To provide the student with the knowledge and skills required to identify the significant energy users in modern process and manufacturing facilities and to actively participate in the implementation of formal energy management programmes.To provide the student with the knowledge and skills required to identify the shortcomings in quality control in modern process and manufacturing facilities and to actively participate in the implementation of formal quality management programmes.
Energy Sources and Usage
Electricity/oil & gas production, transmission and distribution systems in Ireland, energy markets and tariffs, energy and environmental policies and regulations. Significant energy users (SEUs) in the process and manufacturing sector: water, air, gas, electricity and steam (WAGES)
Energy Management
Drivers of energy management, distinction between informal and formal energy management approaches, Formal energy management systems (EnMS): EN16001/ISO50001 energy management standards, company energy policy, planning and energy performance indicators (EnPIs), significant energy users (SEUs), implementation and operation, checking and corrective action. Energy management documentation: control of documents, control of records. Energy audits: preparation, internal and external audits and certification.
Energy Monitoring
Energy reviews: establishment of baseline use from historical data, identification of significant energy users (SEUs), comparison with energy performance indicators (EnPIs). Metering and measurement: WAGES (water, air, gas, electricity, steam) assessment, metering and measurement technologies, energy information systems (EMIS), building management systems (BMS).
Statistical Process Control
The establishment phase and the regular production phase of the process. Understanding the process and the specification limits. Eliminating assignable sources of variation. Common sources of variation and the use of Control charts. the use designed experiments, and Pareto charts to quantify the importance of differing sources of variation. potential steps to eliminate variation.
The Six-Sigma concept
The meaning, principles and origins of Six-Sigma. The debate on the usefulness, originality and limitations of the Six-Sigma concept. The steps of the DMAIC Cycle; Define, Measure, Analyse, Improve, Control, and their relation to significant statistical techniques.The Project definition and project charter, the business case analysis. The basis of measurement definitions and target setting. Measurement Systems, Process Mapping, value stream mapping, the use of SIPOC diagrams in process improvement and the use of these concepts in the Analysis and improvement stages of DMAIC. Failure mode and effects analysis (FMEA) and its use in design and process contexts. The concepts of process variability, dispersion, control limits, process capability (Cp and Cpk), process measurement and qualification.Conventions for short-term data and the case of attributes data. The adjustment for long-term data, the relationship between long- and short-term capability and the justification of the 1.5 sigma shift.
Quality Control Overview
Role of quality control in manufacturing. European and US regulatory authorities and standards bodies: International Standards Organisation (ISO), World Health Organisation (WHO), US Food and Drug Administration (FDA), European Medicines Agency (EMA). Quality standards and regulations: ISO 9000 series of standards, US code of federal regulations (CFRs), EudraLex regulations governing medicinal products in the EU. Good Manufacturing practice (GMP) and variations (cGMP and GAMP): standard operating procedures (SOPs), specification sheets, ingredients lists and master formulas, batch numbering and records, implementation and auditing of GMP.
Quality Management
Drivers of quality management, company quality policy and management buy-in. Formal quality management systems (QMS): ISO9001, ISO13485. Implementing a QMS: gap analysis and reporting, project planning, management and employee training, documentation and document control, implementation of procedures, internal auditing, external audits and certification.
| Module Content & Assessment | |
|---|---|
| Assessment Breakdown | % |
| Other Assessment(s) | 50 |
| Formal Examination | 50 |