Synergistic Chemical Synergistic Chemical Engineering Engineering ManagementManagement

Synergistic Chemical Synergistic Chemical Engineering Engineering ManagementManagement

Bill ZehnpfennigBill Zehnpfennig

DaimlerChrysler CorporationDaimlerChrysler CorporationToledo Machining PlantToledo Machining Plant

Bill ZehnpfennigBill Zehnpfennig

DaimlerChrysler CorporationDaimlerChrysler CorporationToledo Machining PlantToledo Machining Plant

DCX TMP’s Chemical DCX TMP’s Chemical Management SystemManagement System

The Toledo Machining Plant’s Chemical The Toledo Machining Plant’s Chemical Management Engineering System is an Management Engineering System is an

overall program designed to eliminate waste, overall program designed to eliminate waste, reduce costs, improve productivity, increase reduce costs, improve productivity, increase

operator awareness and morale, reduce operator awareness and morale, reduce chemical consumption, and make the facility chemical consumption, and make the facility a better environmental neighbor by reducing a better environmental neighbor by reducing

the usage of chemicals and implementing the usage of chemicals and implementing newer, safer, and robust chemical newer, safer, and robust chemical

technology within the manufacturing technology within the manufacturing environment.environment.

The Toledo Machining Plant’s Chemical The Toledo Machining Plant’s Chemical Management Engineering System is an Management Engineering System is an

overall program designed to eliminate waste, overall program designed to eliminate waste, reduce costs, improve productivity, increase reduce costs, improve productivity, increase

operator awareness and morale, reduce operator awareness and morale, reduce chemical consumption, and make the facility chemical consumption, and make the facility a better environmental neighbor by reducing a better environmental neighbor by reducing

the usage of chemicals and implementing the usage of chemicals and implementing newer, safer, and robust chemical newer, safer, and robust chemical

technology within the manufacturing technology within the manufacturing environment.environment.

The Toledo SystemThe Toledo SystemIs based on interactive chemical unit Is based on interactive chemical unit operations.operations.

Is Is NOTNOT a Supplier Based pay-per unit a Supplier Based pay-per unit program. In manufacturing, chemical program. In manufacturing, chemical usage is independent of productivity, and usage is independent of productivity, and NOT proportional.NOT proportional.

Drives cost, waste, pollution, and Drives cost, waste, pollution, and consumptionconsumption down, and productivity up. down, and productivity up.

A disciplined and defined system that can A disciplined and defined system that can be applied anywhere chemicals are used.be applied anywhere chemicals are used.

Is based on interactive chemical unit Is based on interactive chemical unit operations.operations.

Is Is NOTNOT a Supplier Based pay-per unit a Supplier Based pay-per unit program. In manufacturing, chemical program. In manufacturing, chemical usage is independent of productivity, and usage is independent of productivity, and NOT proportional.NOT proportional.

Drives cost, waste, pollution, and Drives cost, waste, pollution, and consumptionconsumption down, and productivity up. down, and productivity up.

A disciplined and defined system that can A disciplined and defined system that can be applied anywhere chemicals are used.be applied anywhere chemicals are used.

TMP Cost & Consumption TMP Cost & Consumption PerformancePerformance

0

1

2

3

4

5

6

1998 1999 2000 2001 2002

Chem

Lube

Total

0

1

2

3

4

5

6

1998 1999 2000 2001 2002

Chem

Lube

Total

Both Cost & Consumption tracked linearly, and the plot is in units of proportion

Start of Program

Major Program Initiative Examples Major Program Initiative Examples (cost savings)(cost savings)

Satellite system coolant Satellite system coolant consolidationconsolidation

Washer SoapWasher Soap

Die LubricantDie Lubricant

Tier 1 Discount (10%)Tier 1 Discount (10%)

Re-Refined Base stock OilRe-Refined Base stock Oil

QuenchantsQuenchants

Acid Cleaner - PolymersAcid Cleaner - Polymers

Central Coolant SystemsCentral Coolant Systems

Satellite system coolant Satellite system coolant consolidationconsolidation

Washer SoapWasher Soap

Die LubricantDie Lubricant

Tier 1 Discount (10%)Tier 1 Discount (10%)

Re-Refined Base stock OilRe-Refined Base stock Oil

QuenchantsQuenchants

Acid Cleaner - PolymersAcid Cleaner - Polymers

Central Coolant SystemsCentral Coolant Systems

45 K45 K 45 K45 K

HARD DOLLARS

85 K85 K85 K85 K

800 K800 K800 K800 K

180 K180 K180 K180 K

40 K40 K40 K40 K

125 K125 K125 K125 K

14 K14 K14 K14 K

10 K10 K10 K10 K

Implementing a Generic Implementing a Generic SystemSystem

The System, with consideration of different The System, with consideration of different facilities will be similar, but has to be tailored to facilities will be similar, but has to be tailored to the individual requirements of each facility.the individual requirements of each facility.

Not the “Who” - rather the “What” which will be Not the “Who” - rather the “What” which will be used.used.

Traditional Roadblocks.Traditional Roadblocks.

Challenges.Challenges.

System foundation will be the same anywhere, System foundation will be the same anywhere, the details will be individually unique. The key is the details will be individually unique. The key is the up front work.the up front work.

