Course Details

This course is appropriate for a wide range of professionals but not limited to:

• Process engineers and technicians
• Operations and maintenance professionals
• Quality assurance and control personnel
• Supervisors and managers overseeing process operations
• Professionals aiming to master troubleshooting methodologies and tools

• Expert-led sessions with dynamic visual aids
• Comprehensive course manual to support practical application and reinforcement
• Interactive discussions addressing participants’ real-world projects and challenges
• Insightful case studies and proven best practices to enhance learning

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

• Establish core troubleshooting concepts and methodologies
• Apply analytical tools and data in troubleshooting efforts
• Diagnose and solve equipment and system-related problems
• Address human, procedural, and communication-based root causes
• Synthesize learning through comprehensive case studies and peer feedback

DAY 1

Foundations of Process Troubleshooting

• Welcome and introduction
• Pre-test
• Introduction to Process Troubleshooting

• Definition and importance
• Types of process issues (mechanical, operational, quality, human error)
• The cost of unresolved problems

• Troubleshooting Frameworks

• Root Cause Analysis (RCA)
• PDCA (Plan-Do-Check-Act)
• 5 Whys and Fishbone Diagrams
• Introduction to FMEA (Failure Mode and Effects Analysis)

• Case Study 1 – Introduction to Root Cause Analysis

DAY 2

Data-Driven Troubleshooting

• Gathering and Interpreting Data

• Types of data (quantitative, qualitative, historical)
• Process monitoring tools (control charts, trend analysis)
• Identifying critical process variables

• Statistical Tools for Troubleshooting

• Pareto analysis
• Scatter plots and correlation
• SPC (Statistical Process Control) basics

• Case Study 2 – Quality Deviation in a Batch Process

DAY 3

Equipment and System Troubleshooting

• Common Equipment Failures

• Pumps, valves, sensors, and automation systems
• Maintenance vs. operations issues

• Troubleshooting Methodology for Equipment

• Vibration analysis, thermography, and basic diagnostics
• Reading P&IDs and understanding interlocks

• Case Study 3 – Mechanical Failure in Continuous Process

DAY 4

Human and Systemic Issues

• Human Factors in Process Failures

• Errors in operation, miscommunication, and lack of training
• How to gather facts during incident reviews

• Systemic Root Causes

• Procedural gaps, unclear roles/responsibilities
• Organizational contributors to recurring issues

• Case Study 4 – Operator Error in Manual Process

DAY 5

Integrated Troubleshooting and Final Projects

• Troubleshooting in Teams

• Tools for collaboration
• Communication and documentation

• Case Study 5 – Complex Multivariable Process Issue
• Wrap-Up and Review
• Post-test
• Certificate ceremony