Process Automation & Control Optimization (PACO)

1. Introduction to Process Automation Fundamentals of automation, benefits, and applications in industry.

2. Control Systems and Instrumentation Sensors, actuators, controllers, and feedback systems.

3. SCADA (Supervisory Control and Data Acquisition) Systems Architecture, monitoring, and control of industrial processes.

4. Industrial Communication Protocols Modbus, Profibus, Ethernet/IP, OPC, and IoT connectivity.

5. PLC (Programmable Logic Controller) Programming Ladder logic, function block diagrams, and structured text programming.

6. Process Optimization Strategies Lean principles, Six Sigma, and continuous improvement in automation.

7. Advanced Control Strategies PID tuning, model predictive control, and adaptive control systems.

8. Cybersecurity in Process Automation Protecting industrial networks, threat detection, and compliance standards (IEC 62443).

9. Human‑Machine Interface (HMI) Design Designing intuitive operator interfaces, alarms, and visualization systems.

10. Integration of Industry 4.0 Technologies Smart sensors, IoT, cloud integration, and predictive analytics.

• Builds competence in automation, control, and optimization techniques

• Enhances compliance with international industrial standards (IEC, ISA, ISO)

• Strengthens skills in PLC programming, SCADA, and communication protocols

• Provides tools for cybersecurity, HMI design, and Industry 4.0 integration

• Offers recognized certification to support careers in automation, process control, and industrial engineering

• Automation engineers and technicians

• Process control specialists and supervisors

• Industrial engineers in manufacturing, oil & gas, and energy sectors

• Professionals progressing from Level 3 or 4 technical qualifications in engineering or automation

• Assessment Type: Written exam + practical lab assessment + project

• Format: MCQs, short answers, PLC/SCADA programming tasks, and applied project work

• Total Questions: 80 theory + 1 practical assessment + 1 project submission

• Passing Score: 70%

• Duration: 5–6 days (40–45 hours total)

• Certification: Diploma in Process Automation & Control Optimization (PACO)

To deliver this Qualification, HiQual UK Approved ATPs must demonstrate the capability to deliver, assess, and internally quality assure qualifications in line with recognised regulatory principles and the expectations of the Regulated Qualifications Framework (RQF).

Approved centres must operate effective systems to ensure the validity, reliability, fairness, consistency, and security of assessment.

1. Centre Recognition and Legal Compliance

Centres must be formally recognised by HiQual UK prior to the delivery or assessment of any qualification. To maintain recognition, centres must: Be a legally constituted organisation operating in compliance with applicable legislation and regulatory requirements. Demonstrate effective governance, management oversight, and clear lines of accountability. Comply with all HiQual UK policies, procedures, and conditions of centre recognition. Notify HiQual UK promptly of any material changes that may affect delivery, assessment, or internal quality assurance arrangements.

2. Resources, Facilities, and Learning Environment

Centres must ensure that sufficient and appropriate resources are in place to support learning and assessment. This includes: Learning environments appropriate to the mode of delivery, including classrooms and, where applicable, specialist or practical facilities. Access to learning and assessment resources that enable learners to meet qualification outcomes. Secure systems for managing learner data, assessment records, and certification claims. Arrangements that support equality of access and reasonable adjustments for learners where required.

3. Staff Competence and Occupational Expertise

Centres must ensure that all staff involved in delivery, assessment, and internal quality assurance are competent and suitably qualified. Centres must: Appoint tutors with appropriate subject knowledge, teaching competence, and relevant occupational or professional experience. Ensure assessors are trained and competent in applying HiQual UK assessment requirements and standards. Appoint a qualified Internal Quality Assurer (IQA) responsible for monitoring assessment practice and decisions. Maintain records of staff qualifications, experience, training, and continuing professional development (CPD).

4. Assessment Practice and Internal Quality Assurance (IQA)

Centres must operate robust internal quality assurance systems to ensure assessment integrity. Centres must: Ensure assessment is valid, fit for purpose, and conducted in line with HiQual UK requirements. Implement effective IQA procedures to monitor assessor performance and confirm the consistency of assessment decisions. Maintain accurate, complete, and auditable records of learner registration, assessment evidence, and outcomes. Carry out regular internal reviews and standardisation activities to support continuous improvement.

5. Integrity, Risk Management, and Malpractice

Centres must take appropriate measures to protect the integrity of assessment. Centres must: Maintain policies and procedures for the prevention, identification, and management of malpractice and maladministration. Ensure secure handling, storage, and retention of assessment materials and learner evidence. Report any suspected or confirmed malpractice to HiQual UK in accordance with published procedures.

6. Health, Safety, Safeguarding, and Learner Protection

Centres must provide a safe, inclusive, and supportive learning environment. Centres must: Comply with applicable health and safety and safeguarding legislation. Conduct risk assessments for learning activities, particularly where practical or technical work is involved. Maintain procedures to safeguard learner welfare and wellbeing.

7. Learner Information, Support, and Fair Treatment

Centres must ensure learners are informed, supported, and treated fairly. Centres must: Provide clear and accurate information on programme requirements, assessment methods, and certification. Ensure learners receive timely and constructive feedback on assessment outcomes. Operate transparent complaints and appeals procedures aligned with HiQual UK requirements. Manage learner information securely in compliance with data protection legislation.