Manufacturing Maintenance Certification Program

Manufacturing Maintenance Certification Program
Developed in Conjunction with Bluegrass Business Consortium   

Richmond -  Fall 2017 Schedule

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The Manufacturing Maintenance program was developed by Eastern Kentucky University, Community and Workforce Education in cooperation with Kentucky Tech, Madison County ATC, Central Kentucky Technical College, Lexington Community College and in conjunction with the Madison County Business Consortium.

The Manufacturing Maintenance Technician Certification Program is designed to provide basic and advanced training for new and existing maintenance personnel. The program is open to everyone, but job expectations and skills will be reinforced by job activities. We recommend a blend of maintenance training and “on the job” work activities for participants to receive the fullest benefits from the program.

The program features Basic and Advanced Certification. Each certification involves completion of selected technical classes that cover a variety of topics and three modules of foundation classes to provide comprehensive training in basic skills and management tools to complement the technical content of the program.

All technical modules stress the four keys of manufacturing maintenance:

1. Safety
2. OSHA
3. Trouble Shooting
4. Preventive Maintenance
 

Certification Requirements

Basic Technical Certification requires the successful completion of all 3 Foundation Modules and 6 of the 8 Basic Technical Modules. Advanced Technical Certification requires the successful completion of Basic Certification and 2 of the 4 Advanced Technical Modules.

 

Foundation Modules:

 
Module 1--36 hours
Safety
Business Economics
Computer Literacy
Module 2--36 hours
Industrial Math
Blueprints
Interpersonal Communication
Module  3--24 hours
Problem Solving
Predictive / Preventive Maintenance

Basic Technical Modules:

 
   

1 – Machine Maintenance (60 hours)

2 – Industrial Electricity* (45 hours)

3 – Electronics / Ladder Logic* (39 Hours)

4 – Welding* (84 Hours)

5 – Machine Shop* (60 Hours)

6 – Fluid Power* (39 Hours)

7 – Plumbing* (36 Hours)

8 – HVAC* (24 Hours)

   

*Prerequisite:   Maintenance Foundation Module 2

   

Advanced Technical Modules:

 
   

1 – Industrial Electricity* (45 Hours) 

2– Electronics / Ladder Logic* (45 Hours)

3– Welding* (168 Hours)           

4– Machine Shop* (60 Hours)

   

*Prerequisite: Maintenance Foundation Module 2 and Respective Basic Technical Module

Cost:  $20.00 per hour

 

Foundation Modules:

 

Module I

Outline:

SAFETY:

*   Behavioral Safety

*   OSHA Overview

*   Ergonomics

 

BUSINESS ECONOMICS:

*   Analyze economic concepts and the relevance to different economic situations.

 

*   Demonstration of the cause and effect business cycle

     And how monetary and fiscal policy can be used to

     Regulate these problems.

 

COMPUTER LITERACY:

*   Terminology and application of basic computer operating systems.

*   MS Office

        Word – word processing, editing, graphics, and printing

        Excel – spreadsheets, formulas and reports

        Access – database files

*   Web and email use

 

Format:

Recommended Hours of Instruction:

33 hours

 

Module 2

Outline:

INDUSTRIAL MATH:

*   Review of basic math skills for English & Metric systems.

*   Fractions and decimal (add, subtract, divide, multiply),

     Geometry – area and volume calculations.

*   Algebra and Trigonometry – ratios, angles, and measurement calculations.

 

INTERPERSONAL COMMUNICATION

     How improved communications skills can motivate employees to become more productive. Through a series of exercises participants will experience some of the frustrations caused by lack of communication.  Learn and develop ways to overcome or minimize barriers to good communication in the workplace.

*   Listening vs hearing

*   Diversity

*   Verbal and non-verbal communication

*   Identification of communication barriers

*   Participation and group communication

 

BLUEPRINTS

     The participants will achieve the ability to read prints for the purpose of troubleshooting, installation of equipment and interpreting maintenance manuals. They will become familiar with standard symbols, ratings and associated materials utilized in industrial prints. Emphasis will be placed on reference material and safety.

