dfss-materialdevelopment
TRANSCRIPT
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GE Research &Development Center
_____________________________________________________________
Application of Six Sigma Quality Tools toHigh Throughput and Combinatorial
Materials Development
J.N. Cawse and R. Wroczynski
2001CRD055, April 2001
Class 1
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Copyright 2001 General Electric Company. All rights reserved.
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Corporate Research and Development
Technical Report Abstract Page
Title Application of Six Sigma Quality Tools to High Throughput and Combinatorial MaterialsDevelopment
Author(s) J.N. Cawse Phone (518)387-6095R. Wroczynski 8*833-6095
Component Characterization and Environmental Technology Laboratory
ReportNumber 2001CRD055 Date April 2001
Numberof Pages 12 Class 1
Key Words Six Sigma, combinatorial, high throughput, screening, Design for Six Sigma, quality,experimentation, chemistry, materials development
As our ability to generate large numbers of experiments has accelerated, it has become more
important to ensure that the quality of each process step and individual sample is as high as possible.There are too many samples for each data point to be checked individually, and too many process steps
for human oversight. To achieve a reasonable level of quality in the information from a high throughput
experimental system, the principles of modern Six Sigma manufacturing must be applied. The quality of
the end product is then ensured by the quality of each individual process step and the robustness of final
quality to variation in the process steps. Design for Six Sigma tools are particularly appropriate in this
effort.
Manuscript received March 13, 2001
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Application of Six Sigma Quality Tools to High Throughput and
Combinatorial Materials Development
James N. Cawse and Ronald Wroczynski
Introduction
Background
Over the past ten years, the new research technology called Combinatorial Chemistry or High
Throughput Screening has seen exponential growth. This technology a set of techniques for creating amultiplicity of compounds and then testing them for activity has been widely adopted in the
pharmaceutical industry over the past few years. Virtually every major drug manufacturer is now using
these techniques as the cornerstone of their research and development program. In the pharmaceutical
industry, libraries of 1000 to 1,000,000 distinct compounds are routinely created and tested for biological
activity. This is now practical because of the
convergence of low-cost computer systems,
reliable robotic systems, sophisticated molecular
modeling, statistical experimental strategies, anddatabase software tools.
In the last four years, this technology has
expanded to materials design problems outside
the drug field1. Major chemical companies have
entered this arena, either by themselves or in
concert with a company such as Symyx2, which
specializes in new technologies for combinatorialmaterials discovery. Initial work has focussed on
development of robotic sample preparation,
reactors and sensors. Some of this equipment is
becoming available commercially. With the use of
this equipment, we have found that astonishing
increases in the throughput of experimentation
are possible (Figure 1).
Need For Quality
As our ability to generate large numbers of experiments has accelerated, it has become more important to
ensure that the quality of each process step and individual sample is as high as possible. There are too
many samples for each data point to be checked individually, and too many process steps for human
oversight. To achieve a reasonable level of quality in the information from a high throughput experimental
25,000
15,000
10,000
5,000
0
Oct-9
7
NumberofReactions
Dec-9
7
Feb-98
Apr-9
8
Jun-98
Aug-98
Oct-9
8
Dec-9
8
Feb-99
Apr-9
9
Jun-99
20,000Combinatorial Reactor
Conventional Reactors
Figure 1. GE experience with high-throughput screening
of a catalyst system.
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chemicals in making up the stock solutions for a run. An error in any weighing will affect 96 samples,
however, so any weighing defect will result in 96 sample defects. Therefore this step has 96 x 5 = 480
opportunities for defects. We assume that any human operation has 0.6% (6000 dpmo) chances of being
defective4, so the total number of defects potentially arising from this process are 480 x 6000 x 10-6= 2.88
defects/array. Other sources add to this as shown in Figure 2, which is a highly abbreviated total from a
more complex system. It is easy to see that the number of defects/array can quickly become quite large.
Table 1.A Six Sigma glossary.
Process Step Source Defect dpmo # times DPU
Make Stocks Chem. Supplier offspec chemicals 1000 480 0.48
Technician weigh chemicals 6000 480 2.88Make Samples Robot poor mixing 3000 96 0.29
Heatup Time 1500 96 0.15
Temp. Control Temp. 5000 96 0.48
Cooldown Time 1500 96 0.15
Gas Chromatograph Peak Identif ication 100 96 0.01Analyze Samples
GC Endpoint Detection 10000 96 0.96
GC Peak Integration 500 96 0.05
React Samples
Total Defects 5.45
Figure 2. Estimating the total number of defects in an experimental unit:
a 96-well sample array. dpmo = defects per million operations; #times =
the number of times that operation will be performed on that unit; DPU
= defects per unit = #times*dpmo/1000000.
Overall Six Sigma Approach
Critical to Quality (CTQ). Any product or service characteristic that satisfies a key customerrequirement or process requirement.
Defect opportunities. Every operation and every subsystem component is considered to bea potential source of one or more defects.
Defects per million opportunities (DPMO). As actual or statistically probable defects arefound, they are divided by the opportunities. The ratio is multiplied by 1,000,000 to
accentuate the importance of even small numbers of defects.
Unit. An appropriate subdivision of the total effort is defined as a unit. In the present case,a single 96-well sample array was chosen.
Defects per Unit (DPU). To calculate the total number of potential defects in the unit, eachDPMO is multiplied by the number of times it can occur in a single unit. The results aretotaled to give the DPU.
Z. The standard metric for measuring process capability. ZLTis based on the overallstandard deviation and average output. ZSTrepresents the process capability with special
cause variation removed.
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IDOV Step 1: Identify
The critical tasks in the Identify step are identifying the customers (all of them), determining their Critical
to Quality (CTQ) parameters, and generating a seamless connection from those parameters to
controllable elements of the actual experimental process.
CTQ Determination
Step 1 in CTQ determination is iteration of all the customers of the new process. This customer listing is
organized in a structure called the Application Channel (Figure 4), progressing from the most outside
the customer who actually pays money for a product to the most inside the people who are working
on the process. Typically there are three to five customer organizations. Within each of those
organizations, the people whose roles are critical to making a good judgment of the CTQs must be
determined. Once those people are found, the technique of customer needs mapping (CNM)5can be used
to determine the CTQs.
Identify
Design
Optimize
Validate
Q
ualitybyDesign
Identify customer CTQ's Perform CTQ flowdown Analyze measurement system capability
Generate/validate system/subsystem models Build variance predictions (parts, process, performance)
Roll-up variance for all subsystems Capability flow-up
Identify the gaps Low DPU of subsystem
Use DoE on prototypes to find the critical few X's Perform parameter and tolerance design Generate purchase and manufacturing specs
Confirm that pilot builds match predictions Mistake proof the process Refine models and process characterization database Document the effort and results
Figure 3.Outline of the DFSS methodology used for high throughput
screening and combinatorial experimentation.
End UserGE BusinessManufacturingOperation
Final customer forcatalyst, not process
GE BusinessPilot Plant Team
Interface ofdevelopment withend user
GE Corporate Researchand Development CatalystDevelopment Team
Validation of combinatorialdevelopment process andlaboratory scale test ofcandidates
GE Corporate Researchand DevelopmentCombinatorial Team
Development of process forcatalyst development andgeneration of catalyst leadsfor further investigation
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Flowdown of CTQs by Quality Function Deployment
The CTQs determined by customer needs mapping are typically somewhat subjective and a bit fuzzy.Developing these into actionable process items is called CTQ flowdown and is typically done using the
Quality Function Deployment technique.6 A typical interrelationship of the houses of the QFD for a
material or catalyst development project is shown in Figure 5.
The first house (Figure 6) captures the critical to quality needs of the external customer and how the
Business unit expects to fulfill those customer needs. The primary customer CTQs become the rows
(Whats) of the first house of the QFD; the measurements become the columns (Hows). Using
the typical QFD process 6,7, importance levels are assigned (1 to 5, 5 is most important) to the external
Customer CTQs based on the CNM. The relationship of the CTQ's to the Hows (Business
Product Deliverables) is then defined by assigning high, medium, low (9,3,1) values to the cells based
on the impact that the measurements have on the CTQs. The products of the cell values with the
importance values of the CTQ's is determined and totaled for each column. These totals thus gives
the overall impact that each product deliverable has on meeting the Customer CTQs.
The Whats from the first house then become the Hows of the second house and similarly
importance values are assigned to them. The second house (Figure 6) is then used to establish the
relationship for How the materials, catalyst, or process can be varied to deliver the product changes
required by the Business to effect the Customer CTQs.
The third house identifies the variables that can or must be probed in the combinatorial space to be
able to screen the materials, catalyst, or process for desired changes
Finally, the fourth house relates to the actual design of the high throughput system (reagent
preparation, reactor conditions, product isolation and work-up, chemical analysis, and data storage and
data analysis) needed in order to deliver the desired capability of the combinatorial chemistry system.
It is here that the CTQs of the Combinatorial sub-systems are mapped onto the hows or variables
in the HTS factory (Figure 7).
The fully developed QFD assigns importance and impact values to the relationships of items in theWhats (rows) and Hows (columns) within each house. As a result it links (flowdown) the Customer
CTQs to items further down in the process. This ultimately determines the design of the high throughput
Business ProductDeliverables
(HOW s)
House#1
CustomerNeeds
CustomerWants
(WHATs)
Catalyst,Materials, Process(HOW s)
House#2
ProductctDeliverables
(WHATs)
HTS SystemCharacteristics
(HOW s)
House#3
sVariables
)
HTS Variables(HOW s)
Houses
tem
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Importance
Qu
ality
Produ
ct
IncreaseCapacity
@L
ow
estCost
TotalCost
Env
iron
.HealthSafety
New polymer is the same as standard
Lowest cost polymer
Total
House 1
External CustomerExpectation
5
4
h
I
49
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41
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17
Imp
ortance
SideProdu
ctContent
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Manu
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ResinColor
Quality Product
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Total
House 2
Business ProductDeliverables
5
4
h
h
86
I
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78
m
h
56
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ResinColorStability
ResinHy
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ResinMeltFlow
CappingLev
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ResinManu
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Total
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4 I h I I I I I m m I I 92Total Cost
1 I I I I I I I I I m h 21
Business Product Deliverables
Polymer Reaction Measurables
Environ. Health and Safety
Figure 6.First and Second House QFD relating customer CTQs with measurable product and process deliverables.
DataAnalysis
Preparation Chemical
ReactionAnalytical
PreparationChemicalAnalysis
Database System
Importance
Design Space Choice
Accuracy
Total
HTS Variables
CombiChem Factors
5
3
2Design Space Coverage
2
2
Reproducibility
Scaleability
126 72 70 70 5858
h h m m
MonomerStability
Reage
ntVolatility
MonomerRatio
Overa
llVariability
h
h
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h h
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Temp.
Accuracy
MonomerPurity
Liquid
VolumeDelivery
Slurry
Delivery
DiessolutionProcess
SamplePlacementAccuracy
Post-reactionReaction
I
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h m I I I I
h h h h h h
h m
42 42 40 38 3034
m I m I m I
SamplingRates
Chrom
atographyPeakPicking
Secon
daryAnalysisAccuracy
SampleTracking
Cataly
stChoice
MonomerReactivity
SolventChoice
OutlierID
PSStandardsforRelativeMw
Temp.
Uniformity
DataS
torage(Long-Term)
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m m h I h I
28 28 28 28 24 24 24 2 424 20
Order
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Autom
ationofDataAnalysis&Storage
PreparationTime
Cataly
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SolventRemovalProcedure
Cataly
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Total
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screening (HTS) system (the combinatorial factory). Conversely, once the HTS system is in place, its
statistical capability to identify new leads can be related back (flowup) to the ability to reliably deliver
the Customer CTQs.
The next key step in utilizing the QFD is to focus on the design of the HTS system. This is an iterative
process linking the Customer CTQs with the chemical analysis system and the reactor design
specifications. Simply stated, both the analysis and the reaction system have to be sufficiently capable to
allow identification of leads or hits above the composite noise of the systems. However, the ability to
perform certain high throughput analyses is a function of the type of reaction and reactor employed and,
similarly, the reaction system can be configured to more easily allow rapid in-line or off-line analysis. This
iterative process occurs early in the HTS design process and fully utilizes the interactive matrix of
variables and responses delineated by the QFD process.
To fully understand the interaction of the analysis and reaction systems, a complete process map is
constructed for the steps involved in running the HTS factory. Figure 8 depicts a generalized process map
including the design and operation stages of a HTS project. These generalized process steps can be sub-
divided into more detailed actions or steps. Figure 9 highlights an example of detailed steps that
correspond to Prepare Arrays in Figure 8. The detailed process steps that are unnecessary or unwieldy
can be changed or eliminated. The remaining steps in the process map can then be linked to the variables
in the HTS house of the QFD. Process steps related to those elements of the HTS house which have the
greatest impact on the Customer CTQ's are then the focus of significant quality evaluation and refinement
to reduce sources of variability.
IDOV Step 2: DesignThe key Six Sigma activities in the Design stage include setting the specifications for the system and
flowing up the variance from the subsystems to the total system.
Process Design
Analytical SystemDesign
Decide on Systemto Study
PreworkProcess
S P
FactoryDesign
FactoryProduction
Inputs
ChemicalSystem
InputsIdeas,Chemicals
DetermineDesign Required
ConstructPrototype
Validate Safetyand Operation
Define Key Analysisand Analysis Precision
Needed
Evaluate andValidateMethod
Plan and PrioritizeExperimentalUniverse
Plan CombinatorialStrategy forExploration
PurchaseChemicals
SynthesisSafety,
Solubility, andCompatibility Tests
Define StockSolutions andCoat Mixtures
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Specifications
Unlike a conventional factory, a high throughput experimental system has only information as its product,
so the specifications are on the quality of that information. Therefore, all specifications are expressed in
terms of variance (or, more conventionally, standard deviation). Specifications are not internally
determined; they are externally agreed upon by the customer and the process team, and should flowlogically from the measurements of the critical customer parameters (CTQs). In our catalyst
development case, the critical parameters were accurate and rapid identification of catalyst leads. In
addition, the desired catalyst activity was more than double the current level. From that, we agreed that a
25% increase in activity would represent a useful lead, and that we desired a 95% probability of correctly
detecting that lead.
CTQs Specification
Accurate lead identification 95% probability of correctly detecting Rapid lead identification a 25% increase in catalyst activity
>100% increase in catalyst activity
This specification is on the whole system: the major program of the Design effort is to flow that
specification down to the process subsystems then flow the variances of the subsystems back up to the
Transportarray
to oven
Removesolvent
Securepipette
tips
Charge initiatorto array
with replicator
Transportarray to
vac oven
Removesolvent
Weighcatalystfor stock
Addsolvent
for stock
Chargecatalysts toHTS array
Removesolvent
Secure tipsto 96 wellreplicator
Charge reagentsto array with
replicator
Weighreagents for
stocks
Dissolvereagents for
stocks
DataAnalysis
Preparation Chemical
ReactionAnalytical
PreparationChemicalAnalysis
Database System
Figure 9.Detailed process map for array preparation.
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Replicate Stocks
Replicate Reaction Runs
Replicate Samples
Replicate Analyses
Figure 11. A typical process in making a combinatorial or high throughput array.
Figure 12.A hierarchical experimental design for studying a nested system.
Defect AccountingIn defect accounting, the entire system and each subsystem is process mapped in detail. Each step is
examined by the Six Sigma Black Belt and the process expert for potential sources of defects. These can
be classified by type:
Parts. The quality level of components or raw materials (such as chemicals)
Process. The quality level of each unit operation (e.g. weighing, fluid transfer, or reaction).
Performance. The overall quality of subsystem performance vs specifications when all elements are
working correctly but normal variance is present.
Software. The quality of any software specifically written for the system.
The outcome of the process is illustrated in Figure 2, which shows a small part of a high throughput
screening system. Even with this small fraction of the overall opportunities for defects, we predicted 5.6
DPU.
Process Step
1 Make Stocks
2 MakeArray
3 React Array
4 Analyze Array
Factors
Stock solution factors:Amount of chemical
Sample factors:Amounts addedTotal volume
Reactor factors:Temperature
Reaction time Pressure Gas composition
Analysis factors: Peak identification settings
Integration settings
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IDOV Step 3: Optimize
Optimization of the high variance processes identified in the previous steps is done by the standard Six
Sigma Measure-Analyze-Improve-Control (MAIC) process. The following cases illustrate the particularproblems of high throughput screening and the quality level we have been able to achieve through MAIC
methodology.
Case 1: Analytical System Gage Reliability and Reproducibility
The analytical system is the heart of any high throughput experimental operation, so it must operate at the
highest level of reliability for the operation to succeed. There are too many samples per day for the
operator or scientist to scan the raw data (spectra, chromatograms, etc) for accuracy and consistency. In
our catalyst system, the analysis was a rapid gas chromatogram. The MAIC process improved its
capability immensely:
Measure: one subsystem CTQ was peak
identification. A gas chromatograph integration
system identifies components by selecting the
largest peak inside a set retention time window.
(Figure 13.) Therefore the consistency of peak
retention times is critical to the overall system
capability.
Analyze: the initial Six Sigma analysis (Figure
14) of the chromatographic relative retention
time capability showed that the capability of the
system was far too low. The small groups in the
histogram were identified as single day
measurements. There was therefore severe day
to day drift (Zlt), but even the individual groups
indicated poor within-day capability (Zst).
Improve: Designed experiments on the numberand type of internal standards optimized the
system (Figure 15). The Zst improved to 27 and the Zlt to 12 far more than six sigma! Missed peak
identification from this source can be estimated to be in the parts per trillion.
counts
50000
40000
30000
20000
10000
1 1.5 2 2.5
Peakidentification
window
Peak
retention timevariation
Figure 13.The critical parameters in chromato-
graphic peak identification.
ZST1.8
ZLT0.6
LSL USL
Short Term
Long Term
LSL USL
Short Term
Long Term
ZST27
ZLT12
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Control: Careful choice of the internal standards allows diagnosis of potential deterioration in
chromatographic behavior by tracking their relative areas using control charts.
Robot System Mixing Capability
Robotic pipettors are a mainstay of high throughput experimentation. They were primarily developed for
the medical and pharmaceutical industries so they are optimized for operation with water. In our system,
we planned to combine several different stock solutions made with a nonaqueous solvent and mix them by
repetitive aspirate and release operations. This was specified by the manufacturer as an effective mixing
technique. Using MAIC we found otherwise:
Measure: the subsystem CTQ was mixture uniformity. The initial specification was set at 20%
variation around the nominal, as measured by six consecutive chromatographic samples from a single
vial.
Analyze: the variation of the system was found to be more than 30% (Figure 16)
Improve: DOE on the pipette control parameters showed that the variation could not be reduced to
specifications at any available settings! A second experiment comparing alternative mixing methods
showed that a miniature magnetic stirring bar in each vial was the only way to achieve adequate
mixing (Figure 17).
Control: Mistake-proofing the procedure for putting the stirring bars in the vials was important. New
stirring bars for each experiment proved necessary to minimize cross contamination.
Mixture Sample
MixRatios
ZST7.7
ZLT7.5
LSL USL
Short Term
Long Term
Figure 16. The variation in composition of six repetitive measure-
ments taken on 58 samples after mixing by aspiration.
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Reactor Temperature Control
In any materials development program that involves
the rate of a chemical reaction as a critical
parameter, temperature control and uniformity are
often under appreciated. Figure 18 shows the effect
on reaction rate variance caused by a small (2C)temperature variability. With MAIC we:
Measure: Since catalyst TON (Turn Over
Number) is directly related to reaction rate,
temperature was identified as a CTQ. A 2C
change in temperature was found to cause a
20% change in reaction rate in our system, so 2
C variation was set as the specification. Some
immediate low-hanging fruit was discovered
when it was found that the reactor temperature
was controlled with a low quality, easily broken
thermocouple (standard wire error 1.1-2.9C).That was replaced with a platinum resistance
thermometer (deviation 0.35C) 12.
Analyze: Measurement of the actual sample
temperatures showed relatively small sample to
sample variation but large swings caused by the
temperature control system (Figure 20) caused
by the crude control system and the thick walls
of the high pressure reactor.
Improve: Careful examination of the data
shown in Figure 19 showed that the within-
reactor temperature control was quite good (Zst= 4.5, as shown by the closeness of the lines in
the Figure). The critical problem was the
temperature control system, which suffered
severe lags because of the reactor wall
thickness. A control system upgrade followed by
optimization of its parameters reduced the temperature swings to less than 1.5C. We also modifiedthe sample holder to improve gas circulation within the autoclave.
Control: Once the optimized control system was in place, the system was set on an automaticprocedure which minimized the variability. An ongoing program of SPC samples in the process has
shown acceptable performance.
Validate
PercentVariation
Reaction Temperature
ActivationEnergy (Kcal)
16%
12%
8%
4%
0%
120 180240
3005
10
20
Figure 18.Rate variation caused by a 2 C
temperature difference across a reactor array as a
function of reaction temperature and Arrhenius
activation energy.
TC Locations
TC 1TC 2TC 3TC 4TC 5
ManualTC readings
12
34
5
Actual Run Time11:30 12:00 12:30 13:00 13:30 14:00 14:30 15:00
TempC
102
100
98
96
94
92
90
88
86
84
82
2 C Spec
Figure 19. The actual variation in temperature
within the high pressure autoclave as measured
by precision thermocouples.
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being identified as leads for more detailed
traditional evaluation. Out of these leads, 90%
were confirmed as high activity catalysts with
lower side product formation in larger-scale
laboratory experiments. Figure 20 shows the
distribution of catalyst with various activity and
side-product formation. The current catalyst
performance is shown along with some of the
confirmed HTS leads highlighted by arrows.
Conclusion
In two years, we have successfully used this high
throughput screening technology to explore >2000
unique materials combinations in over 10,000
different ratios. Many hits were discovered and
several patents filed. The overall benefits to the
catalyst development program were:
A broad, proprietary technology position has
been developed for this process
New systems with attractive economic and environmental properties have been identified
Wide exploration has been made less risky. We have ended the moth around the flame syndrome, in
which only modest variations were made on a known good system because wild exploration was
too expensive.
From this we have identified the key learnings from application of DFSS (Designfor Six Sigma) to combi-
natorial and high throughput experimental systems:
Link and prioritize multiple complex steps with Quality Function Deployment
Pay special attention to the Gage Repeatability and Reproducibility of the analytical system
Focus on the variance of subsystems to reduce the overall system variance
Roll up subsystem variance to estimate system variance
Attack variance using advanced Design of Experiments tools.
References:
(1) Liu, D. R.; Schultz, P. G. Generating New Molecular Function: A Lesson From Nature.Angew. Chem. Int. Ed
1999, 38, 36-54.(2) Symyx Technologies.http://www.symyx.com, (April 3)
(3) Harry, M. J. The Nature of Six Sigma Quality; Motorola University Press: Schaumburg, IL, 1988.
(4) The quality of routine manual operations (e.g . restaurant bills, prescription writing) tends to cluster at 4
Sigma or 6000 DPMO: Harry, M. J. The Vision of Six Sigma: A roadmap for Breakthrough; Sigma Publishing
Company: Phoenix, AZ, 1994, p19.26.
(5) J J M I J Q li C l H db k 4 h d J J M Ed M G Hill N Y k 1988
ActivitySid
eProd
uct
Frequency
0
5
10
15
20
25
30
35
40
45
50
CurrentCatalyst
Figure 20.Distribution of catalyst activity and side
product production for an oligomerization catalyst.
The small yellow arrows indicate leads which were
confirmed upon scaleup.
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Mt. Vernon, IN 47620
S. Cooper
J. DeRudder
D. Whalen
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7/23/2019 DFSS-MaterialDevelopment
18/18
J.N. Cawse Application of Six Sigma Quality Tools to High Throughput and Combinatorial 2001CRD055
R. Wroczynski Materials Development April 2001