DFSS in Action:DFSS in Action:Re-Design of a Product LineRe-Design of a Product Line

Christian MaierGeneral Electric Advanced MaterialsEngineered Styrenic Resins (ESR)

eESR

2/15

Project GoalsProject Goals

June 2000:By June 1, 2002 the MACT target set by the EPA had to be met, or large capital expenditures be implemented in environmental control equipment

MACT = Maximum Achievable Control Technology

Re-Design Entire Product LineRe-Design Entire Product Line2 Years to Deadline!2 Years to Deadline!

eESR

3/15

AgendaAgenda

BackgroundNew TechnologyRe-OrganizationNew Business ModelProject ExecutionWrap-Up

Entire New CYCOLACEntire New CYCOLAC®® Portfolio In 2 Years Portfolio In 2 Years

eESR

4/15

CYCOLACCYCOLAC®®

ABS is a Terpolymer of

• Acrylonitrile• Butadiene• Styrene

CharacteristicsStrengths:

• Low Specific Gravity• Excellent Processabilty• Practical Toughness• Cost / Value• Heat (up to 185o F)• Appearance

Weakness:• Chemical Resistance• Outdoor Weathering

eESR

5/15

Manufacture of ABSManufacture of ABS

Many Process Steps

Process Steps within Process Steps

Unique for different Products

1000’s of x’s

Reactor

Reactor

CoagulationDewatering

Drying

Finishing

Latex

Latex

Powder

ABS Pellets

Monomer(s)Process Chemicals

Monomer(s)Process Chemicals

Process Chemicals

Polymeric Diluent ≥0Colorant(s)Additive(s)

Highly Complex ProcessHighly Complex Process RiskRisk

eESR

6/15

Total Residual EmissionsTotal Residual Emissions

HAP = Hazardous Air PollutantsTOC = Total Organic Carbon

Max

Document TRE>=4

Monitor 1<=TRE<4

Incinerator TRE<1

Target Start

Stretch GoalGoal: TRE > 1Goal: TRE > 1With ZWith ZSTST > 6 > 6

eESR

7/15

New Technology: MMANew Technology: MMA

US Patent ApplicationUS20040059079A1: Enhanced Polymerization Process

Post-Shot of MMA

eESR

8/15

Numerical DFSS TechniquesNumerical DFSS Techniques

Propagation of Error•Immediate Variance Models•Min Resourcing•Better Scale-Up to Plant Scale•Raws to Pellet•Pareto Sources of Variance

Fractional Factorials•Weed out essential x’s

•Before Optimizations

Optimization•Parallel vs Sequential Expt’s•Temporary Noise Variables•Multivariable Optimization•Plant Scale

Experience•Engineering Know-How•Framework of Transfer Functions

Rigorous Mathematical ExecutionRigorous Mathematical ExecutionBalanced with Checks of RisksBalanced with Checks of Risks

eESR

9/15

DFSS ToolsDFSS Tools

Tollgate ProcessQFDRisk AssessmentScorecards: Raws, Process,

ProductGRR’sContingency PlanningChange Acceleration Process

(CAP)Rigorous Use of Rigorous Use of AllAll DFSS Tools DFSS Tools

eESR

10/15

Portfolio SimplificationPortfolio Simplification

Simplified Lower Cost Number Raws Change-Overs Manufacturing Logistics X-Based Control Digitization Quality Assurance

Molding GradeCYCOLAC MGxxYZ

Rel Flow 1-9

Rel Impact 1-9

Special ID

EXtrusionCYCOLAC EXxxYZ

Rel Flow 1-10

Rel Impact 1-9

Special ID

Flame RetardantCYCOLAC FRxxYZ

Special IDV0 @ xx mm

38 11 21 8

19 4

3 Families, 23 Products3 Families, 23 Products

eESR

11/15

Molding GradesMolding Grades

Melt Viscosity @240°C/1000 s-1 (Pa-s)270 190

12

35

ImpactISO Izod(kJ/m2)

Very High ImpactMG29 High Impact

MG38

Medium ImpactMG47

High FlowMG94

MG37EPPlatable

Low GlossMG34LG

FoodMG38F

MG38PPipe

ColorableMG47CL

StiffGF20

RecycleMG45REC

38 38 11 Grades 11 Grades

eESR

12/15

Project Schedule OverviewProject Schedule Overview

3Q00 4Q00 1Q01 2Q01 3Q01 4Q01 1Q02 2Q02

Powder DesignsPowder Designs

MG DetroitSubmissions

Stop Old Portfolio

ProductionPellet DesignsPellet Designs

Early Customer

Communications

Formal Customer NotificationsSampling Info

Sampling Availability

Commercialization, Ordering Capability

T1

T2

T3

T4

T5

T6

…4Q02

Excellent Techno-Commercial ExecutionExcellent Techno-Commercial Execution

eESR

13/15

Re-OrganizationRe-Organization

Dedicated Team Req’dDedicated Team Req’d

LeaderChemical Operations Technology TeamCompounding Technology TeamAnalytical Technology TeamCorporate Research TeamCommercial TeamKey Product Stewardship ContactsKey Mfg ContactsKey Quality Support ContactsKey Business Support ContactsKey Expert Contacts

eESR

14/15

Emission ReductionsEmission ReductionsLatex

0

1000

2000

3000

4000

5000

6000

Total NAVs S+AN NAVs

NA

Vs

(pp

m)

Before

After

Powder

0

1000

2000

3000

4000

5000

6000

Total NAVs S+AN NAVs

NA

Vs

(pp

m)

82%Reduced

93%Reduced

GPM5600 Pellets

0

1000

2000

3000

4000

5000

6000

Total NAVs S+AN NAVs

NA

Vs

(pp

m)

69%Reduced

Molded Parts

0

1000

2000

3000

4000

5000

6000

Total NAVs S+AN NAVs

NA

Vs

(pp

m)

66%Reduced

ChemOps

Out of Compounder

Into Compounder

In Customer Shop

Emission Reductions In All Unit OperationsEmission Reductions In All Unit Operations

eESR

15/15

Wrap-UpWrap-Up

Entire Product Line Redesigned <2 Years

Target TRE MetMajor Capital $’s AvoidedDFSS Tools Critical Success

Factor– Mathematical Techniques– Semi-Quantitative Tools– CAPNew, Revitalized Business Created!New, Revitalized Business Created!