The System, with consideration of different The System, with consideration of different facilities will be similar, but has to be tailored to facilities will be similar, but has to be tailored to the individual requirements of each facility.the individual requirements of each facility.

Not the “Who” - rather the “What” which will be Not the “Who” - rather the “What” which will be used.used.

Traditional Roadblocks.Traditional Roadblocks.

Challenges.Challenges.

System foundation will be the same anywhere, System foundation will be the same anywhere, the details will be individually unique. The key is the details will be individually unique. The key is the up front work.the up front work.

Traditional Approach to Traditional Approach to Chemical ManagementChemical Management

Past experience of individual system focus Past experience of individual system focus only moderately effective, and not long term.only moderately effective, and not long term.

No considerations of effects on subsequent No considerations of effects on subsequent individual systems when 1 system changes.individual systems when 1 system changes.

Unable to use or take advantage of multiple Unable to use or take advantage of multiple independent system interactions for optimal independent system interactions for optimal benefit.benefit.

A system approach is a true example of “The A system approach is a true example of “The Sum of the whole is greater than the Sum of Sum of the whole is greater than the Sum of it’s parts”.it’s parts”.

Past experience of individual system focus Past experience of individual system focus only moderately effective, and not long term.only moderately effective, and not long term.

No considerations of effects on subsequent No considerations of effects on subsequent individual systems when 1 system changes.individual systems when 1 system changes.

Unable to use or take advantage of multiple Unable to use or take advantage of multiple independent system interactions for optimal independent system interactions for optimal benefit.benefit.

A system approach is a true example of “The A system approach is a true example of “The Sum of the whole is greater than the Sum of Sum of the whole is greater than the Sum of it’s parts”.it’s parts”.

Implementation StepsImplementation Steps1.1. Assessment StrategyAssessment Strategy

2.2. Customer PerceptionsCustomer Perceptions

3.3. Requirements into Technical Requirements into Technical SpecificationsSpecifications

4.4. Ideal StateIdeal State

5.5. System Mapping and InteractionsSystem Mapping and Interactions

6.6. Major HittersMajor Hitters

7.7. Testing and DevelopmentTesting and Development

8.8. MeasurementMeasurement

9.9. Implementing & StandardizationImplementing & Standardization

10.10. StudyStudy

1.1. Assessment StrategyAssessment Strategy

2.2. Customer PerceptionsCustomer Perceptions

3.3. Requirements into Technical Requirements into Technical SpecificationsSpecifications

4.4. Ideal StateIdeal State

5.5. System Mapping and InteractionsSystem Mapping and Interactions

6.6. Major HittersMajor Hitters

7.7. Testing and DevelopmentTesting and Development

8.8. MeasurementMeasurement

9.9. Implementing & StandardizationImplementing & Standardization

10.10. StudyStudy

Assessment StrategyAssessment StrategyDefine Scope. All chemicals – Usage, Waste, Define Scope. All chemicals – Usage, Waste, What can be controlled. What are your What can be controlled. What are your Chemical Unit Operations?Chemical Unit Operations?

Define current levels of control. Procedures, Define current levels of control. Procedures, Role Clarity, EducationRole Clarity, Education

Set Goals. Cost, Performance, Define Set Goals. Cost, Performance, Define Internal and External Customer Bases.Internal and External Customer Bases.

Identify potential Low Hanging Fruit.Identify potential Low Hanging Fruit.

Define Risks.Define Risks.

Define Scope. All chemicals – Usage, Waste, Define Scope. All chemicals – Usage, Waste, What can be controlled. What are your What can be controlled. What are your Chemical Unit Operations?Chemical Unit Operations?

Define current levels of control. Procedures, Define current levels of control. Procedures, Role Clarity, EducationRole Clarity, Education

Set Goals. Cost, Performance, Define Set Goals. Cost, Performance, Define Internal and External Customer Bases.Internal and External Customer Bases.

Identify potential Low Hanging Fruit.Identify potential Low Hanging Fruit.

Define Risks.Define Risks.

Customer PerceptionsCustomer Perceptions

How much is actually known about How much is actually known about your chemical system?your chemical system?

What do the different customer bases What do the different customer bases within your facility really need?within your facility really need?

Define the requirements (the “wants”)Define the requirements (the “wants”)

Performance, Cost, Consumption, Performance, Cost, Consumption, Longevity, Engineering Specifications, Longevity, Engineering Specifications, Tools, Hygiene, Safety, Waste Treatment.Tools, Hygiene, Safety, Waste Treatment.

How much is actually known about How much is actually known about your chemical system?your chemical system?

What do the different customer bases What do the different customer bases within your facility really need?within your facility really need?

Define the requirements (the “wants”)Define the requirements (the “wants”)

Performance, Cost, Consumption, Performance, Cost, Consumption, Longevity, Engineering Specifications, Longevity, Engineering Specifications, Tools, Hygiene, Safety, Waste Treatment.Tools, Hygiene, Safety, Waste Treatment.

Requirements into Technical Requirements into Technical SpecificationsSpecifications

Gather the “wants”, for example;Gather the “wants”, for example; SmellsSmells PerformancePerformance CostCost HandlingHandling Control Logistics for different Unit Control Logistics for different Unit

OperationsOperations DeliveryDelivery AvailabilityAvailability Waste TreatmentWaste Treatment

Gather the “wants”, for example;Gather the “wants”, for example; SmellsSmells PerformancePerformance CostCost HandlingHandling Control Logistics for different Unit Control Logistics for different Unit

OperationsOperations DeliveryDelivery AvailabilityAvailability Waste TreatmentWaste Treatment

Define the IDEAL stateDefine the IDEAL state

Using the ‘wants’, answer “Where do Using the ‘wants’, answer “Where do we want to be?”we want to be?”

