1.5 Training & Competency Matrix

A signed attendance sheet proves nothing. In a high-reliability facility, Competency is the only metric that matters. Competency is the demonstrated ability to perform a task to standard, under pressure, without supervision.

This chapter defines the engineering framework for verifying human capability across three vectors: Internal Staff, EHS Critical Roles, and Contractors.

The Competency Framework

Do not treat training as a "one-and-done" event. Skills decay. Competency is dynamic.

Adopt the 4-Level Skills Matrix (ILUO) to quantify capability:

• I (Introductory): Can perform the task only with direct supervision.
• L (Learner): Can perform the task independently but slowly; may need help with anomalies.
• U (User): Fully competent. Can work independently at standard speed and quality.
• O (Owner/Trainer): Expert. Can troubleshoot complex failures and is authorized to train others.

Rule: No one touches critical infrastructure (e.g., High Voltage switchgear, Ammonia Chillers) unless they are Level U or O for that specific asset.

Mandatory EHS Certifications

Certain roles are Statutory Gatekeepers. These are not "nice-to-have" trainings; they are legal requirements for operation.

Role	Certification Required	Refresh Interval	Risk of Lapse
Electrical Authorized Person	HV/LV Switching & Rescue	3 Years	Arc flash fatality; criminal negligence.
Forklift / MHE Operator	License + Practical Test	2 – 3 Years	Crush injury; dropped load.
First Aider / ERT	CPR + AED + Advanced First Aid	2 Years	Failure to revive victim; liability.
LOTO Authorizer	Advanced LOTO Procedure	1 Year	Electrocution during maintenance.
Chemical Handler	HazMat Handling & Spills	1 Year	Chemical burns; environmental release.

Pro-Tip: Sync certification expiries to your access control system. If a forklift license expires, the badge reader on the forklift should deny ignition.

Contractor Management

Contractors are the single biggest source of risk in a facility. They do not know your building, your culture, or your hidden hazards.

Treat them as a hostile variable until proven compliant.

The "Permit to Work" (PTW) Logic

No contractor starts work without a PTW. The PTW is a shared contract of safety.

1. Pre-Qualification (The Gate):

• Before arrival: Verify insurance, trade licenses (e.g., Electrician's Card), and safety history.
• Status: Pass / Fail.

2. Site Induction (The Rules):

• On arrival: 15-minute briefing on Emergency Exits, LOTO rules, and Smoking Policy.
• Validation: Short quiz (Pass mark 100%).

3. The Permit (The Scope):

• Define exactly what they can touch. "Fix the AC" is too vague.
• Use: "Replace Compressor 2 on RTU-04. LOTO Point: Breaker B-12."

4. Supervision:

• High Risk Work (Hot Work, Confined Space) -> Requires Continuous Supervision.
• Low Risk Work (Painting, Cleaning) -> Spot Checks.

The Training Matrix (Visual Management)

Do not hide training records in a file cabinet. Make them visible.

Display the Skills Matrix in the maintenance workshop or department area.

Structure:

• Rows: Names of Technicians.
• Columns: Critical Assets / Skills (e.g., HVAC, UPS, ESD, PLC).
• Cells: ILUO Level (Color-coded: Red=I, Yellow=L, Green=U, Blue=O).

Logic:

• If a cell is Red (I) -> Then that person cannot be on call alone for that system.
• If a column has only one Blue (O) -> Then you have a Single Point of Failure (SPOF). Train a backup immediately.

Final Checklist

Control Point	Requirement	Critical State
Skills Matrix	Posted & Updated Quarterly	No Single Points of Failure
Contractor Inductions	Valid for 12 Months	100% Verified
High Risk Licenses	Digital Copies on File	Valid (Not Expired)
PTW Audit	Random check of active permits	Scope matches Activity
Training Budget	allocated for specialized skills	Consumed