Training Course: Process Plant Troubleshooting & Engineering Problem Solving

Introduction

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 Objectives of Process Plant Troubleshooting & Engineering Problem Solving

Participants attending the program will:

• Understand how to become a 'Top Gun' Trouble-Shooter
• 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 a technical 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

Course Outlines of Process Plant Troubleshooting & Engineering Problem Solving

Day One

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 Two

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 Three

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
• Fraction

Day Four

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 Five

Open Forum

• Review of Concepts, Tools, and Techniques
• Your Problems – Your Case Studies
• Your Action Plan
• Configuration Management
• Commercial Programs
• Application of “Standard Questions”
• The Four critical stages of Data Maturity
• Wrap up