Unit of competency Outline

Date retreived
23/07/2026 4:34 PM AWST

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Debottleneck plant

Debottleneck plant

Unit of competency
National Code
PMAOPS601
State Code
AXM67
TGA Status
Current
DTWD Status
Approved
Current Release Number
1.00
Current Release Date
02/06/2016
View on TGA
State Implementation and Classification
Approved Date
05/08/2016
Field of Education
030101 - Manufacturing Engineering
Original Release Date
05/08/2016
Nominal Hours
60
Description
This unit of competency covers the skills and knowledge required to make changes to plant or process that increase the throughput of a plant. It applies to a small plant or a section/area of a larger plant.This unit of competency applies to senior technicians or those in similar roles who are required to apply in-depth technical knowledge of process and plant operation and problem solving in order to identify the rate limiting step/process/plant unit (bottleneck), evaluate possible solutions, select the most appropriate option, and coordinate and supervise the plant and/or process modifications.This unit of competency does not apply to: identification of the need for debottlenecking; the need for the debottlenecking may arise from a continuous improvement project, as a result of an analysis of plant performance or from any other sourcedesign of equipment; this would typically be an engineering role work requiring special certification (e.g. registered structural engineer).No licensing, legislative or certification requirements apply to this unit at the time of publication.
Notes
Elements and Performance Criteria
1 Identify rate limiting step/process
  • 1.1 Determine throughput of plant/area
  • 1.2 Determine capacity of units within plant/area based on design and/or performance data
  • 1.3 Identify which units is operating at capacity/is the bottleneck
2 Investigate bottleneck
  • 2.1 Analyse the science of what is occurring in the bottleneck unit
  • 2.2 Analyse the engineering/design specification of the bottleneck unit
  • 2.3 Determine the root cause of the capacity limitation of the bottleneck unit
  • 2.4 Investigate methods of increasing the capacity of the bottleneck unit
  • 2.5 List solutions to the bottleneck
3 Select technically best solution
  • 3.1 Investigate impact of solutions on the other units of the plant/area
  • 3.2 Identify any 'knock on' effects of solution
  • 3.3 Determine process/quality benefits and costs of solutions
  • 3.4 Determine economic benefits and costs of solutions
  • 3.5 Short list and rank the best solutions
4 Compare hazard profile of possible solutions
  • 4.1 Organise a hazard analysis (e.g. hazard and operability study (HAZOP)) for the solutions according to company procedures
  • 4.2 Ensure that all stakeholders are represented on the hazard analysis team
  • 4.3 Brief the hazard analysis team on the problem and solution alternatives under evaluation
  • 4.4 Eliminate alternatives which do not meet hazard requirements
  • 4.5 Rank remaining competing items by safety performance
5 Make final choice of solution
  • 5.1 Seek further information, where necessary, to allow a rational selection to be made
  • 5.2 Choose the modification which meets all required minimum standards and will provide the best solution
  • 5.3 Verify choice in discussion with production and engineering managers and other key stakeholders
6 Check solution
  • 6.1 Initiate and monitor the implementation of the solution
  • 6.2 Ensure all checks and acceptances are done to procedures
  • 6.3 Conduct trials/test runs as required
  • 6.4 Collect and analyse data
7 Complete modification
  • 7.1 Evaluate performance of solution
  • 7.2 Make adjustments as required
  • 7.3 Ensure plant procedures and training material updated
  • 7.4 Ensure plant drawings and engineering specifications are updated
  • 7.5 Complete all other required paperwork
No information
No information
Replaces
State Code National Code Title Type
W8903 PMAOPS601A Debottleneck plant Unit of competency