Troubleshooting and Problem Solving in Process Plants Workshop

Introduction:

Troubleshooting skills are vital for achieving excellence in industrial companies. Effective training in troubleshooting can significantly reduce downtime and enhance productivity. This workshop focuses on plant troubleshooting and engineering problem-solving, offering essential maintenance techniques and a systematic approach to resolving issues quickly and efficiently.

Objectives:

By the end of this workshop, participants will:

• Master the skills required to become a top troubleshooter.
• Apply a structured approach to troubleshooting and diagnosing problems using common terminology.
• Translate practices into incremental efficiency gains through continuous improvement.
• Differentiate between owning a techniques manual and applying the techniques effectively.
• Identify and motivate individuals who should lead troubleshooting efforts.
• Learn work practices that contribute to successful troubleshooting and problem-solving.

Training Methodology:

• Interactive lectures
• Case studies
• Experiential learning
• Group work
• Analytical problem-solving
• Role play
• Simulated situations

Course Outline:

Unit 1: Introductory Concepts and VI Aspect Structure

• Understanding the nature of problems
• Common troubleshooting terminology
• Framing problems by assets and business processes
• Structured methods (6 Big Losses & 7 Wastes)
• Methods and equipment for diagnosis and troubleshooting
• Establishing a Six Level Performance Standard
• Identifying vital aspects of a problem

Unit 2: Tools and Techniques

• Decision logic in troubleshooting
• Defining maturity indexing in problem-solving
• Analyzing relationships to identify problem sources
• Synthesis for quick problem resolution
• Application of tools and techniques in troubleshooting
• Project selection methods

Unit 3: People Issues

• Enhancing effective work practices
• Role of user groups in problem-solving
• Motivational factors for troubleshooting
• Internal vs. external motivation
• Troubleshooting and engineering management approaches
• Managing changes from problem-solving interventions
• Using a Transition Matrix to improve troubleshooting

Unit 4: Operator, Maintainer, Designer Interface

• Promoting interdepartmental cooperation for fault repair
• Impact of maintenance plans on troubleshooting
• Understanding roles in problem-solving
• Life Cycle Concepts and operational/maintenance aspects in design
• Variability analysis for problem prediction
• Strategies and tactics for better troubleshooting
• Aligning operational parameters

Unit 5: Refresher Concepts, Instruments, and Techniques

• Action planning for troubleshooting and issue resolution
• Role of configuration management
• Commercial programs for issue resolution
• Using predefined questions for troubleshooting
• Engineering problem-solving stages of Data Maturity

Conclusion:

This structured workshop will equip participants with essential engineering problem-solving skills, critical for addressing and preventing issues in process plants.