Maintenance Apprenticeship Program

Health and Safety (30 hours)/Team Building (10 Hours)

1. Safety Culture
2. Industrial Safety and Maintenance Techniques
3. OSHA 30 Certification
   OSHA 30 teaches the material employees need to know to build a culture of safety and reduce on-site accidents. Students receive a comprehensive overview of the policies, procedures, and best practices to help ensure a safe working environment. All students will be eligible for OSHA 30 Certification. Primary Topics of this course include, but are not limited to:

• Introduction to OSHA
• Managing safety and health
• Fall protection
• Exit routes and emergency action plans
• Fire protection & prevention plans
• Electrical issues
• Personal Protective Equipment (PPE)
• Materials handling
• Hazardous materials
• Lockout / tagout
• Machine guarding
• Introduction of industrial hygiene
• Blood borne pathogens
• Powered industrial vehicles

Team Building

Uses the DISC Classic Personal Profile System to help the apprentice understand themselves and others. The profile provides a framework for looking at human behavior while increasing one’s knowledge of their unique behavioral pattern. The goal of this practical approach is to help one create an environment that will ensure success. At the same time the individual will gain an appreciation for the different motivational environments required by other behavioral styles. The three interpretation stages, which progress from general to specific, will help the participant master the DISC Dimensions of Behavior approach for understanding people. Knowledge of a person’s type can help them better understand the culture of the place they work, develop new skills, understand their participation in teams, and cope with change in the workplace. When someone understands their behavioral style, they can approach their work in a manner that best suits their style, which leads to the development of positive relationships within the cohort:

• Time Management
• Problem solving
• Effective Decision Making
• Stress Management

Principles of Technology (40 hours)

• Core Math
  *The Core Math Course is designed to build on student’s strengths while increasing their overall mathematical understanding and skill. This course will focus on several topics of study designed to the students’ mathematical aptitude. Some topics include, but are not limited to:
  • Converting units of measure
  • Use of exponents
  • Area and volume calculations
  • Order of operations
  • Graphing
  • Percent calculations
• Mechanical Measurement and Technical Drawing
  Instruction in the use of precision measuring tools and the interpretation of technical drawings. Topics include the use of calipers, micrometers, steel rulers, dial indicators, identifying types of lines and symbols of technical drawings, recognition and interpretation of various types of views, tolerances, and dimensions.
• Blueprint Reading
  Basics of reading a blueprint.
• Preventive and Predictive Maintenance
  Instruction on the concepts and applications of preventive and predictive maintenance. Topics include the introduction of alignment equipment, job safety, tool safety, preventive maintenance concepts, procedures, tasks, and predictive maintenance concepts. (clean and lubrication of equipment, maintain mechanical and electrical systems, use of electrical test equipment, perform inspection of hydraulic and pneumatic systems, replace pneumatic system components, lubricate hydraulic and pneumatic systems.

Problems Encountered and Resolutions (40 hours)

• Common problems and resolutions
  Learn how to use an eight-step problem solving model in conjunction with the PDCA cycle (plan, do, check and act)
  • Clarify the Problem (plan)
  • Breakdown the problem (plan)
  • Set the target (plan)
  • Analyze the root cause (plan)
  • Develop countermeasures (do)
  • Implement countermeasures (do)
  • Monitor results and process (check)
  • Standardize and share success (act)
• Core Communication
  • Technical Communication
  • Proper documentation
  • Proper email communication
• Work orders
  What are work orders, how work orders are used, basics of initiating a work order (basic information required), and managing work orders, completing, troubleshooting and service reports. Basic examples of service/maintenance reports, how to complete, reason why they are completed, how they are utilized by companies.

Introduction to Electronics (40 hours)

