Chemical Industry Success Stories Using MVT

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Chemical Industry Success Stories

Afton Chemical - Afton Chemical uses the QualPro 12-Step Procedure and MVT^® to reduce variation in motor oils and gasoline additives. Making products to target, not simply within specifications, has been the goal for Afton Chemical. The specialty chemicals are used to formulate motor oils and gasoline additives sold to oil companies worldwide. Teams used MVT^® in three different operating units. In each of the manufacturing units, substantial improvements were realized. In the main manufacturing unit for ashless dispersants, used in motor oils to control sludge, the level of chloride contaminants was reduced by 30% while the variation was sharply reduced in the key quality measures. In addition, a 20% capacity gain and $650,000 in cost reductions were gained on an annualized basis.

Olin -- Olin, a large chemical manufacturer found itself unable to meet increasing demand for one of its products, hydrochloric acid, losing potential sales and profit. They turned to MVT^® to both improve its method of measuring the levels of free chlorine for one facility and to improve the production process for hydrochloric acid at the other. The measurement experiment found two significant factors and several interactions that were able to detect 100% of the chlorine used to spike samples. The production experiment found seven significant factors that contributed to the production process. By using accurate measures and implementing procedures that would preclude operations from chasing common variation, an increase in production was achieved. The MVT^® process lead to $750,000 increase in annual profits.

Valspar - Valspar, a large manufacturer of coatings has been experiencing decreasing batch runs as a result of global competition and the need to decrease the cost of inventories. The process involved mixing, heating, extruding, and grinding the components. Between runs, the line would have to be shut down and cleaned to reduce chances of contaminating the next run. In order to quickly evaluate changes and see if improvement was possible, they turned to MVT^®. One hundred brainstorming ideas were generated of which 19 that were practical, fast, and cost free were tested. Six of the 19 ideas were found to significantly reduce changeover time. Changeover time was decreased by 44% across the three plants, representing an annual savings of $15 million. Also, a savings of $800,000 due to inventory reductions was realized.

E.I. DuPont, DeLisle - E.I. Dupont had the problem that would not stay solved costing $5 million per year.. For over two decades, the best minds were baffled by this problem with a defect in paint uniformity. When the problem appeared, all efforts were made to make it go away. The problem did always go away, seemingly by itself, only to return a few months later, also seemingly on its own. During the brainstorming, a technician came up with an idea that conventional wisdom regarded as ridiculous. It proved to be the most significant improvement among several revealed by the MVT^® methodology. The recurring problem is no longer recurring, with savings estimated at over $5 million per year.

E.I. DuPont, Delrin - E.I. DuPont experienced millions in savings of raw materials. The process was spending millions of dollars a year in raw materials--much more than was needed. DuPont Delrin put the process on a diet, reducing consumption of a capping agent by 20%, resulting in fiscal fitness. During the screening experiment, every factor actually hurt performance. Going the opposite direction made the difference and led to another set of experiments upstream from the final product. The potential yield is $3 million.

E.I. DuPont Teflon® - E.I. DuPont used MVT^® to meet worldwide demand of Teflon". --When worldwide demand for Teflon® soared, a bottleneck in DuPont's process threatened their ability to meet that demand. Millions of dollars in lost sales were at risk. The competition was encroaching. With only three weeks of MVT^® testing, line capacity was increased by 38% with an annual sales impact in the millions.

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Since 1982, QualPro has used Multivariable Testing (MVT®) with 1000+ companies to test 100,000+ improvement ideas. MVT® tests between 20 and 40 ideas simultaneously, accurately predicting the bottom-line impact of potential process changes in weeks. Take existing process initiatives, like Six Sigma, to a whole new level. All process improvement tools and approaches (TQM, DOE, Six Sigma, Re-Engineering, SPC) can be enhanced through the use of Multivariable Testing by QualPro.