1 Chemical Manufacturing CM4120 Chemical Plant Operations D. Caspary.

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Chemical ManufacturingCM4120

Chemical Plant OperationsD. 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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Agricultural Products

Automotive Coatings and

Adhesives Consumer Products Energy Environmental

Remediation Food Processing

Intermediate Products

Petrochemical Pharmaceutical /

Health Care Polymer

Processing Pulp and Paper Semiconductor

Industry

Some of the 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 Manage complex customer relationships Sufficient quality, consistently 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 Homeland Security Act 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 –

European Union and the Euro NAFTA and, soon CAFTA Expanding markets and infrastructure

development in India, China, S. Korea, other Pacific Rim countries as well as African nations

9/11 Incident and other terror attacks worldwide

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

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

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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

Ways to improve profitability:

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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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Introduction to

-Quality Manufacturing-


Quality Manufacturing

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How is Quality defined?

Quality is what adds value to your raw materials.

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.

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Traditional thinking: Quality costs $ higher quality higher cost = no gain

Current practice: “Un-quality” costs $must recognize and evaluate the 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 ?

Creating an environment for continuous improvement.

Managing systems and processes for the elimination of errors.

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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 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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Formula for a generic process:

A+B=C

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

manipulating either A or B causes variation in C

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

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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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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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Some UsefulQuality Management

Tools


Quality Management Tools

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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. Friday’s lecture

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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-


Introduction to Supply Chain Management

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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

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A quote from:

The Germ Theory of Management

Myron TribusDirector of the American Quality and Productivity

InstituteCopyright 1995-2000 by Deming Electronic

Network – all rights reserved

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