““How long till we can get there?”How long till we can get there?”

““Can the customer ‘wants’ be Can the customer ‘wants’ be converted into solid, usable Technical converted into solid, usable Technical Requirements?”Requirements?”

Beware: Fundamental Limit of Beware: Fundamental Limit of TechnologyTechnology

Using the ‘wants’, answer “Where do Using the ‘wants’, answer “Where do we want to be?”we want to be?”

““How long till we can get there?”How long till we can get there?”

““Can the customer ‘wants’ be Can the customer ‘wants’ be converted into solid, usable Technical converted into solid, usable Technical Requirements?”Requirements?”

Beware: Fundamental Limit of Beware: Fundamental Limit of TechnologyTechnology

System Mapping & InteractionsSystem Mapping & Interactions

Identify ALL major & minor chemical Identify ALL major & minor chemical operational unitsoperational units

Define InteractionsDefine Interactions

Define the significance of the Define the significance of the interactionsinteractions

Create System Map(s)Create System Map(s) OverallOverall Department or Process operationDepartment or Process operation

Identify ALL major & minor chemical Identify ALL major & minor chemical operational unitsoperational units

Define InteractionsDefine Interactions

Define the significance of the Define the significance of the interactionsinteractions

Create System Map(s)Create System Map(s) OverallOverall Department or Process operationDepartment or Process operation

Simple Macro System MapSimple Macro System Map

IN OUT

WASTE TREATMENT

Raw Steel Finished Parts

Detailed Process System MapDetailed Process System Map

Machined parts in packing

containers

Milling Operation

Visual Inspection

Packed Off if Bad

Washing operation if

Good

Scrapped

Re-Used

Welding Operation

Washing operation

Assembly

Packaging

Shipping

Rust PreventativeRust Preventative

CoolantCoolant

CleanerCleaner

InteractionInteraction

Petro-Based

Straight Oil

Petro Soluble

Oil

High pH Alkaline

Soap

Petro-Based

Straight Oil

Main Main Interaction+ =

ConsiderationsConsiderations

Welding Operation

AssemblyPackagingShipping

Machined parts in packing containers

Type of RP used,Open to atmosphere,

Condition of Parts,Part Material properties,

Storage length

Type of RP used,Open to atmosphere,

Condition of Parts,Part Material properties,

Storage length

Milling Operation

Hydraulic, way, spindle oils

Tool Material,Wear Surfaces,

Operational Characteristics of

the machine,Sump Control,

Biological

Hydraulic, way, spindle oils

Tool Material,Wear Surfaces,

Operational Characteristics of

the machine,Sump Control,

Biological

Visual Inspection

Handling, gage interactions with

chemicals, Hygiene,

Films

Handling, gage interactions with

chemicals, Hygiene,

Films

Washing operation

Heat, Sump Control, Film Build-ups, Cleanliness, Oil

rejection, biological

Heat, Sump Control, Film Build-ups, Cleanliness, Oil

rejection, biological

Storage Length,Open to atmosphere,Packing Condition of

Parts,

Storage Length,Open to atmosphere,Packing Condition of

Parts,

Handling, Hygiene

Handling, Hygiene

Handling, Hygiene

Handling, Hygiene

Heat, Welding tips, Welding

type, Film Build-ups, Cleanliness

Heat, Welding tips, Welding

type, Film Build-ups, Cleanliness

Law of SimilarityLaw of Similarity

Like Substances tend to act like each other Like Substances tend to act like each other and are and are Usually CompatibleUsually Compatible..

Applies to Interactions.Applies to Interactions.

Integrate Customer Needs to Define Your Integrate Customer Needs to Define Your OverallOverall SYSTEMSYSTEM Strategy, focus on Strategy, focus on compatibility & Similarity.compatibility & Similarity.

Soap (Amine Base)Soap (Amine Base)

Oil (Petroleum Base)Oil (Petroleum Base)

Like Substances tend to act like each other Like Substances tend to act like each other and are and are Usually CompatibleUsually Compatible..

Applies to Interactions.Applies to Interactions.

Integrate Customer Needs to Define Your Integrate Customer Needs to Define Your OverallOverall SYSTEMSYSTEM Strategy, focus on Strategy, focus on compatibility & Similarity.compatibility & Similarity.

