Request Expert

When evaluating the level of process control, the expert uses the concept of "Quality Windows". He will quantify to what extend the process is erratic and how that contributes to the (lack of) capability of the process. Depending on the outcome, he will decide whether instrumentation and/or human control need to be improved. For improving human control, the expert will advice and lead a group of operators to a set self-made SPC rules with the emphasis on "proven stability" before further process improvements. For improving instrumentation control, the expert will identify a stable operational range via Design of Experiments.

The expert will approach chemical process developments from different angles : 1. Theoretical approach : what is the process delivering vs. what is expected. 2. Troubleshooting approach: what have we learned from deviations from the expected? 3. Find creative solutions to improve the process without spending major capital. What happens if chemicals are fed concurrently rather than batch, what happens if we add water ... 4. Explore the creative solutions via design of experiments in the lab, pilot plant or industrial plant.

The expert has been course instructor on a "Deviation analysis course" . In this 2,5 day residential course, exempts and/or operators learn to systematically analyze problems. After clearly identifying the problem, the deviation is analyzed in terms of what (what not) - where (where not) - When (when not) - etc..... The expert has applied this deviation analysis process numerous times in Chemical Process Troubleshooting sessions. As ex-course instructor, the expert also knows how to control and utilize the group dynamics in such situation. The combination of using "deviation analysis”, controlling group dynamics AND 20 years of experience in chemical process development, is unique.

The expert has been course instructor on a "Decision analysis" course. In this course, the decision is split into "Musts" and "Wants". Once these are defined and quantified, the different alternatives can be scored and the "Best Balanced Decision" is identified. Before taking the decision however, a systematical Risk Analysis is done. As ex-instructor, the expert masters the art of controlling the group dynamics, a necessity in the (often emotional) decision taking process.

When evaluating the level of process control the expert uses the concept of "Quality Windows". He will quantify to what extend the process is erratic and how that contributes to the (lack of) capability of the process. Depending on the outcome, he will decide whether instrumentation and/or human control need to be improved. For improving human control, the expert will advice and lead a group of operators to a set self-made SPC rules with the emphasis on "proven stability" before further process improvements. For improving instrumentation control, the expert will identify a stable operational range via Design of Experiments.

The expert has started up a major monomer plant. He has been involved in the technology selection process, the subsequent risk analysis and risk abatement, making sure the analytical lab was capable, operator training and finally starting up the process.

The expert has been part of a "Advanced process control" team for several years. In a problematic crystallization process, he identified a particle size analyzer which was capable of measuring particle slurries of up to 30%. He subsequently determined the vital control parameters (using Design of experiments - DOE). Using the mathematical function coming out of the DOE, the on-line analyzer info could be used to control the addition of solvent which stabilized the particle size. The expert has also used process parameters (distillation temperature, pressure ...) to predict the distillation product quality. In this way, a set of parameters (temperature, pressure) was converted into an on-line analyzer.

The expert has run SPC courses for operators and has led operator teams to develop their own "process control rules". This approach ensures the total buy-in from operators. Working in the micro-electronics industry, the expert was responsible of setting "capable" specifications. The expert separated analytical variation (GR&R analysis)from process variation so that appropriate development plans could be made with the process engineers and operators AND the lab operators/instruments.

Expert can teach and apply systematic troubleshooting via the "Kepner Tregoe" style Deviation Analysis. Such analysis is done with a team of 5-10 people. The analysis is a very good technique is 2 or 3 causes jointly result in a deviation. The minimum which the team will get out of the analysis is an agreement of what the problem is + agreement on what facts are known and what facts remain uncertain. Via this analysis we once solved a "blocking rotary vacuum filter" problem, which had existed for years. The cause was a combination of operating a too high vac and too pure solvent (and hence too much evaporation).Via analysis of the crystallization mechanism in combination with using a special particle size analyzer, the expert was able to find the critical X-es in a crystallization process. Via a Design of experiments, the effect of 2 variables on crystal size was mathematically characterized. The mathematical formula was used to steer an advanced process control loop which controlled the particle size at the desired level.Via Technology Risk Analysis, the critical areas for a new plant start-up were identified. The expert assisted at the 6 weeks plant start-up, continuously verifying the quality and output of the plant at various stages.Together with a team of operators, the expert led the plant operators to agree amongst themselves how to run the process stable. Without knowing, the operators designed themselves their own version of "SPC" around the plant bottleneck.