Process Troubleshooting and Problem Analyze and Solving

Overview:

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.

Course Objectives:

At the end of this course the participants will be able to: 

• Apply the appropriate knowledge and cross-functional resources in addressing issues.
• Consider alternatives and chooses the best, workable solution (i.e., considers the pros and cons, trade-offs, timing, available resources).
• Make effective decisions by balancing analysis with decisiveness.
• Fully understand problems by gathers relevant information.
• Integrate information from a variety of sources to arrive at optimal solutions.
• Apply accurate logic to facts; detects inaccuracies or flaws in reasoning.
• Create alternative ideas & innovative thinking.
• 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

Targeted Audience:

• Employees who are responsible for leading and directing people to achieve and improve productivity levels
• Those faced with the challenge of solving plant-related problems
• Production, Maintenance Engineering, and Process Engineering personnel
• Supervisors who are involved in the Operations / Maintenance function
• Planners, Coordinators, Engineers, and Technologists

Course Outlines:

Unit 1: 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

Unit 2: Tools and Techniques - Practical Experience:

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

Unit 3: People Issues:

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

Unit 4: 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

Unit 5: Open Forum:

• Revisit Concepts, Tools, and Techniques
• Your Problems - Case Studies
• Your Action Plan
• Wrap up