Soap (Amine Base)Soap (Amine Base)

Oil (Petroleum Base)Oil (Petroleum Base)

Revised with New System Revised with New System Strategy (Amine)Strategy (Amine)

Machined parts in packing

containers

Milling Operation

Visual Inspection

Packed Off if Bad

Washing operation if

Good

Scrapped

Re-Used

Welding Operation

Washing operation

Assembly

Packaging

Shipping

Veg Soap Veg Soap Based Alkaline Based Alkaline Coolant with Coolant with RPRP

Amine Based Amine Based Alkaline Alkaline

Cleaner with Cleaner with RPRP

Amine Based Amine Based Alkaline Cleaner Alkaline Cleaner

with RPwith RP

Amine Based Amine Based Alkaline Alkaline Cleaner with Cleaner with RPRP

Interaction Interaction FriendlyFriendly

Interaction Interaction FriendlyFriendly

Elimination of Elimination of Rust PreventativeRust Preventative

BenefitsBenefits

Machined parts in packing

containers

Milling Operation

Visual Inspection

Packed Off if Bad

Washing operation

Scrapped

Re-Used

Welding Operation

Washing operation

Assembly

Packaging

Shipping

Less Consumption due Less Consumption due to longevity and not to longevity and not

being fouled by the RP. being fouled by the RP. Biological resistance, No Biological resistance, No

tankside additives tankside additives necessary, high operator necessary, high operator acceptance, tool life, no acceptance, tool life, no

odorsodorsCoolant acts as Coolant acts as saponification saponification

agent - augments agent - augments soap - LESS soap - LESS

consumption and consumption and longevity from no longevity from no oil contaminationoil contamination

Complete Complete Elimination of Elimination of an individual an individual

chemical chemical processprocess

Lower Cost Per Lower Cost Per unit, Less unit, Less

Consumption due Consumption due to longevityto longevity

Interaction Interaction FriendlyFriendly

Interaction Interaction FriendlyFriendly

Elimination of Elimination of Rust PreventativeRust Preventative

Most Changes result in a Most Changes result in a lower cost per new unit lower cost per new unit

AND less Consumption. A AND less Consumption. A double benefit with the double benefit with the

result of far less pollution. result of far less pollution.

Determine Major HittersDetermine Major HittersUsing Similarity, Interactions, and Customer Using Similarity, Interactions, and Customer Needs, RANK “Major” Systems (Hence, Major Needs, RANK “Major” Systems (Hence, Major Unit Ops).Unit Ops).

Rank in order of Cost, Consumption, Rank in order of Cost, Consumption, RiskRisk, , Logistics, Time to Implement.Logistics, Time to Implement.

Use FMECA and FTA types of ToolsUse FMECA and FTA types of Tools FMEAFMEA = Failure Mode Effects Criticality Analysis = Failure Mode Effects Criticality Analysis

(Bottom Up Approach)(Bottom Up Approach)

FTAFTA = Fault Tree Analysis (Top Down Approach) = Fault Tree Analysis (Top Down Approach)

Using Similarity, Interactions, and Customer Using Similarity, Interactions, and Customer Needs, RANK “Major” Systems (Hence, Major Needs, RANK “Major” Systems (Hence, Major Unit Ops).Unit Ops).

Rank in order of Cost, Consumption, Rank in order of Cost, Consumption, RiskRisk, , Logistics, Time to Implement.Logistics, Time to Implement.

Use FMECA and FTA types of ToolsUse FMECA and FTA types of Tools FMEAFMEA = Failure Mode Effects Criticality Analysis = Failure Mode Effects Criticality Analysis

(Bottom Up Approach)(Bottom Up Approach)

FTAFTA = Fault Tree Analysis (Top Down Approach) = Fault Tree Analysis (Top Down Approach)

FMECAFMECAFailure Mode, Effects and Criticality Analysis (FMECA) or simply Failure Mode, Effects and Criticality Analysis (FMECA) or simply (FMEA) is a disciplined design review technique that focuses the (FMEA) is a disciplined design review technique that focuses the development of products and processes on prioritized actions to development of products and processes on prioritized actions to reduce the risk of product field failures, and documents those reduce the risk of product field failures, and documents those actions and the review process.actions and the review process.

FMEAs are intended to result in preventative actions; they are not FMEAs are intended to result in preventative actions; they are not "after-the-fact" exercises done to satisfy a customer or obtain "after-the-fact" exercises done to satisfy a customer or obtain QS 9000 status. Time and resources for a comprehensive FMEA QS 9000 status. Time and resources for a comprehensive FMEA must be allotted during design and process development, when must be allotted during design and process development, when design and process changes can most easily and inexpensively be design and process changes can most easily and inexpensively be implemented. Only after a product failure or financial crises arising implemented. Only after a product failure or financial crises arising from late changes in production is the cost of from late changes in production is the cost of notnot performing an performing an FMEA revealed. FMECA as a systematic group of activities FMEA revealed. FMECA as a systematic group of activities intended to:intended to:

Recognize and evaluate the potential failure of a product or process Recognize and evaluate the potential failure of a product or process and its effects. and its effects.

Identify actions which could eliminate or reduce the chance of the Identify actions which could eliminate or reduce the chance of the potential failure occurring. potential failure occurring.

Document the process. Document the process.

Failure Mode, Effects and Criticality Analysis (FMECA) or simply Failure Mode, Effects and Criticality Analysis (FMECA) or simply (FMEA) is a disciplined design review technique that focuses the (FMEA) is a disciplined design review technique that focuses the development of products and processes on prioritized actions to development of products and processes on prioritized actions to reduce the risk of product field failures, and documents those reduce the risk of product field failures, and documents those actions and the review process.actions and the review process.

