Introduction to Process Technology

1. Introduction to Process Technology Principles of Quality

2. Today’s Agenda • Quality – I’ll Know It When I See It • Current Issues and Trends • Pioneers of Quality • Total Quality Management (TQM) • The Production Line Activity • Quality Cycle • International Standards Organization (ISO) • Statistical Process Control (SPC) • You Be the Expert • Six Sigma • Supporting Quality – Role of Scientists, Engineers, & Technicians

3. Quality – What it Means to Me • List your expectations for quality as a customer • List your expectations as a member of a plant community • List your expectations of quality as a potential plant employee • List your expectations of quality as a potential investor (stockholder)

4. Quality • Product or service free of deficiencies • Characteristics of a product or service that bear on its ability to satisfy stated or implied needs

5. Industry Responses • Total Quality Management (TQM) • ISO-9000 Series • ISO-14000 Series (environmental) • Six Sigma • Statistical Process Control (SPC) • Self-directed or Self-managed Work Teams

6. Pioneers of Quality • Dr. W. Edward Deming – every job or every task is part of a process • Joseph Juran – Pareto Principle of 80/20 • Philip Crosby – Zero Defects

7. Total Quality Management (TQM) • Customer Focus • Continuous Improvement • Manage by Data and Facts • Empower Employees

8. TQM Applied • The Production Line Activity (see handout)

9. Quality Improvement Cycle • Phase 1: PLAN • Increase current knowledge of process • Specific objectives, questions, make predicitons, and propose plan for testing • Outcome of plan should consider methods, resources, schedules, and people

10. Quality Improvement Cycle • Phase 2: OBSERVE & ANALYZE • Implements data collection process to address questions from Phase 1. • Reveals what is actually happening and can lead to refinement of initial questions

11. Quality Improvement Cycle • Phase 3: LEARN • Combines activities from Phase 1 & 2 • Results of data analysis are compared to current knowledge and theories to see there are any contradictions

12. Quality Improvement Cycle • Phase 4: ACT • Results from Phase 3 are used to decide whether to make changes to process or not. • If change is indicated, brainstorming session can be conducted to determine what changes would result in improvement

13. International Organization of Standardization (ISO) • Founded after WW II. Headquartered in Geneva, Switzerland • Voluntary, non-governmental • Global standards of product and service quality that aims to maintain quality standards and fixed defects and ensure repeated acceptable performance

14. ISO & TQM • Overlapping expectations • TQM is defined in many ways, while ISO standards are consistent • ISO world-wide, TQM more US based

15. Why Companies Seek ISO Certification • Contractual – requirement of suppliers • Liability – improved product liability procedures and documentation • Cost savings – increased efficiency, less product loss • Competition – global advantage for large and small companies • Customer Satisfaction – increased by certification

16. ISO in the Processing Industry • Continuous Improvement • Statistical Process Control (SPC) • Process Technicians & Quality • Global Market

17. Statistical Process Control (SPC) • Statistical Process Control – using data-driven methodology to control a process • STATISTICAL • With the help of numbers • PROCESS • We study the characteristics of our process • CONTROL • To make it behave the way we want it to behave

18. SPC • Product Directives – following the “recipe” • Correct feed • Temperature and pressure profile • Equipment speed • Additive setpoint • Level and flow setpoints

19. SPC • Sample Types – • Raw materials • Additives • Intermediates • End products

20. SPC Data Types • Attributes – called discrete data. Data that can be counted and plotted as distinct or unconnected events. • Percentage of late shipments • Number of mistakes made during a process

21. SPC Data Types • Variables – called continuous data. Data that can be measured and plotted on a constant scale. • Flow through a pipeline • Volume in a tank

22. SPC – Select Proper Category

23. Quality Control Tools • Control Charts • Flow Charts • Cause and Effects Diagrams, Fishbone • Pareto Charts • Histograms • Scatter Plots • Others

24. Fishbone Diagrams • Each branch of the diagram represents a different category of causes • Typical categories: • Materials • Machinery • Measurement • Methods • People • Environment • However, can create other/different categories better suited to your specific problem.

27. Pareto Chart • Purpose: • Ranking problems from big to small • Helps when: • Team needs to know which problems to address first. • Demonstrates 80/20 rule • 20% of the causes account for 80% of the problems • Highlights the important elements (the “vital few”) and the insignificant ones (the “trivial many”)

31. Histograms • Purpose: • To indicate the distribution and variation of sample data • Helps to: • Determine if process is in statistical control – can indicate if “special causes” are causing control problems • Histograms roughly approximate the normal distribution if everything is in control.

34. Distributions can be represented in several ways.

36. Control Charts • A line graph that indicates: • Samples vary from the process average • If samples are in statistical control (w/in control limits) • Purpose: • To track process variation • Helps to: • Determine if process is in statistical control

38. Control Charts

39. Scatter Plots • Indicate: • Relationships between two variables or pairs of data • Purpose: • To determine cause (independent variable) and effect (dependent variable) relationships • Helps to: • Determine if process is in control and rate of change of conditions

40. Six Sigma • Developed in 1980’s based on Crosby’s concept of ZERO DEFECTS • Aim is to reduce process variation so that there are no more than 3.4 defects per 1,000,000. (99.99966%)

41. Six Sigma • DMAIC – Define, Measure, Analyze, Improve, and Control. • Improvement system for existing processes that fall below specifications and will be improved incrementally

42. Six Sigma • DMADV – Define, Measure, Analyze, Design, Verify • Improvement process system utilized to develop new processes or products at levels that meet Six Sigma from the beginning. • System can also be used for existing processes that require more than incremental improvement

43. Maintenance Programs • Corrective – waiting for failure to occur, then fix • Preventative – conduct regular maintenance to avoid failure • Predictive – monitor condition of equipment and use data to identify possible failure and their prevention • Detective – regular check of alarms, detectors

44. Maintenance and Quality Improvement • Total Productive Maintenance (TPM) – Overall Equipment Effectiveness • Predictive/Preventive Maintenance (PPM) • Using Quality Control Tools • Working as Self-Directed Teams

45. Scientists, Engineers, and Technicians & Quality • Familiarize oneself with quality programs • Practice quality habits • Provide good customer service – internally and externally • Gather data for SPC tools • Follow documented procedures

46. Scientists, Engineers, and Technicians & Quality • Monitor and control process operations • Assist with maintenance tasks such as TPM or PPM • Troubleshoot with goal of continuous improvement in mind • Communicate effectively • Keep quality records

47. Scientists, Engineers, and Technicians & Quality • Participate in quality training sessions • Work with quality teams to achieve goals • Utilize skills in time management, organization, planning, prioritization, and attention to detail • CONTINUALLY IMPROVE

48. Summary • Quality is applied to all aspects of the process industry • Everyone has a role and a responsibility in quality • There are accepted methods and statistical tools in place to perform quality analyses

49. Student Activities • Quality exercise (Voice of the Customer) • Textbook questions: • CAPT Ch. 13, pages 218 – 219, questions 1 – 13, pages 219 – 220, activities 1 - 5 • Thomas Ch. 16, page 356, questions 1 - 10