Carry out preventative planned maintenance on engineered systems within food and drink operations

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This standard identifies the competences you need to carry out preventative planned maintenance activities on engineered systems used in food and drink operations, in accordance with approved procedures. You will be able to carry out the maintenance activities on engineered systems involving interactive technologies: mechanical, electrical, fluid power or process controller. You will be able to organise and carry out the maintenance activities to minimise down time, and ensure that the maintained system performs at optimal level and functions to the required specification.

You must comply with organisational policy and procedures for the maintenance activities undertaken, and report any problems with the maintenance activities, tools or equipment used that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You must ensure that all tools, equipment, and materials used in the maintenance activities are removed from the work area on completion of the work, and that all necessary job/task documentation is completed accurately and legibly. You will be able to work with minimal supervision, taking personal responsibility for your own actions, and for the quality and accuracy of the work that you carry out.

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1. work safely at all times, complying with health and safety, environmental and other relevant, food and drink regulations, directives and guidelines
2. plan and communicate the maintenance activities to cause minimal disruption to normal working
3. confirm all relevant paperwork is completed before beginning work activity
4. obtain and use the correct issue of company and/or manufacturers' drawings and maintenance documentation
5. select equipment and materials for maintenance activities
6. check equipment has been safely isolated in accordance with organisational procedures (including mechanical, electricity, gas, steam, air or fluids)
7. provide and maintain safe access and working arrangements for the maintenance area
8. carry out the maintenance activities using appropriate techniques and in accordance with organisational procedures
9. follow the relevant planned maintenance schedules to carry out the required work
10. reconnect and return the system to service on completion of the maintenance activities
11. report any instances where the maintenance activities cannot be fully met or where there are identified defects outside the planned schedule
12. complete maintenance records and documentation in accordance with organisational procedures
13. dispose of waste materials in accordance with safe working practices and approved procedures

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1. the health and safety and environmental requirements of the area in which the maintenance activity is to take place, and the responsibility these requirements place on you not to compromise food safety
2. the isolation and lock-off procedure or permit-to-work procedure that applies to the system being maintained, including critical control points
3. the specific health and safety food and drink precautions to be applied during the maintenance activities, and their effects on others
4. the requirements of the British Retail Consortium (BRC) guidelines and standards in relationship to the maintenance activities
5. the specific requirements of your customer/client specifications in relationship to the maintenance activities
6. your responsibilities in relationship to Hazard Analysis and Critical Control Points (HACCP), Threat Assessment and Critical Control Points (TACCP), Vulnerability Assessment and Critical Control Points (VACCP) during the maintenance activities
7. what constitutes a hazardous voltage and how to recognise victims of electric shock
8. how to reduce the risks of a phase to earth shock (including insulated tools, rubber mating and isolating transformers)
9. the importance of wearing protective clothing and other appropriate safety equipment (PPE) during the maintenance activities, and where it may be obtained
10. hazards associated with carrying out maintenance activities on an integrated system (handling fluids, stored pressure/force/temperature, electrical supplies, process controller interface, using damaged or badly maintained tools and equipment, not following laid-down maintenance procedures), and how to minimise these and reduce any risks
11. how to obtain and interpret drawings, charts, specifications, manufacturers' manuals, history/maintenance reports and other documents needed for the maintenance activities
12. the various planned maintenance schedules that are generally used (such as condition based maintenance, scheduled maintenance, and total preventative maintenance (TPM)
13. the basic principles of how the system functions, its operation sequence, the working purpose of individual units/components, and how they interact
14. the principles of the equipment's design features for safe operation in a food or drink environment such as minimising the chance of contaminates or foreign bodies in the final product
15. the equipment operating and control procedures, and how to apply them in order to carry out the planned maintenance activities
16. the testing methods and procedures to be used to check that the system conforms to acceptable limits
17. how to make sensory checks by sight, sound, smell, touch
18. the procedure for obtaining consumables and `lifed' items that will require replacing during the maintenance activity, including their safe/hygienic storage before use
19. company policy on repair/replacement of components during the maintenance activities
20. methods of checking that components are fit for purpose, and the need to replace `lifed' items such as lubricants, filters, seals, gaskets, belts, chains and bearings
21. how to make adjustments to components and assemblies to ensure they function correctly
22. the processes in place to segregate the tools and equipment used into high or low risk areas
23. the checks required to ensure that all tools, materials and components are all accountable before operating the equipment
24. the cleaning requirements/policies in place before returning the equipment into full operational production
25. the generation of maintenance documentation and/or reports on completion of the maintenance activity
26. the problems that can occur during the planned maintenance activity, and how they can be overcome
27. the organisational procedure to be adopted for the safe disposal of waste of all types of materials including any spoilt food or drink products
28. the extent of your own authority and to whom you should report if you have a problem that you cannot resolve

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3

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31 Jan 2024

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Current

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Original

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NSAFD

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IMPEM125

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Manufacturing Technologies, Plant and Machine Operatives, Process Operatives, Process, Plant and Machine Operatives

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8111

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Food and Drink; Engineering; manufacturing; maintenance; engineered system; condition based maintenance; scheduled maintenance; total preventative maintenance; operations; functionality; condition

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