CM4120 Chemical Plant Operations Lab Introduction to Chemical

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					CM4120
Chemical Plant Operations Lab

Introduction to Quality Manufacturing

  How is Quality defined?

  ISO9000: The totality of features and
    characteristics of a product or service that
    bear on its ability to satisfy stated or implied
    need.




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CM4120
Chemical Plant Operations Lab

Introduction to Quality Manufacturing

  What is Quality Management?

  Managing systems and processes for the
   elimination of errors.

  Creating an environment for continuous
    improvement.


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CM4120
Chemical Plant Operations Lab

Introduction to Quality Manufacturing
 Formula for a generic process:

 A+B=C
 where A=system contribution
       B=human contribution
       C=desired (measurable) output

 Deming’s 14 Principles -- Handout


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CM4120
Chemical Plant Operations Lab

Introduction to 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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CM4120
Chemical Plant Operations Lab

Introduction to 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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CM4120
Chemical Plant Operations Lab

Introduction to Quality Manufacturing
What is Variation?
Measurable change in the system output(s).
Inherent to all processes or systems.

    Common cause – built into the system.
    Special cause – assignable to an event.
    Tampering – result from tampering.
    Structural – regular, systematic changes.


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CM4120
Chemical Plant Operations Lab

Introduction to Quality Manufacturing

  What is 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.

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CM4120
Chemical Plant Operations Lab

Introduction to Quality Manufacturing

  Additional tools:

  Fishbone (Cause and Effect) Diagrams



                                         Viscosity
                                         variation




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CM4120
Chemical Plant Operations Lab

Introduction to Quality Manufacturing
 Additional tools:

 Pareto Charts
 A bar graph showing frequency of problem
   occurrence.
 Optionally, can have a “cumulative frequency”
  line and show percentage of total on bar
  graph.
 Used to display the relative importance or
   frequency of problems or conditions
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CM4120
Chemical Plant Operations Lab

Introduction to Quality Manufacturing
                                                                                           cumulative
                      cause                                       frequency      percent     total
      miscalculated loadings                                          13           37          13
      neutralize too soon                                             7            57          20
      added wrong qty EB                                              6            74          26
      inadequate strip                                                4            86          30
      bad viscometer reading                                          4            97          34
      loaded wrong chemical                                           1            100         35


                                        Viscosity Variation Problems
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CM4120
Chemical Plant Operations Lab

Introduction to Quality Manufacturing

  Additional tools:


  Deming Cycle




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CM4120
Chemical Plant Operations Lab

Introduction to Quality Manufacturing

  Additional tools:


  Goal setting




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