Process Control, Troubleshooting & Problem Solving

OBJECTIVES:
• Focus on how to become a ‘Top Gun’ Troubleshooter
• 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 actually 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

COURSE OUTLINE:
CONCEPTS
• The nature of process problems affecting performance
• Performance defined in terms of generic variables: Speed; Quality; and Cost
• Effort inputs in context – Asset based or Business Process based
• Structured approach – The Operations Process redefined
• Configuration; Operation; and Optimization
• Maturity Indexing: Planning; Control, Congruence, Empowerment
• 6 Big Losses, 7 Wastes
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• TOOLS & TECHNIQUES – PRACTICAL EXPERIENCE
• Interactive and Dynamic variable relationships analysis
• Techniques introduction
• Tools introduction
• Problem Analysis
• Practical Use of Tools and Techniques
• Case Studies
• Tools & Techniques – selecting the right one
• PEOPLE ISSUES
• Working practices – empowerment or impairment?
• Group dynamics
• Individual motivators
• Developing Troubleshooting and Problem Solving skills
• Managing change
• OPERATOR, MAINTAINER, DESIGNER INTERFACE
• Cross functional and Team working
• Introduction to the Theory of Inventive Problem Solving
• Auditing your process to a dynamic standard
• Effect of Maintenance/Operations strategy
• Development of Standards and Key Performance Indicators
• Life Cycle Costing, Design for Operation, Design for Maintenance
• OPEN FORUM
• Revisit Concepts, Tools and Techniques
• Your Problems – Case Studies
• Your Action Plan
• Wrap up