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Technical Courses

Process Plant Troubleshooting

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

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