Process Plant Optimization Technology and Continual Improvement

Tujuan

• Menjelaskan konsep utama process plant optimization.

• Mengidentifikasi bottleneck utama

• Menganalisis parameter kunci plant: throughput, yield, energy use, downtime, losses, hingga waste.

• Menggunakan metode continual improvement (Lean, Six Sigma, RCA, Kaizen) dalam konteks process plant.

• Menyusun rencana optimasi berbasis data.

• Menerapkan teknologi monitoring dan digital tools seperti dashboards, sensors, predictive models.

• Melakukan evaluasi performa plant.

• Mengembangkan strategi sustainability & efisiensi energi untuk meningkatkan profitabilitas plant.

Target Peserta

1. Process Engineer / Operation Engineer

2. Production Supervisor & Plant Manager

3. Maintenance Engineer / Reliability Engineer

4. HSE Officer terkait improvement & efficiency

5. Quality Control / QA Engineer

6. Continuous Improvement Specialist

7. Energy Manager

8. Operator Senior / Control Room Operator

9. Profesional di industri proses: Oil & Gas, Refinery, Chemical, Petrochemical, Power Plant, Pulp & Paper, Food & Beverage, Manufacturing Proses

Silabus

• Definisi dan ruang lingkup optimasi plant

• Value chain dan cost structure process plant

• Konsep throughput, yield, variability, dan efficiency

• Basic process engineering & mass-energy balance

• Key Operating Parameters (KOPs)

• Identifikasi losses: inefficiency, reprocessing, downtime

• Bottleneck identification

• Capacity vs Constraint analysis

• Debottlenecking techniques (equipment, control, flow, maintenance)

• Heat integration & pinch analysis overview

• Steam, power, cooling, fuel optimization

• Energy intensity & energy loss mapping

• Reliability tools (RCA, RCM, FMEA)

• Preventive & predictive maintenance

• Downtime reduction strategy

• Asset criticality & life cycle

• Advanced Process Control (APC) overview

• Control loop tuning & stability

• Alarm management

• Process variability reduction

• Real-time monitoring & dashboards

• Data analytics & AI for optimization

• Predictive analytics untuk failure prediction

• Industrial IoT & smart sensors

• DMAIC framework

• Waste elimination (TIMWOODS)

• OEE calculation & improvement

• Kaizen event & quick wins

• HAZOP overview

• Barrier & critical equipment

• Risk-based maintenance

• Integrasi safety & optimization

• Fishbone, 5 Why, Fault Tree

• Statistical tools sederhana

• Failure trend analysis

Fasilitas

• Modul pelatihan dan seminar KIT
• Makan siang dan rehat kopi.