*   Standard symbols

*   Electrical print comprehension

*   Fluid print comprehension

*   Mechanical print comprehension

 

Format:

Recommended Hours of Instruction:

36 hours

 

Module 3

Outline:

PROBLEM SOLVING

     Participants will develop familiarity with several creative techniques used for problem solving. They will learn to apply these creative techniques of problem solving in groups and as individuals.

*   Learn the traits of a creative person

*   Develop an understanding of the theories and philosophy of creativity

*   Learn the steps of the creative process: preparation, incubation, illumination, and verification.

*   Learn the roles of a creative person; explorer, artist, judge, warrior.

*   Learn techniques for stimulating creativity; brainstorming, attribute listing, forced relationships,
     bionics, synectics.

 

PREDICITIVE/PREVENTIVE MAINTENANCE

     This course is designed to demonstrate goals, methods and practical benefits of Total Productive Maintenance. The participants will explore the fundamental strategies that are required for successful TPM efforts.

*   Five key elements of TPM

*   Making TPM work

*   Overall equipment effectiveness

*   Preventive & predictive maintenance

*   Importance of safety and maintenance

 

Format:

Recommended Hours of Instruction: 27 hours

 
 

Basic Technical Module 1

Machine Maintenance

Description:

     This class utilizes mobile training workstations and established competency based exercises to review standard machine structures. The participant will have hands on experience in basic design and operation of basic mechanical devices.

 

Outline:

*   Standard fasteners

*   Shafts and bearings

*   Couplings

*   Gears

*   Drives

*   Seals

*   Motors, brakes & clutches

*   Machine disassembly and re-assembly

 

Format:

Recommended Hours of Instruction:

60 hours

 
 

Basic Technical Module 2

Industrial Electricity

Description:

(Prerequisite – Foundation Module 2)

The instruction of fundamental industrial electricity is the focus of this class. The participants will receive hands on training on AC/DC electricity, Single Phase/Three Phase, Electro Mechanical devices and sensors utilized in Electro mechanical systems. Emphasis will be placed on troubleshooting modifying and maintaining process control systems.

 

Outline:

*   Passive devices; resistors, inductors, & capacitors

*   Active elements: DC and AC independent power sources, voltage controlled voltage source,
     current controlled voltage source, voltage controlled current source, and current controlled
     current source.

*   Kirchoff’s voltage and current laws, OHM’s Law and other measurement/calculations.

*   Series, parallel, and series/parallel circuits, mesh current analysis and Nodal Voltage Analysis.

*   AC Voltage and current; Phasor and complex numbers, three phase circuits.

Format:

Recommended Hours of Instruction:

45 hours

 
 

Basic Technical Module 3

Electronics/Ladder Logic

Description:

(Prerequisite – Foundation Module 2)

This class will focus on Programmable Logic Controllers (PLC) selection, troubleshooting and programming using the Allen-Bradley PLC 500 series as a teaching example. Each participant will use an individual PLC lab station enabling them to employ the Normally Open (NO) and Normally Closed (NC) contact switches to write programs for process and industrial control systems.

 

Outline:

*   PLC ladder diagram rules, Contacts Relays and switches in the PLC system.

*   Use of timer relays, On-Delay and Off-Delay timer contacts, and Retentive and Non-Retentive
     Timer functions

*   Counter relays and Counter contacts

*   Write, debug and run PLC programs.

 

Format:

Recommended Hours of Instruction:

39 hours

 
 

Basic Technical Module 4

Welding

Description:

(Prerequisite – Foundation Module 2)

The welding class will focus on materials, processes and safety for Shielded Manual Arc welding and MIG welding. Emphasis will be placed in Hands on experience and utilization of standard equipment, techniques and applications. A combination of reference material and competency based welding exercises will provide a full range of knowledge and perspective.

