Process Plant Troubleshooting

Course details

Excellent Troubleshooting Skills are considered a core competency for 'Best-in-Class' modern industrial companies. If your company's goals include minimizing downtime then this workshop is a must because it delivers rapid, efficient Troubleshooting.
The following aspects will be addressed:

• Problem Solving Terminology
• Numerous Tools and Techniques
• A standard "Blue-Print" for problem analysis and resolution
• Strategies; Planning; and Protocols
• Variability Analysis
• "Human Factor" analysis as a Source of Error

Course Objective

The delegates will learn:

• Understand how to become a 'Top Gun' Trouble-Shooter
• Develop a structured approach to Troubleshooting and Problem Solving which uses a common terminology and shared understanding
• Point the way to Continuous Improvement in the way you run your processes and make incremental efficiency gains
• Understand the difference between having a techniques manual on the bookshelf - and actually making it work
• Identify the ""motivated"" people who should be the champions of Troubleshooting and Problem Solving - and who should just follow
• Understand work practices which ""allow"" success in Troubleshooting and Problem Solving

Who should Attend

• Supervisors who are involved in the Operations / Maintenance function
• Employees who are responsible for leading and directing people to achieve and improve productivity levels
• Planners and Coordinators
• Engineers and Technologists
• Those faced with the challenge of actually using the various techniques of Troubleshooting and Problem Solving to reduce downtime and waste and improve run efficiencies will benefit
• It is of equal importance to Production, Maintenance Engineering and Process Engineering personnel

Course Outline

Day 1: Introductory Concepts

• The nature of problems
• A Common Terminology
• Context - Asset based or Business Process based
• Structured approaches - 6 Big Losses, 7 Wastes
• Techniques introduction
• Tools introduction
• A Six Level Performance Standard
• Critical Relationships

Day 2: Tools & Techniques - Practical Experience

• Decision Logic
• Maturity Indexing
• Relationships Analysis
• Problem Analysis and Synthesis
• Practical Use of Tools and Techniques
• Case Studies
• Project selection methods
• Tools & Techniques - selecting the right one

Day 3: People Issues

• Working practices - empowerment or impairment?
• Group dynamics
• Individual motivators
• External vs. Internal Motivation
• Developing Troubleshooting and Problem Solving skills
• Managing change
• Transition Matrix
• Frication

Day 4: Operator, Maintainer, Designer Interface

• Cross functional working
• Effect of Maintenance strategy
• Functional Contribution analysis
• Life Cycle Analysis, Design for Operation, Design for Maintenance
• Variability Analysis
• Strategies; Planning; and Protocols
• Effect of improved "Fit" between critical parameters in Operations
• Continuous Improvement

Day 5: Open Forum

• Review of Concepts, Tools and Techniques
• Your Problems - Your Case Studies
• Your Action Plan
• Configuration Management
• Commercial Programs
• Application of "Standard Questions"
• Case Studies