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Maintenance Fundamentals Training

Broad-based training on industry essentials such as safety, practical math and print reading, and quality principles. Broad-level overview of the various power systems.

prerequisites: none
potential career paths: maintenance machinist, maintenance mechanic, maintenance electrician

Below is a list of the online classes and offline tasks included within the competency Maintenance Fundamentals.

Electrical Systems

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	Class	Offline Task
1.	Electrical Units 110 This class describes how electricity flows and explains the basic units used to measure electricity.	For equipment used in the work space, find the current, voltage, and resistance requirements for each piece of equipment.

Hydraulics and Pneumatics

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	Class	Offline Task
1.	Intro to Fluid Systems 100 This class provides an introduction to fluid power systems, including hydraulic and pneumatic components.	Walk along a hydraulic and/or pneumatic system used in the shop, identifying each type of component included within it; identify points for safely relieving potential energy.

Inspection

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	Class	Offline Task
1.	Basic Measurement 110 This class introduces the basic measuring devices used in the shop to ensure part quality. Includes an Interactive Lab.	For a series of sample parts and prints, determine the most appropriate device to use for measuring a series of features.

Materials

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	Class	Offline Task
1.	Intro to Materials 100 This class identifies the major categories of materials used in manufacturing and compares their general properties.	Choose five common workpiece metals manufactured in the shop and compare them to the ASTM standard.
2.	Overview of Plastic Processes 145 This class describes the most common plastic manufacturing processes and the machinery used to manufacture plastic components.	Scan plastic processing equipment used within the facility and point out major components and power systems.
3.	Metal Classification 150 This class introduces the AISI-SAE classification for steels.	Produce a list of metals used in the shop and list their matching AISI-SAE classifications.

Mechanical Systems

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	Class	Offline Task
1.	Intro to Mechanical Systems 100 This class examines simple machines such as the lever and inclined plane and covers basic concepts of physical science, including mechanical advantage and friction.	Move a load using a lever/pry bar; lift a load using a simple block and tackle.

Quality

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	Class	Offline Task
1.	Quality Overview 100 This class identifies how each department and function of a company plays a role in producing quality products for the customer.	State the company's quality policy and how it impacts the daily responsiblities on the job.
2.	ISO 9000 Overview 110 This class identifies and describes the key components of the ISO 9000:2000 standard.	Identify job-related documentation potentially covered in an ISO 9000 audit and explain the document and process to an internal auditor.
3.	Approaches to Maintenance 120 This class provides an introduction to the maintenance profession and describes various approaches to the practice of maintenance.	Obtain the operator-driven daily maintenance task list for each machine used in the work space; demonstrate each maintenance task.
4.	Lean Manufacturing Overview 130 This class describes the basic principles of lean manufacturing and compares them to traditional manufacturing approaches. Includes an Interactive Lab.	Within a cell, find the machine or process that requires the longest cycle time; locate two or three instances of waste and recommend ways to eliminate this waste.
5.	Total Productive Maintenance Overview 150 This class describes the elements of Total Productive Maintenance (TPM) and explains how TPM helps reduce losses and waste.	Assess over time the availability, performance rate, and quality rate of a bottleneck machine in an identified work cell. calculate the overall equipment effectiveness for the machine.
6.	5S Overview 155 This class provides an introduction to the 5S quality system and describes techniques for implementing 5S.	Choose a set of tooling and improve its arrangement and organization; schedule a self-audit to ensure sustaining of the improved organization.

Rigging

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	Class	Offline Task
1.	Intro to Machine Rigging 110 This class covers basic rigging equipment, calculating loads, inspecting equipment, and following safety precautions.	Demonstrate how to safely operate a hoist in order to move a load within a work cell.
2.	Rigging Equipment 120 This class covers the different kinds of equipment used in rigging, the properties of rope and chains, basic knots, hitches, and sling configurations, and fittings and end attachments.	Construct an eye splice; correctly tie various knots used on the job; identify rigging devices used on the job.
3.	Lifting and Moving Equipment 130 This class covers the different kinds of lifting devices, moving equipment, and scaffolds used in rigging.	Demonstrate how to safely operate all lifting equipment used on the job.
4.	Rigging Inspection and Safety 210 This class covers basic inspection and safety procedures for rigging equipment and lifting devices.	From samples of rope, cable, and chain, choose the samples that have defects and are unfit for use; inspect rigging equipment used in the facility and determine load limitations.

