There is an alarming trend in industry to discount the potential contribution of the Technical/Operations function to productivity improvement, product quality and gains in market share. Principles taught in this training session will help you to understand the true nature and different techniques of problem solving and problem prevention in the operational/process environment.

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.

Upon successful completion of this course, the delegates will be able:

• To become a ‘Top Gun’ Troubleshooter by acquiring new skills
• To develop a structured approach to Troubleshooting and Problem Solving which uses a common terminology and shared understanding
• To point the way to Continuous Improvement in the way you run your processes and make incremental efficiency gains
• To understand the difference between having a techniques manual on the bookshelf – and actually making it work
• To identify the “motivated” people who should be the champions of Troubleshooting and Problem Solving – and who should just follow
• To understand work practices which “allow” success in Troubleshooting and Problem Solving through reducing the variability of your process

This course is intended for all those supervisors/section heads 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. The program elements are of equal importance to Production, Maintenance Engineering and Process Engineering personnel.

Day 1:

INTRODUCTION AND PREPARATION

• Introduction to Process Plant Start Up and Commissioning
• Organization, Roles and Leadership
• Cost Estimation
• Spare Parts Planning

COMMISSIONING STRATEGY

• Commissioning Strategy
• Mechanical Completion & Integrity Checking
• Pre-commissioning and Operational Testing
• Start-up/Initial Operation, Testing and Acceptance

Day 2:

PROCESS PLANT AND MACHINERY SPECIFIC ISSUES

• Process Plant and Machinery Commissioning
• Instrumentation and Control Systems
• Preparing and Isolating Process Plant

PROJECT MANAGING THE START-UP/COMMISSIONING

• Work Breakdown Structures
• The Critical Path Method of Planning and Control
• Short-Cut Planning Methods
• Budgeting, Progress and Cost Control
• Earned Value Analysis

Day 3:

TROUBLESHOOTING, RISK AND HSEQ

• Introduction to Problem Solving and Trouble Shooting
• Problem Solving in Commissioning and Start Up Situations
• Managing Risk
• Managing Health, Safety, Quality and Environment

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

Day 4:

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

PEOPLE ISSUES

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

Day 5:

OPERATOR, MAINTAINER, DESIGNER INTERFACE

• Cross functional and Team working
• 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

A variety of methodologies will be used during the course that includes:

·         (30%) Based on Case Studies

·         (30%) Techniques 

·         (30%) Role Play

·         (10%) Concepts

·         Pre-test and Post-test

·         Variety of Learning Methods

·         Lectures

·         Case Studies and Self Questionaires

·         Group Work

·         Discussion

·         Presentation

This rate includes participant’s manual, Hand-Outs, buffet lunch, coffee/tea on arrival, morning & afternoon of each day.

Daily Course Timings:

    08:00 - 08:20       Morning Coffee / Tea

    08:20 - 10:00       First Session

    10:00 - 10:20       Coffee / Tea / Snacks

    10:20 - 12:20       Second Session

    12:20 - 13:30       Lunch Break & Prayer Break

    13:30 - 15:00       Last Session