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Process Plant Troubleshooting

Designed for operators, supervisors, and engineers, Process Plant Troubleshooting shares a common method for process troubleshooting, and helps participants understand their own personal strengths and weaknesses related to troubleshooting and abnormal situation management. Process monitoring and troubleshooting skills are practiced to the point of practical mastery using the Simtronics DSS-100 simulator.  Supervisors receive helpful coaching points to enhance their understanding and ability to effectively lead and coach their crews in troubleshooting applications.

Key takeaways for Process Plant Troubleshooting include

  • A practical, easy-to-use method for troubleshooting process problems
  • Skills necessary to recognize and manage process deviations when they occur
  • An understanding of how personal barriers can affect process troubleshooting
  • Critical skills and coaching points to ensure successful deployment

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Advanced Communication Skills for Process Plant Supervision

The way we communicate across generations, genders, and cultures is always changing. Now more than ever, communication skills on the shop floor are essential to ensuring safe and effective operations.

This course is designed for the first-line supervisors and their managers who want to advance their communication skills and become more confident applying practical solutions to real-world problems. Our team of expert facilitators has a unique blend of plant experience and communication expertise that allows our clients to experience training at a different level.

Key takeaways for Advanced Communication Skills for Process Plant Supervision include

  • Practice in real-world plant communication scenarios
  • Increased awareness of personal communication styles and tips for advancing personal skills
  • How to improve shop floor operations through better teamwork and communication
  • How to confidently handle difficult communications such as performance reviews, disciplinary actions, and conflict resolution
  • Tips for maximizing the quality of communications (both verbal and nonverbal) in a variety of settings

Advanced Operations Skills for Process Leads

This workshop gives process leads a practical approach to working within defined operating envelopes and supporting further optimization of unit performance. The content expands on previous training developed specifically for process leaders, digging deeper into process troubleshooting and optimization, abnormal situation management, and team effectiveness.

Key takeaways for Advanced Operations Skills for Process Leads include

  • Review of process control system basics and how control elements are combined in complex control systems, including practice on a process simulator
  • Training in alarm system performance, including design criteria, human factors, and alarm management
  • Practical skills to monitor the performance of a 24/7 process unit, recognize deviations as they occur, and respond quickly and effectively
  • How to evaluate the capability of a process to perform within the desired operating envelope, assess proposed process changes, and analyze situations before determining a course of action

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Advanced Troubleshooting

A follow-up to Process Plant Troubleshooting, this course is the next step toward developing a standardized method for process troubleshooting. Operators, supervisors, and engineers have the chance to take a deeper look into troubleshooting and abnormal situation management.

Key takeaways for Process Plant Troubleshooting include

  • Additional training on real-world plant scenarios using the Simtronics DSS-100 simulator
  • Further development of existing troubleshooting skills

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Effective Performance Management

Effective performance appraisal skills and procedures are critical to using an appraisal system to establish and maintain workplace standards and to get the most out of plant staff. But sharing difficult performance feedback doesn't come easily to most supervisors, whether they're new to the job or experienced. Supervisors who have a clear understanding of the benefits associated with effective performance management and peer support in implementing standards find critical evaluations less intimidating.

This workshop gives supervisors and management staff an opportunity to address plant performance standards, to establish a baseline for performance evaluation, and to set and communicate common targets for future performance.

Key takeaways of Effective Performance Management include

  • How to establish performance standards and apply them to the workforce using the existing appraisal process
  • Guidance for conducting performance reviews and handling difficult cases
  • How to develop a plan to raise future performance levels and communicate it to the workforce

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Managing Conflict

Process plants with a positive, team-oriented atmosphere perform best, but the nature of the work and the pressure to perform often create an environment where a certain amount of conflict is inevitable. Effective leaders recognize conflict or the potential for conflict, prevent it when possible, and manage it effectively when it can't be avoided.

This workshop introduces skills that are critical to managing conflict, whatever the source. Participants gain an understanding of common sources of conflict in a plant environment and learn a practical method for conflict resolution and tips for handling difficult cases. In addition, they are taught to manage the emotional content of conflict situations.

Key takeaways of Managing Conflict include

  • An understanding of typical sources of conflict and how to act to avoid or mitigate them when possible
  • How to assess conflict situations in the plant and then apply a practical method for conflict resolution, including knowing when to get help
  • Coaching points to verify mastery of these skills and support their continued use

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Process Risk Analysis

For process plants, risk has recently evolved into a critical component of business operations. In the past 20 years, plants in the process industries have integrated Process Hazard Analysis (PHA) and Management of Change (MOC) techniques into their operations and engineering projects. In addition, insurance providers occasionally require a review of the risks of business interruptions. Because the broader area of risk analysis and management is not yet a routine part of plant operation, some process plants are finding a gap in knowledge: plant leaders know they need to manage risk and use relevant risk information to drive better decisions, but they lack the skills to do that.

Process Risk Analysis is a workshop that's designed to teach established risk management techniques and methodologies to engineers, front-line supervisors, and process plant operations managers. Participants learn skills that will help them prioritize risks to the plant's processes, product quality, and productivity, enabling them to make better-informed decisions. Plant leaders and managers can use these tools to identify which risks need attention and then apply methodologies that lead to a consistent response.

Key takeaways of Process Risk Analysis include

  • Understanding the language of risk management
  • Methodology that can be used to evaluate risk in any process
  • Practical experience with identifying and reviewing operational and business risks
  • Familiarity with risk management tools for use in evaluating the probability and impact of risk
  • Ideas and processes that can be integrated into the plant planning cycle

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Process Safety Leadership

This workshop prepares supervisors to develop and lead a culture of safety. Participants learn to apply process safety elements often encountered by the shift team, and receive practical guidance for addressing typical issues faced by front-line supervisors. In addition, supervisors learn to use their process understanding to gain the operational benefits associated with effective Process Safety Management (PSM) compliance practices.

Key takeaways of Process Safety Leadership include

  • An understanding of the concepts underlying the PSM practices
  • Skills critical to ensuring practical, 24/7 support of safe work practices
  • How to master critical skills and provide coaching points to support their continued use

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Training and Developing the Shift Team

Few plant training departments have the resources to meet site training needs in a practical, cost-effective manner. To achieve the required workplace performance levels, supervisors and other staff must be actively engaged in training and development. This workshop introduces the skills and practical methods needed to establish effective training practices or improve existing programs.

Key takeaways of Training and Developing the Shift Team include

  • An understanding of the concepts and program elements required for an effective process plant training program
  • Skills needed to provide practical, 24/7 support of shift team training and development
  • How to master critical skills and provide coaching points to support their continued use

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