Process Operation Troubleshooting: Achieving World-Class Operational Excellence 30th – 4th July, 2025
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Course Overview
This 5-day course focuses on equipping professionals with the knowledge and tools to troubleshoot and enhance process operations, aiming to develop world-class operational practices. Through a structured approach to maintenance, performance measurement, and problem-solving, participants will learn to optimize their operations, improve efficiency, and foster a culture of continuous improvement. The course covers strategic integration of maintenance and production, operational resource analysis, and advanced troubleshooting techniques to ensure operational excellence in any process environment.
Course Objectives
By the end of this course, participants will be able to:
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Integrate maintenance and production effectively to enhance operational efficiency.
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Develop and apply performance measurement models to track and improve process operations.
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Identify and implement standard maintenance improvement initiatives tailored to their operations.
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Utilise problem-solving tools and techniques to address complex operational challenges.
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Create a comprehensive action plan to drive operational excellence within their organisation.
Target Audience
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Operations managers and engineers.
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Maintenance supervisors and engineers.
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Process plant personnel.
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Continuous improvement specialists.
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Plant managers and decision-makers.
Daily Agenda
Day One: Review of Basic Modern Operations Practice
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Overview of modern operational practices in the context of the global economic recession.
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Integrating maintenance and production to create world-class operations.
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Applying a generic performance measurement model using a 6-point scale.
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Combining the parameters of speed, quality, and cost in maintenance performance.
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Understanding the 10-point planning standard and the role of the planning department.
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Conducting variability analysis to identify performance gaps.
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Developing effective strategies for operational excellence and continuous improvement.
Day Two: Standard Maintenance Improvement Initiatives
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Selecting the correct maintenance tactic mix for different operational environments.
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Exploring Reliability Centered Maintenance (RCM) principles.
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Understanding Total Productive Maintenance (TPM) practices and their applications.
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Applying the Run-To-Failure (RTF) strategy effectively.
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Implementing Condition-Based Maintenance (CBM) and Time-Based Maintenance (TBM).
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Introducing Skills Level Upgrade (SLU) for continuous workforce development.
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Designing out maintenance with Design Out Maintenance (DOM) strategies.
Day Three: Operational Resource Analysis
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Creating a blueprint for effective operational practice.
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Conducting resource and support system analysis with gap analysis techniques.
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Leadership development and employee motivation in operations.
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Applying the PAS 55 Maintenance Process Standard for operational excellence.
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Managing information in operations: principles of information management.
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Enhancing operational performance through training, awareness, and competence development.
Day Four: Problem Solving in the Operations Environment
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Identifying and assessing operational risks and applying risk control methods.
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Understanding the theory of inventive problem-solving.
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Exploring various problem-solving techniques and their practical applications.
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Hands-on exercises and facilitation of problem-solving scenarios.
Day Five: Scenario Analysis and Action Plan Development
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Conducting relationships scenario analysis to assess operational complexity.
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Reviewing assessment assignments and scoring operational processes.
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Putting everything together: developing an actionable plan for operational improvements.
Why Choose this Course?
This course provides a holistic approach to troubleshooting process operations, combining proven methods for performance measurement, maintenance improvement, and problem-solving with real-world applications. By mastering these techniques, participants will be able to drive operational excellence, enhance efficiency, and ensure their organisation’s competitiveness in a challenging global economy.
Learning Outcomes
By the end of this course, participants will be able to:
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Develop and implement world-class operations strategies that integrate production and maintenance.
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Apply performance measurement models to track and enhance operational performance.
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Implement a range of maintenance improvement initiatives suited to their operational needs.
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Effectively solve complex problems using structured problem-solving techniques.
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Create and execute action plans that lead to measurable improvements in operational efficiency and reliability.
