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Engineering, Oil and Gas

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 course is a must because it delivers rapid, efficient troubleshooting

Targeted Groups:

  • 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 Objectives:

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

  • 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 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 Competencies:

  • 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 Content:

Unit 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

Unit 2: Tools & Techniques:

  • Decision Logic
  • Maturity Indexing
  • Relationships Analysis
  • Problem Analysis and Synthesis
  • Practical Use of Tools and Techniques
  • Project selection methods
  • Tools & Techniques – selecting the right one

Unit 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
  • Fraction

Unit 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

Unit 5: Review of Concepts, Tools, and Techniques:

  • Action Plan
  • Configuration Management
  • Commercial Programs
  • Application of “Standard Questions”
  • The Four critical stages of Data Maturity