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SOUTH AFRICAN QUALIFICATIONS AUTHORITY 
REGISTERED UNIT STANDARD: 

Coordinate predictive and preventative maintenance (PPM) 
SAQA US ID UNIT STANDARD TITLE
335898  Coordinate predictive and preventative maintenance (PPM) 
ORIGINATOR
SGB Manufacturing and Assembly Processes 
PRIMARY OR DELEGATED QUALITY ASSURANCE FUNCTIONARY
-  
FIELD SUBFIELD
Field 06 - Manufacturing, Engineering and Technology Manufacturing and Assembly 
ABET BAND UNIT STANDARD TYPE PRE-2009 NQF LEVEL NQF LEVEL CREDITS
Undefined  Regular  Level 5  Level TBA: Pre-2009 was L5  12 
REGISTRATION STATUS REGISTRATION START DATE REGISTRATION END DATE SAQA DECISION NUMBER
Reregistered  2018-07-01  2023-06-30  SAQA 06120/18 
LAST DATE FOR ENROLMENT LAST DATE FOR ACHIEVEMENT
2024-06-30   2027-06-30  

In all of the tables in this document, both the pre-2009 NQF Level and the NQF Level is shown. In the text (purpose statements, qualification rules, etc), any references to NQF Levels are to the pre-2009 levels unless specifically stated otherwise.  

This unit standard replaces: 
US ID Unit Standard Title Pre-2009 NQF Level NQF Level Credits Replacement Status
9895  Coordinate predictive and preventive maintenance  Level 5  Level TBA: Pre-2009 was L5  12   

PURPOSE OF THE UNIT STANDARD 
Learners credited with this Unit Standard will understand know various types of maintenance, especially predictive and preventive maintenance and their roles in the production processes of the company. They will be able to identify root causes of problems, use various analytical techniques to analyse the production process with respect to maintenance, develop a practical maintenance plan and make recommendations that will increase the synergy between production and maintenance.

Learners credited with this standard will be able to:
  • Explain the purpose of predictive and preventative maintenance.
  • Identify root-causes of break-downs and propose solutions.
  • Appraise the resources for effective coordination with production.
  • Discuss the safety, health and environmental (SHE) factors in maintenance.
  • Explain the principles of production scheduling systems.
  • Discuss the principles of maintenance scheduling.
  • Coordinate maintenance schedules with production schedules. 

  • LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING 
  • Further Education and Training Certificate: Automotive Components. 

  • UNIT STANDARD RANGE 
  • The automotive components environment includes both the manufacturing and assembly departments or sections.
  • This Unit Standard is not restricted to the automotive environment. It can be used in any component assembly or manufacturing context.
  • 'Production process' includes both manufacturing and assembly. 

  • Specific Outcomes and Assessment Criteria: 

    SPECIFIC OUTCOME 1 
    Explain the purpose of predictive and preventative maintenance. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    The different types of maintenance are described in terms of their advantages and disadvantages. 

    ASSESSMENT CRITERION 2 
    Total Quality Management (TQM) and PPM are discussed in terms of their similarities and differences. 

    ASSESSMENT CRITERION 3 
    The concept of the Overall Equipment Efficiency (OEE) index is explained and calculated to demonstrate how it is as an important measurement for assessing the performance of production and processing equipment. 

    ASSESSMENT CRITERION 4 
    The housekeeping of the company is appraised using methodology. 
    ASSESSMENT CRITERION RANGE 
    Methodology includes but is not limited to the 5s's method.
     

    ASSESSMENT CRITERION 5 
    Work instruction for operators are written to enable them to perform 'pre-flight' checks of their machines. 

    ASSESSMENT CRITERION 6 
    The purpose of PPM objectives and targets is explained to assess whether the company's maintenance strategies are supporting the production process. 

    SPECIFIC OUTCOME 2 
    Identify root-causes of break-downs and identify solutions. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    The meaning of the term 'machine utilisation' is explained and utilisation is calculated using the formula. 

    ASSESSMENT CRITERION 2 
    The types of Iosses of equipment in production are identified, classified and explained to show how they can be prevented. 
    ASSESSMENT CRITERION RANGE 
    Types include breakdown losses, speed losses, setup Losses, defect losses, start-up or yield losses, planning losses, chronic losses, irregular losses.
     

    ASSESSMENT CRITERION 3 
    The Bath-tub model is explained and the appropriate PPM strategies (counter measures for each of the phases are discussed as part of the proactive maintenance process and data on). 

