1 -quality manufacturing- in the chemical process industries cm4120 chemical plant operations d....

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-Quality Manufacturing-in the

Chemical Process IndustriesCM4120

Chemical Plant Operations

D. Caspary

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CM4120Chemical Plant Operations Lab

Introduction to Chemical Manufacturing

CM4120 Course Description:

A capstone laboratory course focused on chemical manufacturing processes from the perspective of manufacturing excellence.

Lecture material includes quality management, the application of statistical process control, and current trends in quality manufacturing.

Experimental reinforcement of these concepts occurs in the department's pilot plants.

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Additional Professional Development:

MTU Courses BA3600 Quality Management BA4620 Supply Chain Management ME4650 Quality Engineering ME5990 Design for Experiments – (JWS) MA2720 Statistical Methods MA3710 Engineering Statistics

Many good web resources Carillon Technologies iSix Sigma W. Edwards Deming Institute

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Entry-level titles of B.S. Chemical Engineers: Chemical Engineer Process Engineer Product Specialist Product Engineer Research Engineer Production Engineer

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Petrochemical Energy Automotive Food Processing Agricultural

Products Environmental

Remediation Pharmaceutical /

Health Care

Consumer Products Pulp and Paper Coatings and

Adhesives Intermediate

Products Polymer Processing Semiconductor

Industry

Industries Served:

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Primary Goal of Chemical Manufacturing?

How does your company achieve that goal?

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Corporate Survival Skills: Must provide service or product on a

timely basis Manage multiple supplier relationships Sufficient quality, consistently Manage complex customer relationships Expand existing markets Develop new products Continuing education/professional

development

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Business ConstraintsMust maintain a level of profitability while complying with: Environmental laws Health and safety regulations Labor laws Tax laws International trade agreements Certifications or quality assurance standards Internal politics Moral and ethical standards

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Major political events changed the business climate worldwide Breakup of Soviet Union Free and open trade in western Europe and

a re-united Germany NAFTA Expanding markets and infrastructure

development in India, China, S. Korea, other Pacific Rim countries

Formation of the European Union and the creation of the Euro

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What you did today isn’t good enough for tomorrow!

Your company is driven to continuous improvement by your customers by your competitors

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Ways to improve profitability increase throughput increase on-time order fulfillment improve stability of process improve quality reduce inventory – product and feedstocks reduce maintenance costs reduce labor costs reduce production costs reduce/eliminate environmental releases reduce energy costs reduce/eliminate off-spec product

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All improvements fall into one of two categories:

Improved processing and control thru Quality Management, or

Increased profitability thru efficient Supply Chain Management

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Quality Manufacturing

How is Quality defined?

ISO9000: The totality of features and characteristics of a product or service that bear on its ability to satisfy stated or implied need.

Quality is always defined by the customer.

Quality is what adds value to your raw materials.

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Traditional thinking: Quality costs $ higher quality higher cost

no gain

Current practice: Un-quality costs $must recognize and evaluate cost/ quality relationship

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Costs related to quality, 4 primary categories Prevention costs Appraisal costs Internal failure costs External failure costs

reference: Dr. Joseph Juran

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What is Quality Management?

Managing systems and processes for the elimination of errors.

Creating an environment for continuous improvement.

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Formula for a generic process:

A+B=C

where A=system contribution, B=human contribution, and C=desired (measurable) output

manipulating A and B causes variation in C

W. Edwards Deming – Variation is the enemy of quality manufacturing

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Deming’s 14 Principles: Quality manufacturing means “elimination of errors”

1. Create constancy of purpose toward improvement and service, with the aim to become competitive and to stay in business, and to provide jobs.

2. Adopt the new philosophy. We are in a new economic age. Western management must awaken to the challenge, must learn their responsibilities, and take on leadership for change.

3. Cease dependence on inspection to achieve quality.

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4. End the practice of awarding business on the basis of price tag. Instead, minimize total cost. Move toward a single supplier for any one item, on a long-term relationship of loyalty and trust.

5. Improve constantly and forever the system of production and service, to improve quality and productivity, and thus constantly decrease costs.

6. Institute training on the job.

7. Institute leadership.

8. Drive out fear.

see www.deming.org for more

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What is a Process?

A logical sequence of tasks that repeatedly transform inputs into outputs.

Inputs may be people, information, or material.

Outputs may be products, services, or behaviors.

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What is a System?

Group of people and/or processes that are united with a common purpose.

Have identifiable characteristics. Have measurable performance (quality)

indicators.

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What is Variation?

Measurable change in the system output(s).

Inherent to all processes or systems.

4 types of variation: Common cause – built into the system. Special cause – assignable to an event. Tampering – result from tampering. Structural – regular, systematic changes.

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Quality Management Tools

What is Statistical Process Control?

Application of statistical methods to separate common cause variation from other causes.

Uses control charting to convert fluctuations in a measured characteristic into useful information.

A tool commonly used in quality systems.

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Fishbone (Cause and Effect) Diagram

Viscosity variation

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Pareto ChartUsed to display the relative importance

or frequency of problems or conditions

A bar graph showing frequency of problem occurrence.

Optionally, can have a “cumulative frequency” line and show percentage of total on bar graph.

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cause frequency percentcumulative

totalmiscalculated loadings 13 37 13neutralize too soon 7 57 20added wrong qty EB 6 74 26inadequate strip 4 86 30bad viscometer reading 4 97 34loaded wrong chemical 1 100 35

Viscosity Variation Problems

02468

101214161820

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Deming Cycle

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Goal setting

Helps us “maintain constancy of purpose” if we define our purpose and set appropriate goals.

Goals must be attainable Goals must be measurable

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Introduction to Supply Chain Management

What do we mean by the Supply Chain?

Concerns the flow of material from procurement to delivery of finished products purchasing receiving warehousing processing packaging shipping

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What do we mean by the Supply Chain?

Concerns the flow of information through business processes sourcing planning technology solutions inventory management sales, marketing, and advertising order fulfillment customer service

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Why manage the supply chain?

U.S. Chemical Industry is $400 billion/yr. in sales

Better management of supply chain yields 7.5% of sales in savings for typical chemical manufacturer

$30 billion/yr. potential savings

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Where do gains come from?

It is estimated that U.S. CPI has 80 days inventory

Reduce inventory by 50% and save 30% of the value of inventory

Estimated savings are $20 billion/yr.

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Where do gains come from?

Typical cash-to-cash cycle time is 6 months

Best-in-class implementations will reduce cash-to-cash cycle time to 30 days



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Where do gains come from? Automation of business processes

Open communications w/ suppliers

Open communications w/ customers

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Advancements in computing technology enable improvements in business efficiency

computing hardware and software technologies

networked computer systems and WWW

database systems

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Enterprise management tools available

SAP, i2, iBaan, others manages everything from order entry to invoice provides links to suppliers and customers

Require that all relevant data at all levels of the business be available in real time

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Information flow in a manufacturing environment:

Originates at the field device or from an operator

DCS or other control system and their operators

Manufacturing Execution System (MES) and their operators

Supply Chain (Enterprise) Management System and their operators

1 -quality manufacturing- in the chemical process industries cm4120 chemical plant operations d....

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