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Maintenance, Inspection, Testing, Corrosion, Painting, Turnaround & Industrial Services

Troubleshooting Process Operation


This course will enable delegates to remain abreast of the latest researched trends, techniques, and strategies to improve the condition and performance of their operational process. This hands-on intervention will equip you with the necessary basic knowledge and skills to optimize the function, daily running, and maintenance of the main aspects of the operation, such as demographics, infrastructure, systems, and plant.

Delegates will learn and review the core competencies required for the successful operation and implementation of an effective operations process against the background of the current global economic downturn. They will complete several in-course assignments, which will enhance their problem-solving skills and which will serve as an action plan for improvement. Setting the correct priorities and DOING THE RIGHT THING, makes all the difference to your performance

Targeted Groups:

  • Engineering and Technical Managers and Supervisors from any industry
  • Maintenance Planners and Coordinators
  • Operations and Manufacturing Managers and Supervisors
  • Foremen and Team leaders
  • Plant Engineers and Process System Managers
  • Section Engineers and Planners

Course Objectives:

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

  • Gain a broad understanding and appreciation of the core functional aspects of how an effective operational process should operate
  • Review the six standard maintenance improvement tactics and their selection technique to ensure reliable process plant & equipment
  • Learn how to develop a comprehensive operational process resource and support system analysis
  • Understand the principles of an operational audit, develop your process standard
  • Gain insight and understanding into the unique leadership and motivation principles required for technical process operation and management

Targeted Competencies:

  • Terminologies; 112 Tools and Techniques for RCFA
  • A modern holistic approach to understanding the operational process
  • Process Maturity Indexing; Planning; and Protocols
  • Exact performance measurement and performance management modeling
  • More than one hundred “Human Factors” as a Source of Error

Course Content:
Unit 1: Review of Basic Modern Operations Practice:

  • Review of Modern Operational Practice in the light of the Global Economic Recession
  • Integration of Maintenance and Production to establish a World Class Operations Department
  • Generic Performance Measurement Model using a 6 Point Scale
  • Combining the parameters of Speed; Quality; and Cost; in maintenance performance measurement
  • The 10 point Planning Standard and the role of the Planning Department
  • Variability Analysis
  • Developing Effective Strategies for the Operational Process to achieve organizational excellence and continuous improvement

Unit 2: Standard Maintenance Improvement Initiatives:

  • Selecting the “Correct” maintenance tactic mix
  • Reliability Centered Maintenance (RCM)
  • Total Productive Maintenance (TPM)
  • Run To Failure (RTF)
  • Condition Based Maintenance (CBM)
  • Time-Based Maintenance (TBM)
  • Skills Level Upgrade (SLU)
  • Design Out Maintenance (DOM)

Unit 3: Operational Resource Analysis:

  • A “Blueprint” for effective operational practice
  • Resource and Support System analysis with “Gap Analysis
  • Leadership Development and Motivation of Operations employees
  • The PAS 55 Maintenance Process Standard
  • Principles of Information Management
  • Training, Awareness and Competence

Unit 4: Problem Solving in the Operations Environment:

  • Risk identification, assessment and control
  • Theory of Inventive Problem Solving
  • Problem Solving Techniques and application

Unit 5: Scenario Analysis and Action Plan Development:

  • Relationships Scenario Analysis
  • Assessment Assignment
  • Scoring of your Operational Process
  • Understanding the complexity