Document 3Na4bRpBnnLjRqvD20NxBkBZJ

QUALITY REPRODUCIBILITY IMPROVEMENT PROGRAM R. E. Peavy 6/7/83 N 31745 BACKGROUND COLORED PIGMENTS MANUFACTURE TWO PLANT OPERATION NEWPORT: CPC BLUE AND QUINACRIOONE CRUDE NEWARK: LEAD CHROMATE, KROLOR, AZO ORGANICS, FINISHING CPC AND QA CRUDE MULTIPLE PRODUCT MANUFACTURE - 120 FINISHED PRODUCT CODES 21 COMPONENT CODES (KROLOR, ORGANIC DISPERSIONS) SPECIALTY BUSINESS - MANY CODES HAVE MULTIPLE QUALITY GRADES (PQ'S) - VARIOUS PACKAGES (BAGS, DRUMS, AIR PALLETS) DUP050146590 NEWARK MANUFACTURING .-SCHEMES BATCH MOLYBDATE ORANGE, KROLOR, AZO'S SYNTHESIS (STRIKE) QA, CPC NPT. SEMI-FINISH CHROME YELLOW CONTINUOUS MOLYBDATE ZINC ORANGEYELLOW SYNTHESIS (STRIKE) V ISOLATE/WASH Y DEWATER/WASH Y DEWATER/WASH Y BLEND V p/o V P/O DUP050146591 PRODUCT MIX PRODUCT GROUP CHROME YELLOW MOLYBDATE ORANGE KROLOR AZO ORGANICS QUlNACRlDQNE CPC BLUE '82 PROD. MM LBS. 6.1 4.4 3.6 1.3 1,3 1,0 '82 SALES $ MM 7.0 7.8 11,4 12.0 31.6 11.9 END USE INKS, INDUSTRIAL PAINTS INKS, INDUSTRIAL PAINTS PAINTS, PLASTICS. PAINTS, INKS ALL INDUSTRIES ALL INDUSTRIES HISTORICAL QUALITY PERFORMANCE % RE PROD, 1978 1979 1980 1981 1982 IQ83 * 83 YTD <54 69 69 76 84 92 88 NOTE: '83 YTD REFLECTS PART OF RECENT MOLYBDATE ORANGE CAMPAIGN PROBLEMS . COMPLEX MANUFACTURING SCHEME OLD EQUIPMENT POOR UNDERSTANDING OF PROCESS TECHNOLOGY . INCOMPLETE DOCUMENTATION OF EXISTING TECHNOLOGY DUP050146592 OBJECTIVE ACHIEVE QUALITY REPRODUCIBILITY: - >95% FDR CONTINUOUSLY MANUFACTURED PRODUCTS - >90% (BLENDABLE) FOR BATCH MANUFACTURED PRODUCTS APPROACH IMPROVE DOCUMENTATION OF EXISTING TECHNOLOGY UPGRADE PLANT EQUIPMENT INITIATE PROCESS TECHNOLOGY IMPROVEMENT PROGRAM UPGRADE PRODUCT EVALUATION TEST PROCEDURES IMPLEMENT AREA CHEMIST CONCEPT IN MANUFACTURING AREAS ESTABLISH QUALITY COMMITTEE TO IMPROVE THE DIVISIONS ABILITY TO MANAGE QUALITY. UPGRADE PRODUCT STANDARD SELECTION PROCESS DUP050146593 CONTINUOUS INORGANICS ACCOMPLISHMENTS COMPLETED DOCUMENTATION OF EXISTING PROCESS TECHNOLOGY INSTALLED BAUER MILL FOR IMPROVED PRODUCT & COMPONENT GRINDING INSTALLED CONTROL SYSTEM TO IMPROVE LEAD NITRATE & SODIUM CHROMATE SOLUTION FLOWS TO THE CASCADE INSTALLED CONTROL DEVICES (TEMPERATURE, LEVEL, FLOW) TO IMPROVE REGULATION OF CASCADE CONDITIONS IMPLEMENTED EVALUATION OF PRODUCT BY INSTRUMENTAL COLOR MEASUREMENT TO IMPROVE SHIPMENT RELIABILITY PROGRAMS , COMPLETE FLOW CONTROL INSTALLATION TO STABILIZE SOLUTION STANDARDIZATION , DEFINE PROCESS VARIABLES FOR MOLYBDATE ORANGE MANUFACTURE TO IMPROVE QUALITY REPRODUCIBILITY INSTALL DURANT PACKER TO PROVIDE MORE RAPID AND ACCURATE PACKAGING