    ASSESSMENT CRITERION 4 
    The manner in which losses decrease with improved levels of maintenance is discussed using actual and predictive examples. 

    SPECIFIC OUTCOME 3 
    Appraise the resources for effective coordination with production. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    The various types of resources required to ensure effective PPM are identified and discussed in terms of how they contribute to the production process. 
    ASSESSMENT CRITERION RANGE 
    Resources include but are not limited to human resources, well-maintained equipment, the budget, safety legislation, data on machine availability.
     

    ASSESSMENT CRITERION 2 
    The company's current organisational structure pertaining to maintenance is analysed to identify shortcomings. 

    ASSESSMENT CRITERION 3 
    A proposal is prepared and presented in order to deal with organisational shortcomings with respect to maintenance. 

    SPECIFIC OUTCOME 4 
    Discuss the safety, health and environmental (SHE) factors in maintenance. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    The basic principles of SHE applicable to maintenance are explained by identifying the types of workplace hazards and to minimise risk. 

    ASSESSMENT CRITERION 2 
    SHE targets are defined and applied to improved maintenance procedures. 
    ASSESSMENT CRITERION RANGE 
    Targets include but are not limited to zero accident, zero health damage, zero hazards.
     

    ASSESSMENT CRITERION 3 
    Safety slogans/posters are created and used to increase employees' awareness of safety aspects during maintenance. 

    SPECIFIC OUTCOME 5 
    Explain the principles of production scheduling systems. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    The importance of scheduling to production is explained in terms of the benefits accruing to the company. 

    ASSESSMENT CRITERION 2 
    The performance measures that are important in selecting a schedule are identified and discussed to assess the success of scheduling production. 

    ASSESSMENT CRITERION 3 
    Constraints on the production system are identified and discussed to develop ways and techniques of dealing with them to ensure efficiency in the system. 
    ASSESSMENT CRITERION RANGE 
    Constraints include but are not limited to waiting lines, bottlenecks.
     

    ASSESSMENT CRITERION 4 
    The production process is described in detail and documented in order for the quality standard to be applied across the system. 

    ASSESSMENT CRITERION 5 
    The aspects of job shops and flow shops are discussed in terms of their differences and how they are managed. 

    ASSESSMENT CRITERION 6 
    Gannt Charts are explained and used to obtain a deeper understanding of the production process and the limitations of this instrument are also discussed. 

    ASSESSMENT CRITERION 7 
    The Theory of Constraints (TOC) is explained in terms of determining impediments in the production system so that these can be removed to optimise production. 

    ASSESSMENT CRITERION 8 
    The Material Requirement Planning works (MRP) is explained with a view to manage all the resources of the business. 

    ASSESSMENT CRITERION 9 
    A Master Production Schedule (MPS) is explained and used to set performance criteria for the business and then manage the results or performance against those criteria. 

    SPECIFIC OUTCOME 6 
    Discuss the principles of maintenance scheduling. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    The differences between production and PPM scheduling are explained in order to ensure that the PPM works in synch with the production process. 

    ASSESSMENT CRITERION 2 
    Gantt Charts are prepared and used for periodic and preventative maintenance to save costs to the company. 

    ASSESSMENT CRITERION 3 
    Preparation for breakdown maintenance is planned to avoid unnecessary delays in the production process. 

    SPECIFIC OUTCOME 7 
    Coordinate maintenance schedules with production schedules. 

    ASSESSMENT CRITERIA
     

    ASSESSMENT CRITERION 1 
    Determine if scheduled maintenance procedures are documented as laid down in company procedures. 

    ASSESSMENT CRITERION 2 
    The maintenance library of equipment specifications is appraised to ensure that all relevant detail is easily accessible. 
    ASSESSMENT CRITERION RANGE 
    Library includes but is not limited to part number cross referencing, equipment manuals.
     

    ASSESSMENT CRITERION 3 
    The history of equipment maintenance is verified to efficiently track and control every aspect of both routine and unscheduled equipment maintenance. 

    ASSESSMENT CRITERION 4 
    The relationship between maintenance and production is analysed to determine whether these aspects work together for the benefit of the company. 

    ASSESSMENT CRITERION 5 
    Recommendations are presented to improve the coordination between maintenance and production. 


