Troubleshooting and Problem-Solving in Process Management

Introduction:

In engineering industries, effective troubleshooting is critical to minimizing downtime and maintaining operations. This course focuses on rapid troubleshooting training and enhancing techniques for quick problem resolution with minimal risk. The program addresses the need to bridge gaps between operators, maintainers, and designers to improve troubleshooting capabilities and problem-solving effectiveness. 

Objectives:

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

• Interact across departments and utilize available resources to resolve issues.
• Evaluate various solutions and choose the most feasible one, considering pros, cons, compromises, schedules, and resources.
• Combine analytical skills with timely decision-making.
• Gather and understand relevant information to identify the problem.
• Synthesize diverse information to create optimal solutions.
• Analyze information, identify logical errors, and propose corrections.
• Encourage creative problem-solving and alternative thinking.
• Benchmark against top performers to become a skilled troubleshooter.
• Develop a structured troubleshooting approach with a common understanding and terminology.
• Drive process improvements and incremental efficiency gains.
• Apply theoretical knowledge to practical contexts effectively.
• Identify and support key individuals as troubleshooting advocates.
• Implement practices that ensure efficient problem resolution.

Training Methodology:

• Case Studies
• Group Discussions
• Role-Playing
• Simulations
• Problem-Based Learning
• Interactive Exercises
• Hands-On Practice
• Presentations
• Peer Reviews

Course Outline:

Unit 1: Concepts

• Types of process problems impacting performance
• Performance metrics: speed, quality, and cost
• Variance in inputs and efforts: Asset vs. process
• Principles of restructuring operations
• Definitions: Configuration, operation, optimization
• Maturity indexing: Planning, control, congruence, power
• 6 Big Losses, 7 Wastes

Unit 2: Tools and Techniques

• Interactive and dynamic analysis of variable relationships
• Introduction to tools and techniques
• Problem formulation methods
• Selection and creation of suitable tools and techniques

Unit 3: People Issues

• Empowerment vs. incapacitation in working practices
• Group dynamics and personal motivations
• Enhancing task performance and troubleshooting skills
• Implementing changes effectively

Unit 4: Operator, Maintainer, and Designer Interface

• Teamwork and cross-functional collaboration
• Theory of inventive problem solving
• Process audit against static standards
• Maintenance/operations strategy impact
• Formulating technical and commercial standards
• Life cycle costing and design considerations

Unit 5: Entry Document Forum

• Application of ideas, tools, and techniques to problems
• Application management and commercial software solutions
• Stages in data set maturation
• Action plans and case studies