FMEAs are intended to result in preventative actions; they are not FMEAs are intended to result in preventative actions; they are not "after-the-fact" exercises done to satisfy a customer or obtain "after-the-fact" exercises done to satisfy a customer or obtain QS 9000 status. Time and resources for a comprehensive FMEA QS 9000 status. Time and resources for a comprehensive FMEA must be allotted during design and process development, when must be allotted during design and process development, when design and process changes can most easily and inexpensively be design and process changes can most easily and inexpensively be implemented. Only after a product failure or financial crises arising implemented. Only after a product failure or financial crises arising from late changes in production is the cost of from late changes in production is the cost of notnot performing an performing an FMEA revealed. FMECA as a systematic group of activities FMEA revealed. FMECA as a systematic group of activities intended to:intended to:

Recognize and evaluate the potential failure of a product or process Recognize and evaluate the potential failure of a product or process and its effects. and its effects.

Identify actions which could eliminate or reduce the chance of the Identify actions which could eliminate or reduce the chance of the potential failure occurring. potential failure occurring.

Document the process. Document the process.

Identify Functions

Identify Failure Modes

Identify Effects of the Failure Mode

Determine Severity

Apply Procedure for Potential

Consequences

Identify Possible Causes

Determine Occurrence

Calculate Criticality

Identify Design or Process Controls

Determine Detection

RPN & Final Risk Assessment

Take Actions to Reduce Risk

Identify Root Cause

Identify Special Characteristics

FTAFTAA fault tree analysis (FTA) is a deductive, top-down method A fault tree analysis (FTA) is a deductive, top-down method of analyzing system design and performance. It involves of analyzing system design and performance. It involves specifying a top event to analyze (such as a fire), followed by specifying a top event to analyze (such as a fire), followed by identifying all of the associated elements in the system that identifying all of the associated elements in the system that could cause that top event to occur.could cause that top event to occur.

Fault trees provide a convenient symbolic representation of Fault trees provide a convenient symbolic representation of the combination of events resulting in the occurrence of the the combination of events resulting in the occurrence of the top event. Events and gates in fault tree analysis are top event. Events and gates in fault tree analysis are represented by symbols.represented by symbols.

Fault tree analyses are generally performed graphically using Fault tree analyses are generally performed graphically using a logical structure of AND OR gates. Sometimes certain a logical structure of AND OR gates. Sometimes certain elements, or basic events, may need to occur together in elements, or basic events, may need to occur together in order for that top event to occur. In this case, these events order for that top event to occur. In this case, these events would be arranged under an AND gate, meaning that all of the would be arranged under an AND gate, meaning that all of the basic events would need to occur to trigger the top event. If basic events would need to occur to trigger the top event. If the basic events alone would trigger the top event, then they the basic events alone would trigger the top event, then they would be grouped under an OR gate. The entire system as would be grouped under an OR gate. The entire system as well as human interactions would be analyzed when well as human interactions would be analyzed when performing a fault tree analysis.performing a fault tree analysis.

A fault tree analysis (FTA) is a deductive, top-down method A fault tree analysis (FTA) is a deductive, top-down method of analyzing system design and performance. It involves of analyzing system design and performance. It involves specifying a top event to analyze (such as a fire), followed by specifying a top event to analyze (such as a fire), followed by identifying all of the associated elements in the system that identifying all of the associated elements in the system that could cause that top event to occur.could cause that top event to occur.

Fault trees provide a convenient symbolic representation of Fault trees provide a convenient symbolic representation of the combination of events resulting in the occurrence of the the combination of events resulting in the occurrence of the top event. Events and gates in fault tree analysis are top event. Events and gates in fault tree analysis are represented by symbols.represented by symbols.

Fault tree analyses are generally performed graphically using Fault tree analyses are generally performed graphically using a logical structure of AND OR gates. Sometimes certain a logical structure of AND OR gates. Sometimes certain elements, or basic events, may need to occur together in elements, or basic events, may need to occur together in order for that top event to occur. In this case, these events order for that top event to occur. In this case, these events would be arranged under an AND gate, meaning that all of the would be arranged under an AND gate, meaning that all of the basic events would need to occur to trigger the top event. If basic events would need to occur to trigger the top event. If the basic events alone would trigger the top event, then they the basic events alone would trigger the top event, then they would be grouped under an OR gate. The entire system as would be grouped under an OR gate. The entire system as well as human interactions would be analyzed when well as human interactions would be analyzed when performing a fault tree analysis.performing a fault tree analysis.

Vent Scrubber Failure

Scrubbing Action Failure Stack

Sensor

Circulation Failure

Flow Impaired

Pump Failure

Ext. Pwr Failure

Distributor Plug

Flow Control

Malfunction

By-Pass Open

Plugged Internals

FTA ExampleFTA Example

“OR” Gate“OR” Gate

“AND” Gate“AND” Gate

Testing & DevelopmentTesting & Development

Accomplished once Major Hitters have been Accomplished once Major Hitters have been establishedestablished

Potential Chemical Choices Potential Chemical Choices Soap, Petroleum Oil, Vegetable, or CombinationsSoap, Petroleum Oil, Vegetable, or Combinations

Potential Chemical SuppliersPotential Chemical Suppliers Reputation, willingness to contribute time and Reputation, willingness to contribute time and

technical details, cost, and Servicetechnical details, cost, and Service

Bench Tests!!!!!! Must be driven by Real Bench Tests!!!!!! Must be driven by Real World Requirements.World Requirements.

