On-Job- Training program Manuals and Technical Documentation
Operations Manuals Maintenance Manuals Standard Operating Procedures Preventive Maintenance (PM) Procedures Equipment-Specific Manuals Job Aids Troubleshooting Guides System Descriptions
Effective Operation and Maintenance Documentation
A Checklist
Overview Operation and maintenance documentation is a small, but very important, part of the total capital equipment procurement effort. In order to avoid the problems caused by inadequate documentation, it is important to understand the end user needs and what information is contained in an effective documentation package. This article provides an overview of the needs of the operators and maintenance technicians, and a checklist of specific information that should be covered in an effective documentation package. What Does an Operator or Maintenance Technician Need? An operator needs to: Understand how to operate the equipment safely, Have a grasp of the entire process and the function of each component in the process, Understand the purpose and basic use of all the controls, Perform basic adjustments and troubleshooting tasks, and Assist in changeovers.
A maintenance technician needs to: Understand the nuts and bolts of how each machine operates, Understand the control system that ties the machines together, Know how to effectively troubleshoot the process, Know how to effectively troubleshoot and repair the individual machines, Perform routine maintenance, and Perform setups and changeovers.
Operator Level Documentation Checklist
The ten most important features of an effective operator level documentation package are listed.
Accurate safety information - should provide a list of all the hazards associated with the process, identify e-stop locations and zones, identify electrical disconnects, and identify air shutoffs. Basic process flow descriptions - should provide a process overview flow diagram that identifies the function of each component.
Plant specific component operation descriptions - should provide descriptions of each
component at the level that supports the understanding of task specific information provided in the SOPs (Standard Operating Procedures) and changeover instructions.
Clear and concise descriptions of all operator controls - should locate each control panel
and describe the controls. Where touch screens panels are used, it is useful to have screen hierarchy diagrams and a description of the functions that are performed at each screen.
Symptom-based troubleshooting and tips - should locate and describe the process alarm
annunciators. It should also provide tables listing possible alarm messages with guidance for responding to each alarm.
Quality task list - should identify the quality tasks and reference the documents needed to
perform each task.
Operator maintenance SOPs and job aides Critical process control settings SOPs and job aides Line cleaning SOPs and job aides Changeover SOPs and job aides
Maintenance Level Documentation Maintenance documentation builds on the operator documentation. The ten most important features of an effective maintenance level documentation package are listed.
Detailed component operation descriptions - should identify the major components for
each machine, and describe the function and operation of each component at a level that supports troubleshooting.
Clear and concise descriptions of all maintenance controls - should locate each control
panel and describe the controls.
Process control information, such as:
o Control program sequence and architecture o Control device identification and function
Detailed electrical, pneumatic, and hydraulic circuits Process level symptom-based troubleshooting and tips - should include basic
troubleshooting approaches, information on what triggers annunciated faults, and
guidance for responding to each alarm.
Preventive maintenance activities and intervals Recommended lubricants and lubrication frequencies Recommended spare parts and quantities Changeover instructions and settings An OEM documentation library and index
Applied Performance Strategies supports OEMs and customers in the design and development of user documentation and training courses. We can assist you with OEM documentation specifications, job task analysis, plant specific training manuals, SOP and job aide development, training course design and presentation.
Procedures:
Standard Operating Procedures (SOPs) (Startup, Shutdown, Adjustment) Emergency Operating Procedures (EOP) Equipment Changeover and Conversion Procedures Manufacturing Procedures Consumer Product Assembly Procedures Product and Process Quality Inspection Procedures Preventive Maintenance Procedures - and complete Preventive Maintenance Program support Corrective Maintenance Procedures Equipment Overhaul Procedures Lubrication Procedures Cleaning Procedures Laboratory Analytical Equipment Procedures Lock Out & Tag Out Procedures (LOTO) Learn more about our Lockout Tagout services here. Electrical Switching Procedures Administrative Procedures Personnel Policies & Procedures
Approach to Preventive Maintenance
Specific action steps for the performance of each PM task Information or data to be recorded during the performance of the task Appropriate warnings or cautions relating to specific equipment Acceptance criteria and actions to be taken upon out of specification results Special tools and equipment needed for PM performance
Recommended performance frequency of the PM