OF PRODUCT WITH LESS DUST CONTINUE PROCESS IMPROVEMENT PROGRAMS FOR PRIMROSE AND ZINC YELLOW. DUP050146594 QUALITY REPRODUCIBILITY CONTINUOUS INORGANICS PERCENT REPROD. DU P050146595 bat c h in o r g an ic s ACCOMPLISHMENTS COMPLETED DOCUMENTATION OF EXISTING PROCESS TECHNOLOGY IMPROVED THE SILICA ENCAPSULATION PROCESS FOR KROLOR . INSTALLED LEAD NITRATE, HCl AND CAUSTIC METERING SYSTEMS FOR MORE ACCURATE DELIVERY OF THESE REACTANTS INSTALLED DURANT PACKER FOR ACCURATE, DUST FREE PACKOUT OF KROLOR YELLOW INSTALLED AUTOMATIC TITRIMETER FOR CONTROL OF MOLYBDATE ORANGE MANUFACTURE PROGRAMS DEFINE .PROCESS VARIABLES FOR MOLYBDATE ORANGE MANUFACTURE INSTALL DURANT PACKER FOR KROLOR ORANGE PACKOUT EVALUATE ROTARY FILTER AS POTENTIAL REPLACEMENT OF FILTER PRESSES FOR ISOLATING KROLOR TRANSFER MANUFACTURE OF BATCH MOLYBDATES TO THE CONTINUOUS UNIT IMPLEMENT PRODUCT SHIPMENT BASED ON INSTRUMENTAL COLOR MEASUREMENT FOR IMPROVED EVALUATION RELIABILITY DUP050146596 QUALITY REPRODUCIBILITY BATCH INORGANICS PERCENT REPROD. DU P050146597 AZO ORGANICS ACCOMPLISHMENTS COMPLETED DOCUMENTATION OF EXISTING PROCESS TECHNOLOGY COMPLETED PROCESS IMPROVEMENT FOR SEVERAL LARGE VOLUME CODES (RT-618, RT-761, YT-808) RESULTING IN IMPROVED QUALITY REPRODUCIBILITY INSTALLED THE MEMBRANE PRESS AND DELUMPER FOR BETTER ISOLATION AND PRYING OF ORGANIC PRESSCAKES INSTALLED THE SUPER MILL TO PROVIDE MANUFACTURING CAPABILITY FOR HIGH SOLIDS DISPERSIONS AT NEWARK PROGRAMS . CONTINUE PROCESS IMPROVEMENT EFFORT FOR OTHER PROBLEM ORGANIC CODES (YT-858, RT-698, RT-565) INSTALL SODIUM NITRITE METERING SYSTEM FOR IMPROVED STOICHIOMETRY IN DIAZOTIZATION PROCESS MODIFY ORGANIC FINISHING AREA GRINDERS & BLENDERS TO IMPROVE PRODUCTIVITY AND REDUCE CONTAMINATION IMPLEMENT PRODUCT SHIPMENT BASED ON INSTRUMENTAL COLOR MEASUREMENT DU P050146598 QUALITY REPRODUCIBILITY- AZO ORGANICS PERCENT REPROD. DUP050146599 QUINACRIDONE/CPC BLUE ACCOMPLISHMENTS * COMPLETED DOCUMENTATION OF EXISTING PROCESS TECHNOLOGY INITIATED COOPERATIVE MEETINGS BETWEEN NEWPORT/NEWARK TO COORDINATE MUTUAL QUALITY PROGRAMS INSTALLED TORIT DUST COLLECTORS IN ORGANIC FINISHING AREA TO REDUCE CROSS PRODUCT CONTAMINATION INTRODUCED SEVERAL NEW PRODUCTS (RT-859, RT-343) PROGRAMS CONTINUE COOPERATIVE NEWPORT/NEWARK QUALITY MEETINGS MODIFY ORGANIC FINISHING AREA GRINDERS & BLENDERS IMPLEMENT MODIFIEO PH ADJUSTMENT PROCEDURE FOR QA CODES CRITICAL IN OUTDOOR DURABILITY PERFORMANCE , CONTINUE NEW PRODUCT INTRODUCTION IMPLEMENT INSTRUMENTAL PRODUCT RELEASE DU P050146600 q.UALITY REPRODUCIBILITY QUINACRIDONE/CPC BLUE PERCENT REPROD. DUP050146601