Level 3 Diploma In Food And Drink Engineering Maintenance (1255-01)

Assessment TypesUnitTitleAssessment methodWhere to obtainassessment materials301Food and drink engineeringmaintenance complianceShort answer question testwww.cityandguilds.com302Food and drink engineeringmaintenance best s scienceShort answer question testwww.cityandguilds.com304Mechanical maintenance infood and drink ing replacementcomponents for food anddrink operationsAssignmentwww.cityandguilds.com306Fluid power systems forfood and drink g technologies forfood and drink ical maintenance infood and drink es and utilities withinfood and drink dynamicsShort answer question testwww.cityandguilds.com311Maths for food and drinkengineering maintenanceShort answer question testwww.cityandguilds.com312Monitoring for mechanicalmaintenance in food anddrink ing and producingreplacement components infood and drink g skills for food anddrink ical maintenance andtesting in food and utomation in food anddrink tand therequirements of electricalinstallations BS7671 (2015)Online multiple choice testLevel 3 Diploma in Food and Drink Engineering Maintenance (1255-01)11

GradingAll assessment must be achieved at a minimum pass for the qualification to be awarded. Gradesabove Pass are only considered when all units are achieved at Pass. The grades awarded for theunits are converted to points. The points available for each assessment are shown in the followingtable:Short answerquestion testPassMeritDistinction4684684--468(301, 303, 310-311)Online multiplechoice test(317)Assignment(302, 309)Assignment(305 – 308, 312 – 316)The candidate’s points for each assessment are added together, and the overall grade of the Level3 Diploma in Food and Drink Engineering Maintenance will then be determined using thefollowing criteria.Mechanical Pathway12Multi-skilled t76Merit74Pass56Pass56Level 3 Diploma in Food and Drink Engineering Maintenance (1255-01)

Test specificationsThe way the knowledge is covered by each test is laid out in the table[s] below:Test: 301Duration: 2 hoursOutcomeNumber ofquestions%1 understand health and safety requirements6212 understand environmental requirements5213 understand safe working practices andprocedures8364 understand how to use engineering information toensure compliance522Total24100Number ofquestions%1 understand the properties of materials used infood and drink operations737.52 understand why engineering materials fail6303 understand suitability of engineering materials forfood and drink operations632.519100The grade boundaries for this test will be approximately:Pass: 60%Merit: 70%Distinction: 80%Test: 303Duration: 2 hoursOutcomeTotalThe grade boundaries for this test will be approximately:Pass: 50%Merit: 69%Distinction: 87%Level 3 Diploma in Food and Drink Engineering Maintenance (1255-01)13

Test: 310Duration: 2 hours and 30 minutesOutcomeNumber ofquestions%1 understand the principles of heat transfer andenergy conservation8282 understand the operation of heat exchangeequipment7283 understand principles of fluid flow4164 understand the operation of systems transportingand controlling fluids in a pipeline system728Total25100Number ofquestions%1 be able to use arithmetic methods to solveengineering problems6262 be able to use algebra to solve engineeringproblems7283 be able to use trigonometry to solve engineeringproblems7314 be able to use statistical methods to display data31523100The grade boundaries for this test will be approximately:Pass: 50%Merit: 60%Distinction: 70%Test: 311Duration: 2 hoursOutcomeTotalThe grade boundaries for this test will be approximately:Pass: 40%Merit: 58%Distinction: 75%14Level 3 Diploma in Food and Drink Engineering Maintenance (1255-01)

Test: 317Duration: 2 hoursOutcomeNumber ofquestions%1 understand the scope, object and fundamentalprinciples of BS7671472 understand the definitions used within BS7671233 understand how to assess the generalcharacteristics of electrical installations6104 understand requirements of Protection forsafety for electrical installations15255 understand the requirements for Selection anderection of equipment for electrical installations14236 be able to use statistical methods to display data477 understand the requirements of specialinstallations or locations as identified in BS 767110178 understand the information contained within theappendices of BS76715860100TotalThese boundaries may be subject to slight variation to ensure fairness should any variations in thedifficulty of the test be identified.Level 3 Diploma in Food and Drink Engineering Maintenance (1255-01)15

