulatory Policies and mental regulations practices and procedures, requirements and
Standards and emergency response standards
and preparedness
Primary Tasks and Functions Involved in
F. F1 F2 F3 F4
Perform Technical and Maintain manual and Assist in training other Perform Obtain and maintain
Administrative Duties electronic records, employees housekeeping proficiency in
databases and reports current and new
technologies
G. G1 G2
Operate Auxiliary Inspect equipment Operate rolling/mobile
Equipment equipment
(e.g., fork lift, aerial lift)
63
Crisis Scenario
I arrive at the plant and see that, for the day, I’ve been assigned to the team
that deals with machine breakdowns. I spend the morning doing routine
PM, then my cell phone rings and I answer the call. The message is clear:
“The main machine that is feeding product to the conveyor is down.”
I gather my PPE and head over to the machine that is down. Soon I’m joined
by the other member of the breakdown team – a mechanical/electrical team
always works together. We perform lockout/tagout, put on our PPE and begin
to look for the cause of the breakdown.
We always want to find the root cause, and not just band-aid the situation,
otherwise it will likely reoccur. The goal is to get the machine back up and
running, with the cause repaired and the machine running as well or better
than it did before the breakdown.
We start with the motors and controls and move on from there to find the
breakdown. We then work from there to find the root cause. Usually, when
mechanical and electrical teams work together, the cause is discovered
64 fairly quickly, and this is the case today. The problem is the thermostat,
and our next step is to see if we have a new one in inventory. We do find
the thermostat in inventory, and we use it to replace the one that is acting
up. We use test equipment to test the machine and make sure it is running
properly based on company and manufacturer specifications.
C. C1 C2 C3
Install and/or Support the installation, Assist with testing to Fabricate parts or
Modify Equipment move/removal, custom- ensure functionality after components
ization or upgrade of installation, move/removal,
equipment customization or upgrade
D. D1 D2 D3 D4 D5
Table 5.
Communicate with Fill out maintenance and Participate in meetings and Communicate Suggest ways to Promote
Co-Workers to Promote repair logs problem-solving groups job-specific needs prevent future teamwork and
Productivity and equipment continuous
Crisis Scenario
F. F1 F2 F3 F4
Perform Technical and Maintain manual and Assist in training other Perform Obtain and maintain
Administrative Duties electronic records, employees housekeeping proficiency in
databases and reports current and new
technologies
G. G1 G2
Operate Auxiliary Inspect equipment Operate rolling/mobile
Equipment equipment
(e.g., fork lift, aerial lift)
65
Long-Term Scenario
Hiring a new, entry-level maintenance mechanic can be challenging. The
biggest challenge is to instill the skills, culture, values and expectations
needed to satisfy the demands of the company. It is also important to
develop a training program unique to that individual’s strengths.
Our training plan began with having the employee learn how to operate the
machines and familiarize himself with the production process and all safety
procedures and equipment. From there, he learned how our PM program
works. We initially double-teamed him with more experienced veterans
while performing PM.
After the new employee became familiar with the PM program, we expected
him to work independently and we continued to mentor him to improve his
efficiency.
C. C1 C2 C3
Install and/or Support the installation, Assist with testing to Fabricate parts or
Modify Equipment move/removal, custom- ensure functionality after components
ization or upgrade of installation, move/removal,
equipment customization or upgrade
D. D1 D2 D3 D4 D5
Table 6.
Communicate with Fill out maintenance and Participate in meetings and Communicate Suggest ways to Promote
Co-Workers to Promote repair logs problem-solving groups job-specific needs prevent future teamwork and
Productivity and equipment continuous
Customer Responsiveness malfunction or improvement
improve equipment
performance
Long-Term Scenario
E. E1 E2 E3
Adhere to Company and Comply with environ- Adhere to site-specific work Comply with safety
Regulatory Policies and mental regulations practices and procedures, requirements and
Standards and emergency response standards
and preparedness
Primary Tasks and Functions Involved in
F. F1 F2 F3 F4
Perform Technical and Maintain manual and Assist in training other Perform Obtain and maintain
Administrative Duties electronic records, employees housekeeping proficiency in
databases and reports current and new
technologies
G. G1 G2
Operate Auxiliary Inspect equipment Operate rolling/mobile
Equipment equipment
(e.g., fork lift, aerial lift)
67
68
Integration
69
Assessment and Certification: A Vital Connection
Skill standards, while useful on their own, are just one part of a much larger
equation. Skill standards establish the standard of competent performance,
but they do not tell a person whether he or she has succeeded in meeting
that standard.
For this reason, developing skill standards does not end with publication of
those standards. Next steps should include developing voluntary assessments
and certifications, which will make it possible for students, workers and any
interested persons to determine their strengths and weaknesses based on
the standards, and to earn certification showing that they can perform work
competently as established by the skill standards.
Finally, it is critical that industry be involved every step of the way, and
that standards are continuously reviewed and updated. Figure 3 provides a
summary of this process.
Assessment Strategies
Upon completion of skill standards development, performance assessments
can be created to assess the criteria identified (see Table 7). Sample assess-
ments and standards may be distributed to instructors and curriculum
developers who will be educated on the skill standards elements.
Figure 3.
Integrating Skill Standards
71
Please Note: To ensure that the use of standards and related assessments
and certifications do not contradict U.S. employment law, employers will
need to conduct an internal validation of the standards before using the
skill standards to make hiring and promotion decisions. The purpose of
this validation is to ensure that the knowledge, skills and performance
described by the standards are needed for competent performance in an
employer’s organization. The need to validate the standards internally is a
key requirement of U.S. employment law, which seeks to protect individuals
from discrimination in hiring and promotion.
Assessments based on the skill standards may include pre- and post-evalua-
tions of the student to measure skill progression and to track the success rate
of obtaining certification, where applicable.
The preceding section was adapted from Skill Standards Volume 2: Assessment, 1999,
Washington State Board for Community and Technical Colleges, and Designing
Competency-Based Training, Shirley Fletcher, 1991, Pfiffer & Company, pp. 86-88.
Table 7.
Assessment Design
From Center for Occupational Research and Development, November 1996, and Skill Standards
Volume 2: Assessment, 1999, Washington State Board for Community and Technical Colleges.
Notes
74
The California Central Valley region business and industry partners that contributed to this Skill Standard process: