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Plant Maintenance Staff Development Checklist 3. /* .mi:;; •._ .•ice � DISTRICT MENTORSHIP r � PROGRAM PLANT MAINTENANCE STAFF - DEVELOPMENT CHECKLIST PRESENTATION OUTLINE • Background • Purpose - Maintenance Division • Approach • output • Recommendations • Acknowledgements Questions BACKGROUND The project selection was based on alignment with the 2016- 17 Strategic Plan Goal 4 Develop and retain a highly trained and innovative workforce ➢ Goal 5 Maintain a reliable infrastructure PURPOSE MAINTENANCE DIVISION Provide maintenance support to the Treatment Plant, HHW, Annex, Laboratory, 19 Pumping Stations and 3 Metering Stations Maintenance of 6,000 assets Administration and implementation of the Preventative Maintenance Program Perform predictive maintenance including oil analysis, vibration analysis, ultrasound and thermograph o, Administer multiple annual contracts with outside service providers APPROACH Develop two Training and Development Checklist templates • Machine Shop • Mechanical Shop OUTPUT TRAINING AND DEVELOPMENT CHECKLIST CENTRAL CONTRA COSTA SANITARY DISTRICT PLANT MAINTENANCE DIVISION MACHINE SHOP MACHINIST TRAINING AND DEVELOPMENT CHECKLIST .A/ md � I ,g A •r M MACHINE SHOP PERFORMANCE STANDARDS Machine Shop Performance Standards Attendance: • Start Work: Be on the job,dressed in proper attire,and ready to work at the start Integrity: the shift. gam: • Work Day:Two 15-minute work breaks starting at 1000hrs and 1430hrs.and one 30-minute lunch break starting at 1200hrs. The quality of being honest and having strong moral principles;moral uprightness. • If leaving the Plant for any reason,you need to inform your Supervisor. o Example: • The Machine Shop starts cleaning up at approximately 1400hrs.We take a 15- • Inform your supervisor of any mistakes made and any tools or equipment minute break at 1430hrs.Then we head to the locker room for a shower before broken or lost. leaving the Plant at 1500hrs. My motto Is that you cannot make a mistake if you never do anything. Everyone makes Duties: mistakes;not everyone admits them. I cannot fix or replace something if I don't know it's broken or missing. • The standard shall be"able to perform with instruction from your supervisor,"or understand and perform the task. Professionalism: • Quantity is to be judged on completed jobs. • Quality is 95%completed within tolerance as registered • The competence or skill expected of a professional. • Fractional=+-.015,.01=+-.005,.001=+-.001 callouts for bearing fits may be , Examples: +-.0001 to be determined individually. • Clean up your tools and equipment when you have completed a job or Attitude: operation. • Remember that there are fellow Machinists who many need to get into the • We are a service Shop and anyone who comes to us is a customer. machine you have just vacated. • Pay attention to all requests. Leave the machine as serviceable as you would want it upon entering. • Inform the Supervisor of any requests that require our time or material. • Determine the priority and how to proceed. Improvement: Be courteous and respectful to all. • A thing that makes something better or is better than something else. Initiative: We have TPCs'a type of training pamphlet"that are used for learning purposes. They are small pamphlets that will inform you of types of equipment,procedures,or • Inform your Supervisor when you have completed the job. operations.You will be expected to read them and then test on the contents. Time • Hand in any paperwork,including drawings. You may keep a copy for your own will be afforded to you for this.There is no timeline on finishing,just an expectation reference of moving forward. Safety: • Follow the Safety Directives and common sense. '4� x M • •SSr� MACHINE SHOP TRAINING AND DEVELOPMENT STATUS SHEET 7"� Machine Shop Training and Development Status Sheet The Machine Shop Training Status Sheet is designed to provide a system to track an individual Maintenance Technician's training and development progress. The employee is trained by a Machinist. The Machinist ensures that the employee has become familiar with the safe function of the machines in the Machine Shop. The Machinist is responsible for ensuring that the employee is able to perform rudimentary operations on each machine in a safe manor.Supervisors ensure that the Machinist has trained the Machine Shop new employee in current approved procedures. Supervisors will provide the new Machine Shop employee with the Machine Shop Training Status Sheets. Each employee is responsible for maintaining the Machine Shop Training Status Sheets until all have been completed. Upon completion,the Supervisor and the Machine Shop new employee will meet and review the Machine Shop Training Status Sheets and discuss any further training,if necessary. If no continued training is necessary,the Supervisor will sign and file the Machine Shop Training Status Sheets. 1. The Machine Shop new employee is responsible for: • Requesting the Machine Shop Training Status Sheet to be signed off by the Machinist upon acquiring the ability to perform the specified skill set. 2. The Machinist is responsible for: • Training the new employee. • Ensuring that the new employee can perform the required tasks in a safe manner while meeting the required standards. • Passing the employee by signing the status sheet for each specified skill set. Recommending furthertraining or requiring the employee to perform a certain task to demonstrate competence.The new employee should not pass if the knowledge is not demonstrated property. 3. The Supervisor is responsible for: t. Approval of the Machine Shop Training Status Sheet after reviewing the new employee performance. w-. ' I MACHINE SHOP EQUIPMENT SKILLS Demonstrate knowledge of,proper use of,and satisfactory ability in the following Completed Training Approved areas: Date CUTTER CLEANING a n d ESTOP SPEED FEED SAFETY TOOLING and FIXTURES 1. Shear Development 2. Break 3. Rolls Status Sheets 4. Pedestal Grinder 5. Carbide Grinders 6. Surface Grinder 7. Horizontal Bandsaw 8. Vertical ASSET OVERHAUL AND REBUILD CROSS TRAINING Bandsaw 9. Drill Press Demonstrate knowledge of, Disassembly,repair and reassembly of the Completed 10. Radial Drill following assets: Date Approved 11. Vertical Drill 1. Screenings Grinder(Macho Monster) 12. Horizontal Mill 2. Sludge Grinder(Muffin Monster) 13. 13 inch Lathe 14. 22 inch Lathe 3. Cake Pump Gear Box 15. 26 inch Lathe 4. Centrifuge Gear Box 5. Hypo Pumps(B, C, DJ, DK;DM) R. �. 6. Centrifugal Overhung Pumps 7. Split Case Pumps KEY SUPERVISORY FUNCTIONS Demonstrate knowledge of,proper use of,and satisfactory ability in the Completed Training and Development following subjects: Date Approved 1. Weekly Schedule Status Sheets 2. Monthly Report 3. CMMS—Create,Approve,and Close Work Orders 4. Obtain procurement card—training,statement,and reconciliation KEY FABRICATION SKILLS 5. Employee claims for Workers Compensation benefits Demonstrate knowledge of,proper use of,and satisfactory ability in the following Completed Approved areas: Date 6. Incident(Accident Investigation Report PPE SAFETY ROTATION SEQUENCE TEMPERATURES 7. Near Miss Report 1. Drill Motor 8. Familiar with HTE-Purchasing Requisitions 2, Angle Grinder 3. Be@Sander 9. Familiar withOTIS 4. Wire Wheel Buffer 10. Familiar with vendors and contracts used by the shop 5. Iron Worker 6. MIG Welder 11. Familiar with shop accounts 7. TIG Welder 12. Familiar with monthly financials—check year-to date shop budget 8. Arc welder 9. Oxygen Acetylene Cutting 10. Oxygen Acetylene Welding 11. Spot Welder If the Trainee desires,learning techniques in Brazing,Silver Brazing,and Completed Approved Gas Welding,this could be considered. Date 1. (OPT)Brazing 2. (OPT)Silver Brazing 3. (OPT)Gas Welding RECOMMENDATIONS Develop Checklist for all Other Shops r Electrical Shop ➢ Buildings and Grounds ➢ Instrument Shop ACKNOWLEDGEMENTS • Mentor — Plant Maintenance Division Manager Neil Meyer • Senior Engineer Clint Shima • Machine Shop Supervisor Lee Sutherland • Mechanical ShoDSUDervisor Matthew Mahoney THAN K Y .�F. '00�(( 0 oil QUESTIONS ?. WH EIDE? WHAT?