Accomplished once Major Hitters have been Accomplished once Major Hitters have been establishedestablished

Potential Chemical Choices Potential Chemical Choices Soap, Petroleum Oil, Vegetable, or CombinationsSoap, Petroleum Oil, Vegetable, or Combinations

Potential Chemical SuppliersPotential Chemical Suppliers Reputation, willingness to contribute time and Reputation, willingness to contribute time and

technical details, cost, and Servicetechnical details, cost, and Service

Bench Tests!!!!!! Must be driven by Real Bench Tests!!!!!! Must be driven by Real World Requirements.World Requirements.

Bench TestsBench TestsMost Bench Tests will be similar irrelevant of Most Bench Tests will be similar irrelevant of what Unit is under consideration (i.e. what Unit is under consideration (i.e. similarity)similarity)

Must be Must be Worst CaseWorst Case and and Test to FailureTest to Failure!! Rust Chip TestRust Chip Test Extreme Pressure and LubricityExtreme Pressure and Lubricity FoamingFoaming Film residuals and PolymerizationFilm residuals and Polymerization Hard Water StabilityHard Water Stability Vapor FilmVapor Film Biological PerformanceBiological Performance HygieneHygiene

Most Bench Tests will be similar irrelevant of Most Bench Tests will be similar irrelevant of what Unit is under consideration (i.e. what Unit is under consideration (i.e. similarity)similarity)

Must be Must be Worst CaseWorst Case and and Test to FailureTest to Failure!! Rust Chip TestRust Chip Test Extreme Pressure and LubricityExtreme Pressure and Lubricity FoamingFoaming Film residuals and PolymerizationFilm residuals and Polymerization Hard Water StabilityHard Water Stability Vapor FilmVapor Film Biological PerformanceBiological Performance HygieneHygiene

Measurement IndexesMeasurement IndexesThe Measurement must provide The Measurement must provide quantitative data on the effectiveness of quantitative data on the effectiveness of changes. Potential Sources;changes. Potential Sources; Operators (The Best source of Information)Operators (The Best source of Information) Maintenance (Equipment Compatibility)Maintenance (Equipment Compatibility) Production Management (Control, Production Management (Control,

Throughput)Throughput) Comptroller (Costs)Comptroller (Costs) Engineering (Performance Specifications)Engineering (Performance Specifications) External LaboratoriesExternal Laboratories

The Measurement must provide The Measurement must provide quantitative data on the effectiveness of quantitative data on the effectiveness of changes. Potential Sources;changes. Potential Sources; Operators (The Best source of Information)Operators (The Best source of Information) Maintenance (Equipment Compatibility)Maintenance (Equipment Compatibility) Production Management (Control, Production Management (Control,

Throughput)Throughput) Comptroller (Costs)Comptroller (Costs) Engineering (Performance Specifications)Engineering (Performance Specifications) External LaboratoriesExternal Laboratories

ImplementingImplementingKnow your Plant. Choose the worst Know your Plant. Choose the worst case systems to test.case systems to test.

Use a Team Approach (upfront Use a Team Approach (upfront planning and education)planning and education)

Determine the logistics of testingDetermine the logistics of testing Time frame, what will be measured, Time frame, what will be measured,

Shipping, Cleaning, Waste treatment, etc.Shipping, Cleaning, Waste treatment, etc.

Use Life Cycle Analysis ApproachUse Life Cycle Analysis Approach

Test in Machines!!!!!Test in Machines!!!!!

Know your Plant. Choose the worst Know your Plant. Choose the worst case systems to test.case systems to test.

Use a Team Approach (upfront Use a Team Approach (upfront planning and education)planning and education)

Determine the logistics of testingDetermine the logistics of testing Time frame, what will be measured, Time frame, what will be measured,

Shipping, Cleaning, Waste treatment, etc.Shipping, Cleaning, Waste treatment, etc.

Use Life Cycle Analysis ApproachUse Life Cycle Analysis Approach

Test in Machines!!!!!Test in Machines!!!!!

Life Cycle AnalysisLife Cycle Analysis

Cost and Performance Comparisons. For Example: The Cost and Performance Comparisons. For Example: The cost to operate and maintain coolant systems cost to operate and maintain coolant systems encompasses the following criteria to determine the day encompasses the following criteria to determine the day to day economic effectiveness of MWF's; annual cost of to day economic effectiveness of MWF's; annual cost of fluid concentrate, machine/sump cleaning and pump-fluid concentrate, machine/sump cleaning and pump-outs, tankside additive costs, sewage treatment costs, outs, tankside additive costs, sewage treatment costs, waste to be hauled out, parts cleaning costs, and tool waste to be hauled out, parts cleaning costs, and tool costs. Costs are calculated with data provided from tool costs. Costs are calculated with data provided from tool stores, waste treatment, maintenance, & plant stores, waste treatment, maintenance, & plant comptroller. Listed next are example calculations used to comptroller. Listed next are example calculations used to determine listed costs comparisons;determine listed costs comparisons;

Summary of Costs (units consistent) = Summary of Costs (units consistent) = (all items ). A (all items ). A operational summary cost per unit (gal) in use can be operational summary cost per unit (gal) in use can be prepared by using: the summary total/ gallons in system prepared by using: the summary total/ gallons in system of interest x time unit of interest. of interest x time unit of interest.