    UNIT STANDARD ACCREDITATION AND MODERATION OPTIONS 
  • Anyone assessing a learner or moderating the assessment of a learner against this Unit Standard must be registered as an assessor with the relevant ETQA.
  • Any institution offering learning that will enable the achievement of this Unit Standard must be accredited as a provider with the relevant ETQA.
  • Assessment and Moderation of assessment will be overseen by the relevant ETQA according to the ETQA policies and guidelines for assessment and moderation.
  • Moderation must include both Internal and External Moderation of assessments at exit points of the Qualification, unless ETQA policies specify otherwise. Moderation should also encompass achievement of the competence described both in individual Unit Standards as well as the integrated competence described in the Qualification. 

  • UNIT STANDARD ESSENTIAL EMBEDDED KNOWLEDGE 
  • Different types of maintenance.
  • Total Quality Management.
  • Overall Equipment Efficiency.
  • Health and Safety.
  • Gantt Charts.
  • Theory of Constraints.
  • Material Requirement Planning (MRP).
  • Master Production Schedule (MPS). 

  • UNIT STANDARD DEVELOPMENTAL OUTCOME 
    N/A 

    UNIT STANDARD LINKAGES 
    N/A 


    Critical Cross-field Outcomes (CCFO): 

    UNIT STANDARD CCFO IDENTIFYING 
    Identify and solve problems in which responses display that responsible decisions using critical and creative thinking have been made when:
  • Identifying root causes of problems in maintenance and finding solutions. 

  • UNIT STANDARD CCFO WORKING 
    Work effectively with others as a member of a team, group, organisation, community to:
  • Ensure health and safety in maintenance.
  • Coordinate maintenance schedules. 

  • UNIT STANDARD CCFO ORGANISING 
    Organise and manage oneself and one's activities responsively and effectively to:
  • Discuss various concepts associated with maintenance in a production environment.
  • Identify root causes of problems in maintenance and finding solutions.
  • Ensure health and safety in maintenance.
  • Coordinate maintenance schedules.
  • Analyse various aspects in the production system and make proposals.
  • Identify constraints and resolve them. 

  • UNIT STANDARD CCFO COLLECTING 
    Collect, analyse, organise and critically evaluate information to:
  • Solve maintenance coordination problems.
  • Identify constraints.
  • Appraise resources for effective coordination. 

  • UNIT STANDARD CCFO COMMUNICATING 
    Communicate effectively using visual, mathematical and/or language skills in the modes of oral and/or written presentation to:
  • Coordinate maintenance schedule.
  • Develop operator's manuals. 

  • UNIT STANDARD ASSESSOR CRITERIA 
    N/A 

    REREGISTRATION HISTORY 
    As per the SAQA Board decision/s at that time, this unit standard was Reregistered in 2012; 2015. 

    UNIT STANDARD NOTES 
    This Unit Standard replaces Unit Standard 9895, "Coordinate predictive and preventive maintenance", Level 5, 12 credits. 

    QUALIFICATIONS UTILISING THIS UNIT STANDARD: 
      ID QUALIFICATION TITLE PRE-2009 NQF LEVEL NQF LEVEL STATUS END DATE PRIMARY OR DELEGATED QA FUNCTIONARY
    Core  71969   National Certificate: Automotive Components: Manufacturing and Assembly  Level 5  Level TBA: Pre-2009 was L5  Passed the End Date -
    Status was "Reregistered" 
    2015-06-30  MERSETA 
    Elective  79406   National Certificate: Maintenance Coordination  Level 5  NQF Level 05  Passed the End Date -
    Status was "Reregistered" 
    2015-06-30  MERSETA 
    Elective  80686   National Diploma: Supply Chain Management: Sensitive Consumer Products  Level 6  NQF Level 06  Reregistered  2023-06-30  FOODBEV 


    PROVIDERS CURRENTLY ACCREDITED TO OFFER THIS UNIT STANDARD: 
    This information shows the current accreditations (i.e. those not past their accreditation end dates), and is the most complete record available to SAQA as of today. Some Primary or Delegated Quality Assurance Functionaries have a lag in their recording systems for provider accreditation, in turn leading to a lag in notifying SAQA of all the providers that they have accredited to offer qualifications and unit standards, as well as any extensions to accreditation end dates. The relevant Primary or Delegated Quality Assurance Functionary should be notified if a record appears to be missing from here.
     
    NONE 



    All qualifications and part qualifications registered on the National Qualifications Framework are public property. Thus the only payment that can be made for them is for service and reproduction. It is illegal to sell this material for profit. If the material is reproduced or quoted, the South African Qualifications Authority (SAQA) should be acknowledged as the source.