• Applied Electronics Safety
• Electronics Schematic Reading
  Covers the ability to read and understand electrical ladder drawings, schematics and diagrams. Covers several types of industrial control prints for a variety of different motor-driven processes. Will learn to interpret schematic drawings in order to provide verbal or written circuit descriptions as well as use in troubleshooting.
• DC Fundamentals
  Topics to include – magnetism, properties of conductors and insulators, and characteristics of series, voltage, current, parallel, and series-parallel circuits. Inductors and capacitors and their effects on DC circuits. Building, testing and troubleshooting circuits. Calculation of all parameters in DC circuitry, construct equivalent circuits and be able to describe circuit behavior. Analyzing complex DC circuits, solve for unknown circuit variables and use basic electronic test equipment.
• AC Fundamentals
  Topics to include analyzing complex AC circuit configurations with resistors, capacitors, and inductors in series and parallel combinations. Electrical safety and lockout procedures, specific AC theory functions such as RLC / resonant circuit, impedance, phase relationships, and power factor. Construction of circuits, learn the ability to explain circuit characteristics, identify components and make accurate circuit measurements using appropriate instruments.
• Industrial controls
  • Construction, operating characteristics, and installation of different motor control circuits and devices. Control of three phase AC motors.
  • Covers the use of motor control symbols, magnetic motor starters, solid
    state motor controls, running overload protection, pushbutton stations, multiple control stations, two wire control, three wire control, jogging control, sequence control, and ladder diagrams of motor control starters, overload protection, interpret ladder diagrams using pushbutton stations and understand complex motor control diagrams.
• Trouble Shooting and Application of Problem Solving in Electronics
  • Clarify the Problem (plan)
  • Breakdown the problem (plan)
  • Set the target (plan)
  • Analyze the root cause (plan)
  • Develop countermeasures (do)
  • Implement countermeasures (do)
  • Monitor results and process (check)
  • Standardize and share success (act)

Industrial Power Systems – Fluid (40 hours)

• Fluid Schematic Reading
  A simplified line-drawing generally used by engineers and technicians to describe and understand how a system works at an abstract level.
• Fundamentals of Hydraulic Principles
  Provides and introduction to hydraulics. Topics include hydraulic pumps, and system components such as valves, filters, regulators, actuators, accumulators, and lubricators. Students will be able to
  troubleshoot and repair hydraulic pumps and system components such as valves, filters, regulators, actuators, accumulators, and lubricators.
• Fundamentals of Pneumatic Principles
  Provides and introduction to pneumatics. Topics include pneumatic compressors work and system components such as valves, filters, regulators, actuators, accumulators, and lubricators. Students will be able to troubleshoot and repair pneumatic compressors work and system components such as valves, filters, regulators, actuators, accumulators, and lubricators.
• Fluid power systems
  Purpose, components, advantages and disadvantages of fluid power and potential dangers. Fundamental principles, components, symbols, and applications of hydraulic and pneumatic fluid power applications. Reading and understanding drawings and schematics used for verbal and written communication and troubleshooting.
• Applied Industrial Power Systems Safety
• Principles of industrial pumps and piping systems
  Fundamental concepts of industrial pumps and piping systems. Topics include pump identification, operation and installation, maintenance and troubleshooting, and piping systems, and their installation.
• Trouble Shooting and Application of Problem Solving Industrial Power Systems
  • Clarify the Problem (plan)
  • Breakdown the problem (plan)
  • Set the target (plan)
  • Analyze the root cause (plan)
  • Develop countermeasures (do)
  • Implement countermeasures (do)
  • Monitor results and process (check)
  • Standardize and share success (act)

Process Controls (40 hours)

• Industrial Processes
  • Startup procedures
• Introduction to Programmable Logic Controller
  Emphasis is placed on, but not limited to, the following: PLC hardware and software, relay logic, ladder logic, and the development of ladder logic using software, numbering systems, installation, and programming.
• Industrial Networks
  Ethernet media basics, the connections between equipment.
• Advanced Programmable Log Controller
  Advanced principals of PLCs including hardware, programming, and troubleshooting. Emphasis is placed on advanced working programs, and troubleshooting hardware and software communication problems.

Principles of Industrial Maintenance Welding (40 hours)

Basic understanding of weld safety, math, metallurgy, tools, and print reading. Should introduce the different types of weld processes (Shielded Metal Arc Welding “Stick”, Flux Core Arc Welding “Dual or Inner Shield”, Gas Metal Arc
Welding “Mig”, Gas Tungsten Arc Welding “Tig”) with hands on learning of SMAW – “Stick” and GMAW – “MIG”.

Introduction to Robotics (40 hours)

An introduction to robotic programming. Emphasis is placed on, but no limited to the following: Safety, motion programming, creating and editing programs, I/O instructions, macros, file and program storage. Create and modify frames, use motion programming techniques with the manual jog functions, use non-motion commands, and edit programs.