Industrial Processes Course

Lesson 1 • Key Industrial Metrics and KPIs

Introduces throughput, yield, cycle time, and utilisation as standard performance measures. Links metrics to operational decision-making.

Lesson 2 • Classification of Industrial Processes

Categorises processes by continuity, scale, and transformation type. Enables accurate process identification in real facilities.

Lesson 3 • Introduction to Industrial Systems

Defines industrial systems, their boundaries, and key components. Provides the conceptual framework used throughout the course.

Lesson 1 • Storage and Handling of Raw Materials

Addresses storage conditions, segregation, labelling, and handling equipment. Prevents contamination, degradation, and inventory errors.

Lesson 2 • Feedstock Quality and Process Impact

Analyses how feedstock variability affects process yield and product quality. Introduces corrective strategies for managing input variation.

Lesson 3 • Material Receiving and Inspection

Covers incoming quality checks, sampling plans, and rejection procedures. Ensures only conforming materials enter the production stream.

Lesson 1 • Material Conveying and Transfer Systems

Reviews pneumatic, mechanical, and hydraulic conveying methods and their design constraints. Ensures safe and efficient material movement within a facility.

Lesson 2 • Separation and Classification Techniques

Covers screening, filtration, centrifugation, and cyclone separation. Enables selection of the appropriate separation method for a given material.

Lesson 3 • Size Reduction Principles and Equipment

Explains crushing, grinding, and milling mechanisms and equipment selection criteria. Connects particle size targets to downstream process requirements.

Lesson 1 • Evaporation and Drying Operations

Covers evaporator configurations, drying mechanisms, and energy optimisation. Connects moisture removal to product quality and energy cost.

Lesson 2 • Distillation and Absorption Processes

Addresses vapour-liquid equilibrium, column design, and absorption for gas-liquid separation. Enables specification of separation columns for purity targets.

Lesson 3 • Combustion and Furnace Operations

Examines combustion chemistry, burner types, and furnace efficiency. Provides tools for optimising fuel use and managing combustion emissions.

Lesson 4 • Heat Transfer in Industrial Processes

Explains conduction, convection, and radiation in process equipment. Provides the basis for heat exchanger selection and thermal process design.

Lesson 1 • Emergency Response and Preparedness

Addresses emergency planning, evacuation procedures, and spill response for industrial sites. Prepares students to lead and participate in emergency response activities.

Lesson 2 • Process Safety Management Systems

Covers the elements of a process safety management framework including MOC, incident investigation, and audits. Links system elements to regulatory compliance expectations.

Lesson 3 • Hazard Identification Methods

Covers HAZOP, what-if analysis, and checklist methods for identifying process hazards. Systematic identification is the first step in risk reduction.

Lesson 4 • Risk Assessment and Prioritisation

Introduces risk matrices, likelihood-consequence analysis, and risk ranking. Enables prioritisation of safety investments and corrective actions.

Lesson 1 • Distributed Control Systems and PLCs

Introduces DCS architecture, PLC programming basics, and HMI interfaces. Enables navigation and basic configuration of plant automation systems.

Lesson 2 • Alarms, Interlocks, and Safety Systems

Covers alarm management, safety instrumented systems, and interlock logic. Ensures students can identify and respond to abnormal process conditions.

Lesson 3 • Control Loop Fundamentals

Explains feedback, feedforward, and cascade control loop architectures. Connects loop design to process stability and response speed.

Lesson 4 • Measurement and Sensing Devices

Covers temperature, pressure, flow, and level measurement technologies and their selection. Accurate measurement is the foundation of all process control.

Lesson 1 • Quality Management System Fundamentals

Introduces quality policy, documentation hierarchy, and process-based quality management. Establishes the organisational framework for all quality activities.

Lesson 2 • Supplier and Incoming Quality Control

Extends quality controls to the supply chain through supplier audits and incoming inspection plans. Reduces quality risk from external sources.

Lesson 3 • Inspection and Testing Methods

Addresses dimensional, visual, and destructive/non-destructive testing techniques. Links inspection method selection to product type and quality risk.

Lesson 4 • Statistical Process Control

Covers control charts, process capability indices, and variation analysis. Enables real-time monitoring and early detection of process drift.

Lesson 1 • Design of Experiments for Processes

Introduces factorial designs, response surface methods, and factor screening for process optimisation. Enables efficient identification of optimal operating conditions.

Lesson 2 • Sustaining Improvement and Change Management

Addresses control plans, standard work, and organisational change management for sustaining gains. Prevents regression after improvement projects are closed.

Lesson 3 • Process Simulation and Modeling

Covers steady-state and dynamic simulation tools for process analysis and debottlenecking. Links simulation outputs to capital and operational decision-making.

Lesson 4 • Six Sigma DMAIC Methodology

Applies the Define-Measure-Analyse-Improve-Control framework to process variation reduction. Provides a data-driven structure for solving chronic quality and efficiency problems.