Contents

The Troubleshooting Team

• The Troubleshooting Organization
• Plant Staff
• Operations Team
• Production Team
• Process Operator
• Production Supervisor
• The Mechanical Team
• Mechanical-General
• Mechanical-Engineering
• Mechanical-Instrument
• Mechanical-Electrical
• The Technical Team
• Process Control Engineer
• Process Control Laboratory
• Central Engineering

Communications for Troubleshooters

• The Absence of Personal Contact
• Verbal Communications at Shift Change
• The Shift Log
• The Intercom
• The Importance of Terminology in Communications
• General Communications
• Communications with Key Personnel
• Memos, Reports, and Verbal Exchange

Detection and Management of Problems

• The Intrinsic Problem and the Troubleshooter
• Managing Intrinsic Problems
• Teamwork in Problem Detection
• The Plant Patrol
• The Human Factor
• Trusting Instruments
• The Unexpected Problem
• Steps in Solving the Unexpected Problem

Climates for Problem Development

• Changes in Technology
• Tight Schedules with Deadlines
• Operations Than Must Work the First Time
• Activities Involving Many People and Many Skills
• Responsibilties Not Specifically Assigned or Misunderstood
• Communications at Shift Change

Problem Solving as a Process

• Inductive and Deductive Reasoning
• Trial-and-Error Solution to a Problem
• Scientific Method in the Solution to a Problem
• Problem-Solving Process

Troubleshooting in the Team Environment

• Become a Skilled, Well-Trained Process Operator
• Know Your Fellow Troubleshooters
• Know Your Communications
• Teamwork Relies Upon Mutal Respect
• Know How to Detect and Manage Process Problems
• Know the Problem-Solving Process and Faithfully Use It
• Support the Conclusion and Action Taken
• Keep Information Current
• Who Needs to Know?
• Selling the Solution
• Keep the Boss on Board
• Work with Plant Staff
• Training

Prevention of Process Upsets

• Change Is Coming to Problem Prevention
• Basics of Problem Prevention
• Train for Problem Prevention
• Summary of the Problem Prevention Effort

Troubleshooting Exercises

• Discovery
• Documentation
• Analysis
• List Probable Causes and Draw Conclusions
• Action

Glossary
Index