In today’s fully integrated manufacturing processes there is a relentless drive to continually improve the performance and productivity of the plant and machinery.

In many companies the use of best practice in production management, maintenance strategies and material technologies has brought the levels of equipment effectiveness to commendably high levels and the challenge now is to find those incremental steps to continue the improvement process. All these efforts come to focus in the operations area where results depend on the effectiveness of the "plant, + people + process" combination.

This course addresses that combination, and recognizes that many ‘problem’ areas are less to do with technology and more to do with the way people interact with the plant and process. There are many tools, techniques and 3-letter acronyms in use today but they will not, of themselves, make a business more competitive. Only people can do that, and the way people actually achieve the aims of those techniques is what makes the difference.

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

• 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.

This course is intended to those managers, heads, 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.

Day 1:

Module 1

• Concepts
• The nature of problems
• Context – Asset based or Business Process based
• Structured approaches – 6 Big Losses, 7 Wastes
• Techniques introduction
• Tools introduction

Day 2:

Module 2

• Tools & Techniques – Practical Experience
• Problem Analysis
• Practical Use of Tools and Techniques
• Case Studies
• Project selection methods
• Tools & Techniques – selecting the right one

Day 3:

Module 3     

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

• Managing change

Day 4:

Module 4

• Operator, Maintainer, Designer Interface
• Cross functional working
• Effect of Maintenance strategy
• Functional analysis
• Concurrent Engineering, Design for Operation, Design for Maintenance

Day 5:

Module 5

• Open Forum
• Revisit Concepts, Tools and Techniques
• Your Problems – Case Studies
• Your Action Plan
• Wrap up

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