Post on 16-Dec-2015
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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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CM4120Chemical Plant Operations Lab
Introduction to Chemical Manufacturing
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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CM4120Chemical Plant Operations Lab
Introduction to Chemical Manufacturing
Entry-level titles of B.S. Chemical Engineers: Chemical Engineer Process Engineer Product Specialist Product Engineer Research Engineer Production Engineer
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CM4120Chemical Plant Operations Lab
Introduction to Chemical Manufacturing
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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CM4120Chemical Plant Operations Lab
Introduction to Chemical Manufacturing
Primary Goal of Chemical Manufacturing?
How does your company achieve that goal?
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CM4120Chemical Plant Operations Lab
Introduction to Chemical Manufacturing
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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CM4120Chemical Plant Operations Lab
Introduction to Chemical Manufacturing
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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CM4120Chemical Plant Operations Lab
Introduction to Chemical Manufacturing
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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CM4120Chemical Plant Operations Lab
Introduction to Chemical Manufacturing
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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CM4120Chemical Plant Operations Lab
Introduction to Chemical Manufacturing
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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CM4120Chemical Plant Operations Lab
Introduction to Chemical Manufacturing
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-
CM4120Chemical Plant Operations Lab
Quality Manufacturing
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CM4120Chemical Plant Operations Lab
Quality Manufacturing
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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CM4120Chemical Plant Operations Lab
Quality Manufacturing
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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CM4120Chemical Plant Operations Lab
Quality Manufacturing
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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CM4120Chemical Plant Operations Lab
Quality Manufacturing
What is Quality Management ?
Creating an environment for continuous improvement.
Managing systems and processes for the elimination of errors.
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CM4120Chemical Plant Operations Lab
Quality Manufacturing
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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CM4120Chemical Plant Operations Lab
Quality Manufacturing
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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CM4120Chemical Plant Operations Lab
Quality Manufacturing
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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CM4120Chemical Plant Operations Lab
Quality Manufacturing
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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CM4120Chemical Plant Operations Lab
Quality Manufacturing
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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CM4120Chemical Plant Operations Lab
Quality Manufacturing
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
CM4120Chemical Plant Operations Lab
Quality Management Tools
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CM4120Chemical Plant Operations Lab
Quality Management Tools
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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CM4120Chemical Plant Operations Lab
Quality Management Tools
Fishbone (Cause and Effect) Diagram
Viscosity variation
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CM4120Chemical Plant Operations Lab
Quality Management Tools
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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CM4120Chemical Plant Operations Lab
Quality Management Tools
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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CM4120Chemical Plant Operations Lab
Quality Management Tools
Deming Cycle
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CM4120Chemical Plant Operations Lab
Quality Management Tools
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-
CM4120Chemical Plant Operations Lab
Introduction to Supply Chain Management
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CM4120Chemical Plant Operations Lab
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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CM4120Chemical Plant Operations Lab
Introduction to Supply Chain Management
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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CM4120Chemical Plant Operations Lab
Introduction to Supply Chain Management
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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CM4120Chemical Plant Operations Lab
Introduction to Supply Chain Management
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
CM4120Chemical Plant Operations Lab
Introduction to Supply Chain Management
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CM4120Chemical Plant Operations Lab
Introduction to Supply Chain Management
Where do gains come from? Automation of business processes
Open communications w/ suppliers
Open communications w/ customers
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CM4120Chemical Plant Operations Lab
Introduction to Supply Chain Management
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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CM4120Chemical Plant Operations Lab
Introduction to Supply Chain Management
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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CM4120Chemical Plant Operations Lab
Introduction to Supply Chain Management
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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CM4120Chemical Plant Operations Lab
Introduction to Supply Chain Management
A quote from:
The Germ Theory of Management
Myron TribusDirector of the American Quality and Productivity
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