PRODPP003 – Clean down equipment and replace components

Overview

This standard requires the candidate to show understanding and compliance with health and safety requirements whilst cleaning and maintaining equipment in the workplace.

You need to know and to follow the workplace policies for the work which you do. Some recommended working practices and codes of practice for the printing industry are published by the Health and Safety Executive (HSE) and the Printing Industry Advisory Committee (PIAC). You need to know what these say in relation to your job role.

You also need to know what manufacturers or suppliers say about the use of equipment, materials and products that you use at work.

You need to know, ideally from your first day in a new workplace, what emergency arrangements exist in your workplace and work area – for example, how to raise the alarm and what to do in the event of an accident or emergency.

To demonstrate competence, you must show compliance in your day to day working over a significant period of time.

This involves:

  1. Using safe methods and appropriate materials and equipment to clean machines
  2. Lubricating machines at the required times
  3. Identifying defective or worn components
  4. Replacing or realigning defective or worn components, when it is your job to do so
  5. Reporting faults and excessive wear to the responsible person
  6. Restoring cleaned and lubricated machines to a safe operating condition
  7. Accurately updating records of machine maintenance

Performance criteria

You must be able to:

Clean down equipment

  1. switch off the machinery before you start cleaning in accordance with organisational procedures
  2. use the cleaning equipment and materials most suitable for the machine
  3. use cleaning methods which are safe, avoid harm to the environment and which follow the manufacturer's instructions
  4. clean and lubricate machines at the times you are instructed to do so
  5. dispose of used cleaning agents and waste materials in accordance with organisational requirements
  6. check that the machine is safe to operate when you have finished cleaning in accordance with organisational procedures
  7. complete records of machine maintenance in accordance with organisational procedures

Replace defective components

  1. examine machinery for defective components or excessive wear as part of your regular routine
  2. assess components which need replacing
  3. remove and replace components in accordance with organisational procedures
  4. report machine faults in accordance with organisational procedures
  5. restore machines to a safe operating condition after replacing components in accordance with organisational procedures
  6. keep accurate records of the components that have been removed and replaced

Knowledge and understanding

You need to know and understand

  1. legal duties for health and safety in the workplace as defined by the relevant health and safety legislation
  2. your duties and responsibilities for health and safety as defined by any specific legislation covering your job role
  3. manufacturers' and suppliers' health and safety instructions / advice
  4. how to stop the machine in the event of an emergency
  5. how to communicate with colleagues and visitors
  6. the workplace policies, procedures and working practices relevant to your role
  7. the toxicity and health issues related to the cleaning methods and materials you are using
  8. how to dispose of contaminated cleaning materials
  9. the legal requirements for the classification, storage, carriage and disposal of waste
  10. any specific environmental legislation that covers processes in your company
  11. the principal activities involved with machine cleaning, lubrication and maintenance
  12. roles and responsibilities for cleaning, lubrication and maintenance for engineers, manufacturer’s agents, machine operators and machine assistants
  13. types of machine faults including electrical, mechanical and electronic and how they can be rectified
  14. the skills needed to repair particular types of faults
  15. the maintenance plans for machines which you operate including manufacturer’s specifications and recommended maintenance plans
  16. the company plans and arrangements for maintenance
  17. which components wear or become degraded over time including filters, bearings, belts and chains, machine or process specific components
  18. what is meant by the phrase 'safe system of work' and how it applies to cleaning, lubrication and maintenance activities
  19. what parts of the machine you are allowed to clean, lubricate and maintain
  20. preventive versus predictive maintenance
  21. the documented procedures to be followed
  22. how to isolate equipment before commencing cleaning and maintenance
  23. how to replace all guards after cleaning and maintenance
  24. the choice and use of suitable cleaning agents and lubricants
  25. the manufacturer’s specification/recommendations

Scope/range

This standard is concerned with an overview of plant maintenance. Individual technical standards will highlight specific concerns for a piece of equipment.

The operator should be able to deal with all maintenance problems within his/her responsibility. The operator is also responsible for ensuring that the machine is in a safe and clean condition for normal production operations.

Keywords: digital, print, pre-press, maintenance, service, clean, components