Engineering Technician (EngTech) Engineering Operations, Quality and Project Support Syllabus

What is a Pareto chart and the principle behind it?

A Pareto chart is a bar chart ordering causes by frequency/impact, based on the Pareto (80/20) principle — that roughly 80% of problems stem from 20% of the causes — to help prioritise the 'vital few' issues.

What is an Ishikawa (fishbone / cause-and-effect) diagram used for?

To systematically identify and group the possible causes of a problem (the 'effect'). Causes are commonly grouped under the 6 Ms: Man, Machine, Method, Material, Measurement and Mother-nature (Environment).

What is FMEA (Failure Mode and Effects Analysis)?

A structured technique to identify potential failure modes of a product/process, assess their effects, and prioritise them by Risk Priority Number so that the highest risks are addressed first.

How is the Risk Priority Number (RPN) calculated in an FMEA?

$RPN = S \times O \times D$, where $S$ = Severity, $O$ = Occurrence (likelihood) and $D$ = Detection rating. A higher RPN indicates a higher-priority risk.

What is a control plan in quality documentation?

A document that lists the key product/process characteristics to be controlled, the methods used to control them (inspection, measurement, SPC), the frequency, sample size and the reaction plan if results are out of specification.

What is a histogram used for in quality analysis?

A histogram is a bar chart showing the frequency distribution of a continuous variable, revealing the shape, central tendency and spread of process data and whether it follows a normal distribution.

In the context of the 7 Basic Quality Tools, name them.

Check sheet, histogram, Pareto chart, cause-and-effect (Ishikawa) diagram, scatter diagram, control chart and stratification (sometimes flowchart).

What is process capability, and what does a process capability index measure?

Process capability is the ability of a process to produce output within specification limits. The capability index (e.g. $C_p$) measures how the process spread compares to the tolerance width.

State the formula for the process capability index $C_p$.

$C_p = \dfrac{USL - LSL}{6\sigma}$, where $USL$ and $LSL$ are the upper and lower specification limits and $\sigma$ is the process standard deviation.

What is the difference between a work breakdown structure (WBS) and a schedule?

A WBS is a hierarchical decomposition of the total project scope into smaller, manageable work packages (what must be done). A schedule adds the timing, sequence and durations to those tasks (when they are done).

What are the three competing constraints of the classic project management 'iron triangle'?

Scope (or quality), Time (schedule) and Cost (budget). Changing one constraint affects the others; together they bound the achievable quality.

What is a milestone in project planning?

A milestone is a significant point or event in a project that has zero duration, used to mark the completion of a phase, a key deliverable or a decision/review gate.

What information does a Gantt chart display?

A Gantt chart is a horizontal bar chart showing project tasks against a time axis, displaying each task's start, duration and finish, their sequence/overlap, dependencies and milestones.

In the Critical Path Method (CPM), what is the critical path?

The longest sequence of dependent activities through the network, which determines the shortest possible project duration. Any delay to a task on the critical path delays the whole project.

Define 'float' (slack) in network scheduling.

Float is the amount of time an activity can be delayed without delaying the project (total float) or without delaying the next activity (free float). Activities on the critical path have zero total float.

How is total float of an activity calculated?

$Float = LS - ES = LF - EF$, where ES/EF are the earliest start/finish and LS/LF are the latest start/finish times.

What is the difference between CPM and PERT?

CPM uses single, deterministic activity durations and focuses on time–cost trade-offs. PERT uses three probabilistic time estimates (optimistic, most likely, pessimistic) to handle uncertainty in durations.

State the PERT formula for the expected duration of an activity.

$t_e = \dfrac{o + 4m + p}{6}$, where $o$ = optimistic, $m$ = most likely and $p$ = pessimistic time estimates.

What is a project dependency, and name the most common dependency type.

A dependency is a logical relationship that constrains the order of tasks. The most common type is Finish-to-Start (FS): the successor cannot start until the predecessor finishes.

What is the role of a Bill of Materials (BOM) in project/production support?

A BOM is a structured list of all the raw materials, sub-assemblies, components, parts and quantities required to manufacture or assemble a product, used for procurement, costing and production planning.

What is the difference between fixed costs and variable costs?

Fixed costs do not change with the level of output (e.g. rent, machine depreciation). Variable costs change directly in proportion to output (e.g. raw materials, consumables).

What is the difference between direct and indirect (overhead) costs?

Direct costs can be traced specifically to a product or job (materials, direct labour). Indirect costs (overheads) cannot be traced to a single product and are shared (lighting, supervision, rent).

State the break-even formula in units.

$\text{Break-even (units)} = \dfrac{\text{Fixed Costs}}{\text{Selling Price per unit} - \text{Variable Cost per unit}}$, where the denominator is the contribution per unit.

How is the contribution per unit defined and used?

$\text{Contribution} = \text{Selling Price} - \text{Variable Cost per unit}$. It is the amount each unit contributes towards covering fixed costs and then profit once break-even is passed.

What is resource levelling in project scheduling?

Adjusting the start/finish dates of tasks to resolve over-allocation, so that resource demand does not exceed available capacity — usually by delaying tasks within their float, which may extend the schedule.

When selecting equipment for a task, list key selection criteria a technician should consider.

Fitness for purpose/capacity, accuracy/resolution required, safety and compliance, cost and availability, ease of use and maintenance, environmental suitability, and reliability/durability.

Why must measuring equipment be calibrated, and what does a calibration interval mean?

Calibration verifies an instrument reads correctly against a traceable standard, ensuring measurement validity. The calibration interval is the maximum time between calibrations before re-checking is required to maintain confidence.

What is the purpose of stock control / inventory management?

To ensure the right quantity of materials is available when needed while minimising holding costs, avoiding stockouts and obsolescence, and freeing up capital tied in inventory.

What does the Economic Order Quantity (EOQ) model determine, and state its formula.

EOQ determines the order quantity that minimises total inventory cost (ordering plus holding). $EOQ = \sqrt{\dfrac{2DS}{H}}$, where $D$ = annual demand, $S$ = ordering cost per order and $H$ = holding cost per unit per year.

What is the reorder level (reorder point) and how is it calculated for constant demand?

The stock level at which a new order is triggered. $\text{Reorder Level} = \text{Lead-time demand} + \text{Safety stock} = (d \times L) + SS$, where $d$ is demand rate and $L$ is lead time.

Distinguish Just-In-Time (JIT) from Just-In-Case stock strategies.

JIT minimises inventory by receiving materials only as needed for production, reducing holding costs but relying on reliable supply. Just-In-Case holds buffer/safety stock to protect against demand or supply variability, at higher holding cost.

What is the difference between document control and a record in a quality system?

A controlled document (procedure, drawing, specification) states how things should be done and is kept current. A record is evidence that an activity was performed or a result achieved; records are not revised, they are retained as historical proof.

What does version/revision control of documents ensure?

That only the current, approved version of a document is in use, obsolete versions are withdrawn/marked, changes are authorised and traceable, and everyone works from consistent, up-to-date information.