5UnitsAvailability of unitsAll units relating to this qualification can be found in this document.16Level 3 Diploma in Food and Drink Engineering Maintenance (1255-01)

Unit 301Food and drink engineering maintenancecomplianceUAN: K/507/9800Level: Level 3GLH: 70Aim: This unit is concerned with the requirements that are essential toenable food and drink engineering maintenance activities to becarried out safely and effectively in compliance with organisational,national and international standards, where appropriate. It includesdealing with statutory and organisational requirements inaccordance with approved regulations, codes of practice andprocedures and the use of engineering information and coversresponsibilities relating to accident reporting and the identificationof hazards and risks.Assessment type Short answer question testLearning outcome:The learner will:1. understand health and safety requirementsAssessment criteriaThe learner can:1.11.21.31.41.51.61.71.81.9describe the health and safety regulations applicable to food and drink engineeringmaintenance operationsstate the roles, responsibilities and powers of health and safety personnelexplain employers’ responsibilities to maintain health and safetyexplain how the management of health and safety regulations are implementedstate the general rules for the observance of safe practicesexplain the implications of documentary requirementsexplain the Reportable Diseases and Dangerous Occurrences Regulations (RIDDOR)relevant to food and drink engineering maintenanceexplain the procedures for reporting accidentsdescribe the Manual Handling Operations Regulations as they apply to engineeringindustries.RangeRegulationsHealth and Safety at Work Act, Control of Substances Hazardous to Health Regulations (COSHH),Provision and Use of Work Equipment Regulations (PUWER), Electricity at Work Regulations, Controlof Major Accident Hazards Regulations (COMAH), Control of Noise at Work Regulations, LiftingOperations and Lifting Equipment Regulations (LOLER), Manual Handling Operations RegulationsHealth and safety personnelHealth and Safety Advisors, Health and Safety Representatives, Health and Safety ExecutiveInspectors, Environmental Health OfficersLevel 3 Diploma in Food and Drink Engineering Maintenance (1255-01)17

Employers’ responsibilitiesSafe: place of work, plant and equipment, system of work, working environment, methods ofhandling, storing and transporting goods and materials; to employees, to visitorsManagement of Health and SafetyIncluding the four C’s of positive health and safety (Competence, Control, Co-operation,Communication)Safe practicesBe alert, maintain personal hygiene, protect yourself and other people, know emergencyprocedures, report all hazardsRIDDORInformation, instruction, training and supervision of employees, a health and safety policyReporting accidentsSummary of accident, name of victim(s), summary of events prior to accident, details of witnesses,information on injury or loss sustained, conclusions, recommendations, supporting material(photographs, video), diagrams, date, signature of person(s) responsible for reportLearning outcomeThe learner will:2. understand environmental requirementsAssessment criteriaThe learner can:2.12.22.32.42.5analyse the relationship between the human and environmental conditions in theworkplaceexplain how risks from human and environmental conditions are controlled in theworkplaceanalyse the implications of Environmental Management Systems standard ISO 14001 tofood and drink operationsanalyse the implications of environmental legislation to food and drink operationsidentify the signs and nomenclature used for environmental issues.RangeHuman conditions: lack of management control, carelessness; improper behaviour and dress; lackof training, supervision and experience; fatigue; drug-taking and alcohol intakeEnvironmental conditions: unguarded or faulty machinery or tools; inadequate ventilation;untidy, dirty, overcrowded workplace; inadequate lightingControlledEliminate the hazard, replace the hazard with something less dangerous, guard the hazard,personal protection, health and safety education and publicityEnvironmental legislationEnvironmental Protection Act, Pollution Prevention and Control Act, Clean Air Act, RadioactiveSubstances Act, Controlled Waste Regulations, Dangerous Substances and Preparations andChemicals Regulations, Hazardous Waste RegulationsSigns and nomenclatureWarning, prohibition, mandatory, information18Level 3 Diploma in Food and Drink Engineering Maintenance (1255-01)