Cost and Performance Comparisons. For Example: The Cost and Performance Comparisons. For Example: The cost to operate and maintain coolant systems cost to operate and maintain coolant systems encompasses the following criteria to determine the day encompasses the following criteria to determine the day to day economic effectiveness of MWF's; annual cost of to day economic effectiveness of MWF's; annual cost of fluid concentrate, machine/sump cleaning and pump-fluid concentrate, machine/sump cleaning and pump-outs, tankside additive costs, sewage treatment costs, outs, tankside additive costs, sewage treatment costs, waste to be hauled out, parts cleaning costs, and tool waste to be hauled out, parts cleaning costs, and tool costs. Costs are calculated with data provided from tool costs. Costs are calculated with data provided from tool stores, waste treatment, maintenance, & plant stores, waste treatment, maintenance, & plant comptroller. Listed next are example calculations used to comptroller. Listed next are example calculations used to determine listed costs comparisons;determine listed costs comparisons;

Summary of Costs (units consistent) = Summary of Costs (units consistent) = (all items ). A (all items ). A operational summary cost per unit (gal) in use can be operational summary cost per unit (gal) in use can be prepared by using: the summary total/ gallons in system prepared by using: the summary total/ gallons in system of interest x time unit of interest. of interest x time unit of interest.

Life Cycle ConsiderationsLife Cycle ConsiderationsCost of Fluid Concentrate = Usage (Time Unit) x Cost/gal.Cost of Fluid Concentrate = Usage (Time Unit) x Cost/gal.

Machine/Sump Cleaning = Net Pump-outs per machine (#) x Machine/Sump Cleaning = Net Pump-outs per machine (#) x ((service time (unit) rate/unit)) x Number of machines in system ((service time (unit) rate/unit)) x Number of machines in system x Time Unit of interest.x Time Unit of interest.

Sewage Treatment Costs (Acids = Usage (time Sewage Treatment Costs (Acids = Usage (time interval)/Normality of acid x Acid Cost & Polymers = Usage interval)/Normality of acid x Acid Cost & Polymers = Usage (time interval) x cost/gal)(time interval) x cost/gal)

Weekly gallonage of waste = Usage/week (coolant/gal) x Weekly gallonage of waste = Usage/week (coolant/gal) x 1.1(avg. oil retention).1.1(avg. oil retention).

Cost of material to be hauled = Cost/gal or Cost/load x Number Cost of material to be hauled = Cost/gal or Cost/load x Number of loads per time unit intervalof loads per time unit interval

Cleaning costs = to be determined by industrial engineering Cleaning costs = to be determined by industrial engineering (de-rusting, soap consumption in washers, etc.)(de-rusting, soap consumption in washers, etc.)

Tankside Additives = Tankside Additives = (Additive cost/gal x Usage) x unit of (Additive cost/gal x Usage) x unit of time interval.time interval.

Tool Life = Operational Tool Rate x cost x unit of time (see Tool Life = Operational Tool Rate x cost x unit of time (see example)example)

Cost of Fluid Concentrate = Usage (Time Unit) x Cost/gal.Cost of Fluid Concentrate = Usage (Time Unit) x Cost/gal.

Machine/Sump Cleaning = Net Pump-outs per machine (#) x Machine/Sump Cleaning = Net Pump-outs per machine (#) x ((service time (unit) rate/unit)) x Number of machines in system ((service time (unit) rate/unit)) x Number of machines in system x Time Unit of interest.x Time Unit of interest.

Sewage Treatment Costs (Acids = Usage (time Sewage Treatment Costs (Acids = Usage (time interval)/Normality of acid x Acid Cost & Polymers = Usage interval)/Normality of acid x Acid Cost & Polymers = Usage (time interval) x cost/gal)(time interval) x cost/gal)

Weekly gallonage of waste = Usage/week (coolant/gal) x Weekly gallonage of waste = Usage/week (coolant/gal) x 1.1(avg. oil retention).1.1(avg. oil retention).

Cost of material to be hauled = Cost/gal or Cost/load x Number Cost of material to be hauled = Cost/gal or Cost/load x Number of loads per time unit intervalof loads per time unit interval

Cleaning costs = to be determined by industrial engineering Cleaning costs = to be determined by industrial engineering (de-rusting, soap consumption in washers, etc.)(de-rusting, soap consumption in washers, etc.)

Tankside Additives = Tankside Additives = (Additive cost/gal x Usage) x unit of (Additive cost/gal x Usage) x unit of time interval.time interval.

Tool Life = Operational Tool Rate x cost x unit of time (see Tool Life = Operational Tool Rate x cost x unit of time (see example)example)

Major Hitter - ClosureMajor Hitter - ClosureAfter Life Cycle Analysis has determined the best After Life Cycle Analysis has determined the best solution for a given Major Unit Operation, you solution for a given Major Unit Operation, you must implement the next hitter to evaluate must implement the next hitter to evaluate Interactions.Interactions.

To close a major hitter, use statistical To close a major hitter, use statistical measurement to verify effectiveness, and consider measurement to verify effectiveness, and consider the following;the following; Controls – StabilityControls – Stability Training and Education of Team and PlantTraining and Education of Team and Plant SustainSustain

Use the PDCA cycle to determine long term Use the PDCA cycle to determine long term effectiveness.effectiveness.

After Life Cycle Analysis has determined the best After Life Cycle Analysis has determined the best solution for a given Major Unit Operation, you solution for a given Major Unit Operation, you must implement the next hitter to evaluate must implement the next hitter to evaluate Interactions.Interactions.

