Process industry includes petrochemical industry, iron and steel industry, nuclear power industry and so on. All of thses process industries are very important to the development and security of the country. Process industries partly deploy continuous production, the manufacturing process always goes with a series of physical changes and chemical reactions, which makes the whole production process very dangerous due to its inflammable and explosive properties. so security is the first concern for the whole equipment and human resources management in process industry. The production safety degree mainly relies on human resources competency with consideration of disadvantage, and most importantly, it depends on the allocation of human resources. The equipment operation competency always implies specific characteristics that differentiate competent operators from poor or normal ones. Competency management research of process industries still lag behind in the reality need. This issue is most noticeable at the human resources allocation and adjustment planning level. Human resources allocation of process equipment is inclined to use mathematical optimization methods, such as linear programming, nonlinear programming, multi-object programming, combinatorial optimization, integer programming, apply these models to achieve the best economy benefit under the constrains of workload needed with consideration of efficiency. Furthermore, most of the human resources optimization methods propose an optimization model under the condition of the known cost parameters, workload parameters, efficiency parameters, through some algorithm, to determine the value of decision variables( for example resources allocation plan), to achieve the goal of cost as small as possible or the profit as large as possible. There are some particular characteristics of equipment operators, firstly, work efficiency depends on competency; secondly, equipment operation system security follow the “cask principle”, an equipment operation system’s safety depends on the weakest point which is worker’s comprehensive evaluation of competency according to the disadvantage structure. In terms of extending cask principle, with consideration of equipment safety operation, we define work efficiency parameter in the optimization model as the average competency evaluation result according to disadvantage structure. Disadvantage structure is defined as the evaluation weight vector which can make the object achieve worst result. Also according to the characteristics of human resources, we integrate behavioral factors and psychological factors into optimization model.