 

Outline:

*   Safety, OSHA and personal equipment

*   Arc Flat position (Pads, Butts, & Fillet)

*   Oxyacetylene Torch (Cutting, Brazing, & Safety)

*   MIG setup and operation

*   MIG Flat position (Pads, Butts, & Fillet)

*   Horizontal positions (Pads & Butt)

*   Vertical positions (Pads, Butts, & Fillet)

 

Format:

Recommended Hours of Instruction:

84 hours

 
 

Basic Technical Module 5

Machine Shop

Description:

(Prerequisite – Foundation Module 2)

The Machine Shop class will cover the safe and appropriate use of basic machining tools utilized to maintain, modify and fabricate machine parts. The integration of precise measurement processes and machine operation will provide realistic experiences. The class will review of materials, metals and processes used in a machine shop. Emphasis will be placed on applying knowledge and developing machine skills.

 

Outline:

*   Measuring tools

*   Technical Information

*   Basic Lathe setup

*   Lathe safety

*   Tool maintenance

*   Applications and Operations

*   Use of taps and dies

*   Introduction to Milling

 

Format:

Recommended Hours of Instruction:

60 hours

 
 

Basic Technical Module 6

Fluid Power

Description:

(Prerequisite – Foundation Module 2)

The fluid power class will review fluid blueprint symbols and the basic characteristics of fluids and gasses. Hands on experience and technical material will cover the application, maintenance and troubleshooting of fluid systems.

 

Outline:

*   Characteristics of fluids and gases

*   Pascal’s Law and Bernellious Principle

*   Pumps and Reservoirs

*   Directional control valves

*   Speed control circuits

*   Cylinders

*   Single and Multiple cylinder circuits

*   Fluid control circuits

*   Hydraulic fluid and maintenance of systems

*   Troubleshooting

*   Fluid Power Logic Circuits

 

Format:

Recommended Hours of Instruction:

39 hours

 
 

Basic Technical Module 7

Plumbing

Description:

(Prerequisite – Foundation Module 2)

The basic techniques of plumbing and pipefitting will be covered through combining classroom exercises and laboratory experiences. Both national and state plumbing codes and safety requirements will be reviewed. The operation of standard plumbing equipment and applications will be presented.

 

Outline:

*   Use and care of tools (Soldering and Braxing)

*   General piping and Steam heat

*   Boiler and piping

*   Hydronic Heating

*   Plumbing Codes

*   Using the services of a Specialized Certification Plumbers

 

Format:

Recommended Hours of Instruction:

36 hours

 
 

Basic Technical Module 8

HVAC

Description:

(Prerequisite – Foundation Module 2)

This class is focused on understanding the basic operation of cooling systems, the function of system components and the troubleshooting process. Exercises will focus on safety, tools, and support equipment and shop practices. Maintenance and preventative maintenance procedures will be emphasized.

 

Outline:

*   Theory of heat

*   Tools and Equipment

*   System evacuation

*   Basic Automatic Controls

*   Commercial Refrigeration

*   Evaporators and Condensers

 

Format:

Recommended Hours of Instruction:

24 hours

 
 

Advanced Technical Module 1

Industrial Electricity

Description:

(Prerequisite – Industrial Electricity --- Basic Technical Module 2)

This module will be a continuation of the Industrial Electricity -- Basic Technical Module 2. The participants experience laboratory exercises that simulate industrial issues. Emphasis will be placed on trouble shooting, Electrical motors and transformers.

 

Outline:

*   Electrical Transformers, Auto Transformers. Wye-Wye, Wye-Delta, Delta-delta and
     Delta-Wye Transformer connections

*   Three Phase Power Systems, Reactive and Active Power Calculations, Inductive Reactive,
     Capacitive Reactive, Power Factors, Power Factor Correction and Electric Utility Cost.