Learning outcomeThe learner will:3. understand safe working practices and proceduresAssessment criteriaThe learner can:3.13.23.33.43.53.63.73.83.93.103.11describe the range of Personal Protective Equipment (PPE) available and relate its use tothe operations that will be undertakenexplain the Respiratory Protective Equipment (RPE) used when undertaking tasks involvingexposure to hazardous substancesassess health and safety risksexplain the purpose and methods of use of accessories to lifting gearexplain the necessity of a permit to work proceduredescribe the safety systems in place on machinerydescribe isolation proceduresstate situations in which it is unadvisable or unsafe to work in isolationexplain the health and safety procedures that prevent injury or discomfort to skin, eyes,hands and limbsexplain extraordinary hazards that lead to an emergency situation in a food and drinkoperationsdescribe the statutory requirements for maintenance of equipment in food and drinkoperations.RangeHazardous substancesChemicals and solvents, fumes, dust or harmful particulates, heatAssess health and safety risksIdentify hazards, evaluate risk, control measures to mitigate riskAccessoriesHooks, slings, eyebolts, shackles, chains, rings, special-to-purpose equipment, rules for the use ofslingsPermit to workPurpose, description, content, types (including: ‘hot working’, electrical, maintenance operations,pressure testing), procedure for useSafety systemsGuards, emergency stops, safety relays, interlocks and switchesWork in isolationIn confined spaces, above ground or in trenches, in close proximity to unguarded machinery, whena fire risk exists, with toxic or corrosive substances, on siteHealth and safety proceduresPersonal hygiene, skin protection and care, care of eyes, use of eye and face protectors which areto current EN specifications, use of respirators, dangers of hair and loose clothing getting caught inmachinery, means of avoiding such dangers, benefits and use of protective clothing, use of safetyguards, screens and fencesExtraordinary hazardsAmmonia, terrorist threat (trespass, exploding devices, poisons, cyber), sabotage, drowning,hypoxiaLevel 3 Diploma in Food and Drink Engineering Maintenance (1255-01)19

Maintenance of equipmentSpecialist equipment (eg xray machines, metal detector and checkweigher), limits of own authorityto carry out certain activities (eg working with electrical equipment)Learning outcomeThe learner will:4. understand how to use engineering information to ensure complianceAssessment criteriaThe learner can:4.14.24.34.44.5describe the sources of standardsexplain how engineering information is used for food and drink engineeringmaintenance activitiesanalyse implications of information management to food and drink operationsexplain the importance of analysing all compliant engineering information beforedecisions are madeexplain procedures for dealing with issues associated with engineering information.RangeSourcesLegal, company, manufacturers’, industry, customerEngineering informationDrawings, change control documentation, risk assessments, engineering product data sheets,manufacturers’ manuals, production schedules, inspection and calibration requirements, permits towork, standard operating procedures, reference charts, method statements, Critical Control Points(CCP)Information managementPhysical security, change control, storage, access authorisation, data protection, commercialconfidentiality, security rating, cyber risks, ensuring validityProceduresReporting, change control, authorisation and archivingIssuesDiscrepancies, loss, damage, currency20Level 3 Diploma in Food and Drink Engineering Maintenance (1255-01)

