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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!