To close a major hitter, use statistical To close a major hitter, use statistical measurement to verify effectiveness, and consider measurement to verify effectiveness, and consider the following;the following; Controls – StabilityControls – Stability Training and Education of Team and PlantTraining and Education of Team and Plant SustainSustain

Use the PDCA cycle to determine long term Use the PDCA cycle to determine long term effectiveness.effectiveness.

On-GoingOn-GoingContinue the process until all Major Hitters Continue the process until all Major Hitters are addressed, in place, and proven effective.are addressed, in place, and proven effective.Determine the Synergistic Benefits.Determine the Synergistic Benefits. The costs and consumption for each major hitter The costs and consumption for each major hitter

must be determined, as best possible, individually must be determined, as best possible, individually if interactions are to be measured.if interactions are to be measured.

As more Major Hitters are implemented, it As more Major Hitters are implemented, it becomes more difficult to separate out individual becomes more difficult to separate out individual costs.costs.

Standardize! Use as few different brands as Standardize! Use as few different brands as possible across the board.possible across the board.

Continue the process until all Major Hitters Continue the process until all Major Hitters are addressed, in place, and proven effective.are addressed, in place, and proven effective.Determine the Synergistic Benefits.Determine the Synergistic Benefits. The costs and consumption for each major hitter The costs and consumption for each major hitter

must be determined, as best possible, individually must be determined, as best possible, individually if interactions are to be measured.if interactions are to be measured.

As more Major Hitters are implemented, it As more Major Hitters are implemented, it becomes more difficult to separate out individual becomes more difficult to separate out individual costs.costs.

Standardize! Use as few different brands as Standardize! Use as few different brands as possible across the board.possible across the board.

Sustain and ControlSustain and Control

At this point in the process, you’ll be enjoying At this point in the process, you’ll be enjoying significant cost and consumption benefits.significant cost and consumption benefits.

Stay on Top of It! Continue working on units Stay on Top of It! Continue working on units until optimal.until optimal.

Don’t go too Far! Always use sound business Don’t go too Far! Always use sound business case justification (i.e. 20% reduction rule)case justification (i.e. 20% reduction rule)

Shop Around and Research New technologyShop Around and Research New technology

Keep the Change process ALIVEKeep the Change process ALIVE

At this point in the process, you’ll be enjoying At this point in the process, you’ll be enjoying significant cost and consumption benefits.significant cost and consumption benefits.

Stay on Top of It! Continue working on units Stay on Top of It! Continue working on units until optimal.until optimal.

Don’t go too Far! Always use sound business Don’t go too Far! Always use sound business case justification (i.e. 20% reduction rule)case justification (i.e. 20% reduction rule)

Shop Around and Research New technologyShop Around and Research New technology

Keep the Change process ALIVEKeep the Change process ALIVE

RecommendationsRecommendationsUtilize the strengths and weaknesses of multiple chemical Utilize the strengths and weaknesses of multiple chemical vendors working together for major system optimization.vendors working together for major system optimization.

Keeps competition in the picture, eliminates complacency Keeps competition in the picture, eliminates complacency or the “Fat, Dumb, and Happy” syndrome.or the “Fat, Dumb, and Happy” syndrome.

Reward vendors when they work together for your benefit.Reward vendors when they work together for your benefit.

Threat of competition makes vendors work harder for Threat of competition makes vendors work harder for continual improvement.continual improvement.

Instant solutions available. If one supplier falls, others Instant solutions available. If one supplier falls, others waiting to jump in and fix immediately, that are already waiting to jump in and fix immediately, that are already familiar with process (Production Insurance).familiar with process (Production Insurance).

Do not compromise!Do not compromise!

Utilize the strengths and weaknesses of multiple chemical Utilize the strengths and weaknesses of multiple chemical vendors working together for major system optimization.vendors working together for major system optimization.

Keeps competition in the picture, eliminates complacency Keeps competition in the picture, eliminates complacency or the “Fat, Dumb, and Happy” syndrome.or the “Fat, Dumb, and Happy” syndrome.

Reward vendors when they work together for your benefit.Reward vendors when they work together for your benefit.

Threat of competition makes vendors work harder for Threat of competition makes vendors work harder for continual improvement.continual improvement.

Instant solutions available. If one supplier falls, others Instant solutions available. If one supplier falls, others waiting to jump in and fix immediately, that are already waiting to jump in and fix immediately, that are already familiar with process (Production Insurance).familiar with process (Production Insurance).

Do not compromise!Do not compromise!

ConclusionsConclusions

Business Case – Is it Worth the Business Case – Is it Worth the effort of implementing a Chemical effort of implementing a Chemical Management System?Management System?

Pay Backs – Cost, Morale, Pay Backs – Cost, Morale, Through-put.Through-put.

Does this apply to you?Does this apply to you?

Business Case – Is it Worth the Business Case – Is it Worth the effort of implementing a Chemical effort of implementing a Chemical Management System?Management System?

Pay Backs – Cost, Morale, Pay Backs – Cost, Morale, Through-put.Through-put.

Does this apply to you?Does this apply to you?

Thank You for your Attention & Thank You for your Attention & ParticipationParticipation

Questions & AnswersQuestions & Answers

Thank You for your Attention & Thank You for your Attention & ParticipationParticipation

Questions & AnswersQuestions & Answers

wlz1@dcx.comwlz1@dcx.com