*   Magnetism and Electromagnetic; Magnetic Circuit Analysis

*   Electrical Motors, Electro-Mechanical Actuators and Generators

*   Industrial Sensors used in conjunction with Electro-Mechanical devices. Passive Filters;
     RC, RL, RLC Circuits and Transient Analysis

 

Format:

Recommended Hours of Instruction:

45 hours

 
 

Advanced Technical Module 2

Electronics/Ladder Logic

Description:

(Prerequisite – Electronics/Ladder Logic --- Basic Technical Module 3)

Participant will again use the individual PLC lab stations for in depth discussion and exercises involving Programmable Logic Controllers. Connection of PLC Sequencer functions and networking PLC will be discussed and demonstrated.

Outline:

*   Discuss and use DATA MOVE, ADD, SUBSTRACT and DIVIDE functions

*   Discuss and use PLC AND, OR, NOR, NAND and XOR functions

*   Discuss and use COMPARE (EQU, GEQ, GT, LE, LT, NEQ) functions

*   Discuss and use PLC SKIP, JUMP (JP) and MASTER CONTROL RELAY (MCR)
     functions.

*   Discuss and use PLC Logical Shift Right and Logical Shift Left Functions, Sequencer Output
     (SQO), Sequencer Input (SQI), Sequencer Compare (SQC) functions

*   Learn how to connect PLC Sequencer functions to have more outputs and how to cascade the
     PLC Sequencer function to have more steps

*   Networking PLC in a server / Station manufacturing control system

*   Use of Proportional / Integral / Differential (PID) functions in industrial control systems.

 

Format:

Recommended Hours of Instruction:

30 hours

 
 

Advanced Technical Module 3

Welding

Description:

(Prerequisite – Welding --- Basic Technical Module 4)

The Advanced welding class will focus on specific applications and skill improvement for Shielded Manual Arc welding and TIG welding. It will also cover repair of Cast Iron. The class will emphasize Hands on experience and reference material to develop a high level of welding knowledge and proficiency of skills.

 

Outline:

*   Horizontal Position; Pad & Butt Welds

*   Vertical Positions; Pad, Fillet & Butt Welds

*   Overhead Position; Pad, Fillet & Butt Welds

*   Repair of Cast Iron; Nickel Rod & Brazing

*   TIG Welding

        Set up of equipment for Aluminum & Steel

        Flat position; Puddle, continuous bead, Butt Weld & Fillet Welds

 

Format:

Recommended Hours of Instruction:

168 hours

 
 

Advanced Technical Module 4

Machine Shop

Description:

(Prerequisite – Machine Shop --- Basic Technical Module 5)

The Advanced Machine Shop class will apply the experience and skills from the Basic Machine Shop class to new machinery and fabrication techniques. Detailed operation of Milling Machines, Drills, Drilling Machines, Saws and Cutoff Machines will be covered. There will be an increased emphasis in applying machining techniques to complex part production and repair.

 

Outline:

*   Technical Information on Milling

        Arbors, Collets, Adapters and Tool Holders

        Work holding devices

        Milling Cutters, Cutting Fluids, Cutting speeds and feeds

        Work Machine Alignments, Dial Indicators and edge finders

        Dividing Head , accessories and Boring Heads

 

*   Drills and Drilling Machines

        Machines, Drills & Safety

        Drill Holding and Work Holding devices

        Cutting Speeds, Feeds and Compounds

        Sharpening Drills and Drilling

        Countersinking, Counter-boring and Spotfacing

        Tapping and Reaming

 

*   Sawing and Cutoff Machines

        Metal-cutting Saws

        Reciprocating Power Hacksaw and Power Band Saws

        Circular Metal-cutting Saws

        Power Saw Safety

 

Format:

Recommended Hours of Instruction:

60 hours

   

For detailed program information and schedules, please contact:

Cheryl H. Juhasz
Workforce Education Consultant
(859) 622-1164
cheryl.juhasz@eku.edu

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