Building Operational Excellence in The Process Industry

Introduction

The process industry is capital-intensive and is characterized by strong and relentless international competition. Certain operations and processes are also high risks. This means that process companies need to be on the top of their game if they wish to survive and grow in these difficult conditions. Building Operational Excellence into the Process Industry has been designed to explain the main factors of operational excellence and how to build them into a coherent improvement program for the process industry. The latest tools and techniques are introduced and explained with a minimum of jargon so that delegates can see how to use them in their situation.

The following aspects are covered in a straightforward way with case study examples being used to illustrate how best to apply them:

• Safety, risk, and continuity of operations
• People management
• Plant reliability
• Quality systems
• Costing

Objectives

• To provide a step-by-step guide to operational excellence - starting with foundations and building up to best practice that will deliver maximum business benefits. By virtue of dynamic participation in this seminar, it is to be expected that delegates will make a substantial, positive impact on the operational regime within their home organization. At the end of this seminar participants will have:
• A solid understanding of best practice techniques for achieving operational excellence
• An understanding of a range of technical and human risks and their implications to the operational organization.
• The ability to design a tailored operational improvement plan for their organization which tackles the major risk areas.
• A practical approach to developing an action plan to utilize these technologies in their own areas of responsibility, fitting them into the overall operations strategy, and measuring benefits
• The Process
• This workshop is designed to be a hands-on, stimulating experience. The program is highly interactive with many discussion and facilitated practice sessions led by speakers who are at the forefront of their field.
• The Benefits
• Individuals exposed to this training will develop new insights into international best practices. They will learn why the best companies in the world see operations management as the key to delivering the right quality product at the lowest costs.
• Technical knowledge and the ability to engage with colleagues are both key to achieving operational excellence. Both of these areas are addressed in this course.
• The Results
• Organizations that apply effectively operations best practice methodologies are able to better compete on the global stage. The participants of this course and their teams will be better positioned to positively influence the organization with innovative ideas and techniques that in turn produce a higher performing organization.
• On completion of this seminar the delegate will be able to critically analyze the methodologies employed within the organization and instigate improvements where required.
• The Core Competencies
• The delegates will develop an understanding of the key aspects of operational excellence within the process industry and how best to apply them in their situation.
• On completion of the course the delegates should have the confidence to propose operational improvements and deal effectively with any specialists or service providers in order to deliver an effective improvement programme.

Training Methodology

This is an interactive course. There will be open question and answer sessions regular group exercises and activities videos case studies and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them as well as work on issues from their own organizations. The online course is conducted online using MS-Teams/ClickMeeting.

Who Should Attend?

This comprehensive 5-day programme has been designed to benefit both qualified new professionals as well as experienced professionals who might need to refresh their skills It is highly recommended that all Operations, Maintenance, Reliability, Engineering and Technical Support staff including leadership and management attend this workshop. If you and your company are interested in greatly increasing productivity, this will be a very valuable course.

Course Outline

Day 1: Safety

• Safety first
• Behavioral safety
• Risk Assessment
• Permits to Work, Hazard & Operability Studies and other common systems
• Analyzing Near Misses, Incidents & Accidents
• Complete Safety Management System

Day 2: Continuity of Operations – Plant Reliability

• Operational Risks
• Vulnerability & Resilience Assessment
• Reliability Improvement
• Plant Asset Care
• Developing the Right Maintenance Strategy
• Agile Manufacturing

Day 3: Quality

• Process Control
• Six Sigma: minimizing the six losses and seven wastes
• Continuous Improvement Model
•  Quality Assurance
• Standard Operating Procedures
• Error Proofing Techniques

Day 4: Costing

• Costing systems
• Lean manufacturing
• Inventory control systems
• Life cycle approach to equipment selection
• Asset management
• Benchmarking

Day 5: People Management / Development

• Leadership
• Empowerment & Engagement
• Change Management
• Performance Management Systems
• Skills & Competency Development
• Problem Solving