Process Trouble Shooting and Problem Solving

Introduction

Excellent Troubleshooting skills are considered a core competency for Best-in-Class industrial companies. If your company’s goals include minimizing downtime then this workshop is a must because it delivers rapid, safe Troubleshooting.

Objectives

By the end of the course, participants will be able to:

• Focus on how to become a Top Gun Troubleshooter
• Develop a structured approach to Troubleshooting and Problem Solving which uses 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 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

Target Audience

• Supervisors who are involved in the operations function and who are responsible for leading and directing people to achieve and improve productivity levels
• 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

Chemical Engineering Outline

The course covers the following topics:

Concepts

• The nature of process problems affecting performance
• Performance defined in terms of generic variables: Speed; Quality; and Cost
• Effort inputs in context - Asset-based or Business Process-based
• Structured approach - The Operations Process redefined
• Configuration; Operation; and Optimization
• Maturity Indexing: Planning; Control, Congruence, Empowerment
• 6 Big Losses, 7 Wastes

Tools and Techniques - Practical Experience

• Interactive and Dynamic variable relationships analysis
• Techniques introduction
• Tools introduction
• Problem Analysis
• Practical Use of Tools and Techniques
• Tools and Techniques - selecting the right one

People Issues

• Working practices - empowerment or impairment?
• Group dynamics
• Individual motivators
• Developing Troubleshooting and Problem-Solving skills
• Managing change

Operator, Maintainer, Designer Interface

• Cross-functional and Teamworking
• Introduction to the Theory of Inventive Problem Solving
• Auditing your process to a dynamic standard
• Effect of Maintenance Operations strategy
• Development of Standards and Key Performance Indicators
• Life Cycle Costing, Design for Operation, Design for Maintenance

Open Forum

• Revisit Concepts, Tools and Techniques
• Action Plan