Safety

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	Class	Offline Task
1.	Intro to OSHA 100 This class covers the goals and purposes of the Occupational Safety and Health Administration, including its standards, programs, and interactions with employers and employees.	Locate OSHA-related signage within the facility.
2.	Fire Safety and Prevention 110 This class addresses OSHA fire safety and prevention measures and describes emergency action plans, fire prevention plans, fire detectors and alarms, and fire extinguishing equipment. Includes an Interactive Lab.	Locate fire extinguishers within the facility; demonstrate proper use of a fire extinguisher.
3.	Bloodborne Pathogens 115 This class addresses how bloodborne pathogens are transmitted and includes information on preventive measures and procedures for exposure in the manufacturing workplace.	Demonstrate proper cleanup of a workstation after an incident has occurred resulting in blood release.
4.	Personal Protective Equipment 120 This class addresses personal protective equipment requirements from OSHA and includes information about hazard assessments, PPE selection, and standards that govern PPE. Includes an Interactive Lab.	Locate relevant PPE for a specific work station; demonstrate proper maintenance of PPE.
5.	Lockout/Tagout Procedures 130 This class covers lockout/tagout requirements and procedures and includes an explanation of employees' roles during lockout/tagout. Includes an Interactive Lab.	Identify a locked out/tagged out machine; locate the person authorized to remove the lockout/tagout device.
6.	Safety for Lifting Devices 135 This class addresses lifting device and equipment safety requirements from OSHA and surveys lifting devices and equipment commonly used for material handling, inspections, and testing.	Safely lift and move a sample load using lifting equipment in the facility.
7.	Machine Guarding 140 This class covers basic machine guarding practices and devices and includes information on hazardous machine components, motions, and actions.	Identify machine guards on each machine used in the work space and indicate whether or not they are removable during normal operation.
8.	Hand and Power Tool Safety 145 This class covers general safety guidelines for using hand and power tools as regulated by OSHA.	Select the proper PPE for each powered tool used in the work space; demonstrate the safe and proper use of each powered tool.
9.	Environmental Safety Hazards 150 This class explains the different types and levels of environmental hazards in the workplace and how employees may be exposed to these hazards. Includes an Interactive Lab.	Identify up to five common fluids used in the work space; demonstrate the proper steps for cleaning up each fluid.
10.	Flammable/Combustible Liquids 155 This class describes the hazards associated with flammable and combustible liquids and explains proper methods for safe storage, handling, and transferring of these liquids.	Locate the flammable liquid storage area; search the shop for a flammable liquid not stored in its proper container and take steps to store it properly.
11.	MSDS and Hazard Communication 160 This class covers different types of chemical hazards, standards for hazardous chemicals, and how information about chemical hazards reaches the employee, including through MSDS. Includes an Interactive Lab.	Locate and review an MSDS sheet for a chemical used in the shop.
12.	Noise Reduction and Hearing Conservation 170 This class explains the causes of hearing damage and describes how to avoid exposure to excessive noise.	Demonstrate proper use and care of hearing protection required in the work space.
13.	Walking and Working Surfaces 180 This class covers the requirements necessary to ensure the safety of typical walking and working surfaces such as platforms, stairs, ladders, and scaffolds.	Demonstrate proper housekeeping that ensures safe walking paths within the work space; demonstrate how to properly clean up a spill.
14.	Confined Spaces 190 This class covers different types of confined spaces and the hazards they present, the roles and responsibilities of employers and employees, and proper work practices and safety precautions for confined spaces.	Given a specific scenario involving a confined space, correctly fill out a confined space entry permit; gather all equipment necessary for working safely in the confined space.
15.	Respiratory Safety 195 This class covers the most common types of respirators and includes information about fit testing, medical evaluation, and training for employees.	Complete any required respirator training; demonstrate proper fit and use of any respirators required on the job.
16.	Powered Industrial Truck Safety 210 This class covers different types of powered industrial trucks, such as forklifts, and includes guidelines for use, training requirements, and stability principles.	Demonstrate effective awareness of PIT movement within the facility; demonstrate how to properly secure a load on a pallet for movement by a PIT operator.

Shop Essentials

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	Class	Offline Task
1.	Math: Fundamentals 100 This class explains how to add, subtract, multiply, and divide to solve a problem following the correct order of operations.	Successfully complete a series of sample addition, subtraction, multiplication, and division problems.
2.	Math: Fractions and Decimals 105 This class explains how to add, subtract, multiply, and divide fractions and decimals, as well as how to convert these numbers to percentages.	Successfully convert a series of decimals to fractions; convert fractions to decimals; perform a series of common math calculations with decimals and fractions.
3.	Math: Units of Measurement 115 This class addresses common units of measurement used in manufacturing and explains how to convert from one unit of measurement to another.	Successfully convert a series of English units to metric units, and vice versa.
4.	Basics of Tolerance 120 This class explains the purpose of tolerances in manufacturing and describes how these tolerances are specified. Includes an Interactive Lab.	Measure a sample of 10 parts using a caliper and/or micrometer and correctly determine which parts are within tolerance.
5.	Blueprint Reading 130 This class identifies the information communicated on a blueprint with emphasis on interpreting the part drawing. Includes an Interactive Lab.	Read a basic company print and determine the critical features on a part that need measurement.
6.	Geometry: Lines and Angles 155 This class describes the properties of lines and angles and demonstrates how they are used to solve sample part drawings.	Use a sample print to find the measurement of an unspecified angle from other dimensions.
7.	Geometry: Triangles 165 This class describes the properties of the various types of triangles and demonstrates how they are used to solve sample part drawings.	Solve for angles other than the right angles specified in a given print.
8.	Shop Geometry Overview 170 This class presents a general overview and refresher for the the most common rules of geometry.	Identify all perpendicular lines on a given print; calculate the area of each rectangle.
9.	Geometry: Circles and Polygons 185 This class explains basic circle and polygon geometry and how their features are used to find dimensions in sample shop drawings.	Determine the height of a cylindrical part held in a V-gage.