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How can you prioritize process problems for troubleshooting?

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Process troubleshooting and diagnosis is a vital skill for chemical engineers, as it helps to identify and resolve the root causes of process problems that affect product quality, safety, efficiency, and profitability. However, not all process problems are equally urgent or important, and some may require more resources or expertise than others. How can you prioritize process problems for troubleshooting? In this article, we will discuss some practical methods and criteria that can help you rank and tackle process problems in a systematic and effective way.

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Subhodip Banerjee

Process Engineer at Shell | Ex- Process Engineer at Reliance Technology Group (RTG)
Ali Gholamalian

Senior Process Engineer

1 Define the problem

Before you can prioritize process problems, you need to define them clearly and accurately. This means collecting and analyzing relevant data, such as process variables, measurements, samples, alarms, logs, and reports. You also need to verify the data quality and reliability, and compare it with the normal or expected values. Defining the problem will help you to understand its scope, severity, frequency, and impact on the process and the product.

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Subhodip Banerjee

Process Engineer at Shell | Ex- Process Engineer at Reliance Technology Group (RTG)
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Often, it is seen that the problem definition provided for a scenario is quite generic. This leads to situations such as: - The cause identified does not synchronize with the actual problem. - The action points defined as a result of the cause identified does not yield the desired result. - There happens to be a scope creep, which sometimes could lead to a domino effect. The consequences of the aforesaid situations could be detrimental, depending upon the severity. Hence, an ideal problem definition ought include the following: - The affected parameter. - The undesired change. - The extent of change. - Duration of change. - The equipment whose parameter is under consideration. - The consequences of the change (if available).

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2 Identify the possible causes

Once you have defined the problem, you need to identify the possible causes that could explain it. This can be done by using various tools and techniques, such as brainstorming, fishbone diagrams, fault tree analysis, Pareto charts, and root cause analysis. You should consider all the potential factors that could affect the problem, such as equipment, materials, operations, environment, and human factors. Identifying the possible causes will help you to narrow down the search and focus on the most likely or critical ones.

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3 Evaluate the risks and benefits

After you have identified the possible causes, you need to evaluate the risks and benefits of addressing each one. This means assessing the likelihood and consequences of each cause, as well as the feasibility and effectiveness of each solution. You should also consider the costs, time, resources, and trade-offs involved in implementing each solution. Evaluating the risks and benefits will help you to weigh the pros and cons of each option and determine the best course of action.

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4 Prioritize the actions

Based on the evaluation of the risks and benefits, you need to prioritize the actions that will solve the problem or prevent it from recurring. This can be done by using various methods and criteria, such as urgency, importance, ease, impact, return on investment, and stakeholder satisfaction. You should also consider the interdependencies and interactions between the actions, and plan them in a logical and sequential order. Prioritizing the actions will help you to allocate the resources and time efficiently and effectively.

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5 Implement and monitor the actions

Once you have prioritized the actions, you need to implement and monitor them according to the plan. This means following the standard operating procedures, safety rules, and quality standards, and documenting the results and changes. You also need to measure and verify the performance and outcomes of the actions, and compare them with the baseline and target values. Implementing and monitoring the actions will help you to ensure that the problem is solved or improved, and that no new problems are created or overlooked.

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6 Review and improve the process

After you have implemented and monitored the actions, you need to review and improve the process based on the feedback and learning. This means evaluating the effectiveness and efficiency of the actions, and identifying the gaps and opportunities for improvement. You also need to communicate and share the findings and recommendations with the relevant stakeholders, and update the process documentation and knowledge base. Reviewing and improving the process will help you to sustain the results and prevent the problem from reoccurring.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Ali Gholamalian

Senior Process Engineer
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To solve problems well, we need a clear and strategic approach that ensures safety, quality, and efficiency. We can enhance this approach by using quantitative measures, advanced technology, and interdisciplinary perspectives. Tools like FMEA help us find and rank risks by evaluating their severity and frequency. For instance, FMEA can quickly detect a critical reactor failure by its high-risk score. Using the Industrial Internet of Things for constant monitoring makes problem-solving more preventive than corrective. Predictive analytics help us anticipate issues, like noticing when a catalyst might fail. This way, plants can avoid problems before they cause expensive downtime or reduced output.

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How can you prioritize process problems for troubleshooting?

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1 Define the problem

2 Identify the possible causes

3 Evaluate the risks and benefits

4 Prioritize the actions

5 Implement and monitor the actions

6 Review and improve the process

7 Here’s what else to consider

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