Unit 302Food and drink engineering maintenancebest practiceUAN: M/507/9801Level: Level 3GLH: 95Aim: This unit develops in learners the understanding of engineeringmaintenance best practice in food and drink operations. It includesan understanding of different types of maintenance and how toplan maintenance of equipment for food and drink operations. Italso includes an understanding of fault finding and measurement.Assessment type AssignmentLearning outcome:The learner will:1. understand types of maintenance used in food and drink operationsAssessment criteriaThe learner can:1.11.21.31.41.51.61.71.81.91.101.11describe different types of maintenanceexplain the purpose of maintenancedescribe types of engineered systems used in food and drink operationsdescribe the plant and equipment used in food and drink operationsexplain how frequency of maintenance affects productionexplain the costs of maintenance for an engineered systemcalculate maintenance costs for an engineered systemjustify planned maintenance for a specified engineered systemdescribe factors affecting reliability of components and equipmentexplain how the use of technology leads to efficiency and quality in maintenanceexplain how to set up a line.RangeTypes of maintenancePlanned, total preventative (TPM), breakdown, scheduled, shutdown, reactive, preventative,corrective, emergency, post fault, scheduled, modification, condition-basedPurposePlant reliability and availability, improved quality of output, cost effectiveness, improved safety,legal requirements, reduced environmental damage, food safetyEngineered systemsProcess monitoring and control, mechanical, fluid power, electrical, environmentalPlant and equipmentGearboxes, pumps, engines, machine tools, lifting and handling equipment, valves, mechanicalstructures, motors, starters, switchgear, distribution panelsProductionLevel 3 Diploma in Food and Drink Engineering Maintenance (1255-01)21

Downtime, operating performance, product quality, customer service, effects on relatedequipment, systems and plant, secondary damageCostsAs a proportion of total expenditure, use of frontline maintenance, maintenance contracting, lostproduction, financial penalties, stock control, equipment hire, safety and environmental costsTechnologyAdministrative eg Computerised Maintenance Management Systems (CMMS), process eg sensors,testing eg self diagnosisLearning outcomeThe learner will:2. be able to plan maintenance for engineered systems in food and drink operationsAssessment criteriaThe learner can:2.12.22.32.42.52.62.72.8explain the content of a maintenance planexplain the requirements for communicating maintenance plansdescribe planning techniquesdescribe monitoring techniquesexplain the use of monitoring dataanalyse monitoring datacalculate failure rates for components and equipmentinterpret manufacturers’ manuals for maintenance requirements of system components.RangeContentTools and equipment, timelines, waste disposal, safety requirements, activities required, foodsafety requirements and considerations, communication, reporting and documentation,permissions, costs, handoverMonitoring techniquesCondition, scheduled overhaul, routine servicing, hazard studies, failure mode effect analysis(FMEA), self-diagnosisMonitoring dataOperational characteristics, output quality, throughput, environmental conditions, collection points,laboratory testing data22Level 3 Diploma in Food and Drink Engineering Maintenance (1255-01)

Learning outcomeThe learner will:3. understand fault finding techniquesAssessment criteriaThe learner can:3.13.23.33.43.53.63.73.83.9explain the importance of root cause identification and analysis in fault findingdescribe models of root cause analysisexplain the risks of running equipment with faultsexplain fault investigation proceduresdescribe how information is used for fault findingassess the suitability of fault-finding techniques in engineered systemsdescribe procedures for use of aids with fault diagnosisdescribe procedures for use of equipment with fault diagnosisexplain processes used to assess equipment when fault finding.RangeInformationFrom operators, monitoring equipment, recording devices, sensory, plant and/or machineryrecords, condition of the end product, laboratory dataFault finding techniquesHalf-split, emergent problem sequence, six point, equipment self diagnostics, function/performancetesting, injection and sampling, input/output, unit substitutionEngineered systemsMechanical, electrical/electronic, fluid powerAidsManufacturers’ manuals, algorithms, probability charts/reports, equipment self diagnostics, circuitdiagrams/specifications, logic diagrams, flow charts, fault analysis charts, troubleshooting guidesEquipmentMechanical measuring instruments, electrical/electronic measuring instruments, fluid power testequipmentLevel 3 Diploma in Food and Drink Engineering Maintenance (1255-01)23

Learning outcomeThe learner will:4. understand the importance of

M/507/9801 302 Food and drink engineering maintenance best practice 95 T/507/9802 303 Materials science 70 A/507/9803 304 Mechanical maintenance in food and drink operations 80 F/507/9804 305 Producing replacement components for food and drink operations 210 J/507/9805 306 Fluid power systems for food and drink operations 95 .