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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

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    IncreaseCapacity

    @L

    ow

    estCost

    TotalCost

    Env

    iron

    .HealthSafety

    New polymer is the same as standard

    Lowest cost polymer

    Total

    House 1

    External CustomerExpectation

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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

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    2

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    Reproducibility

    Scaleability

    126 72 70 70 5858

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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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    Distribution List 2001CRD055

    Corporate Research and Development

    Research Circle

    Niskayuna, NY 12309

    M. Brennan

    D. Buckley

    J. Carnahan

    J. CawseG. Chambers

    B. Chisholm

    K. Cueman

    D. Dietrich

    N. Doganaksoy

    T. Early

    V. Eddy-HelenekW. Flanagan

    J. Flock

    J. Hallgren

    C. Hansen

    B. Johnson

    T. Jordan

    R. Kilmer

    T. LeibJ. Lemmon

    R. Mattheyses

    R. May

    C. Molaison

    GE Plastics5th and Avery Streets

    Parkersburg, WV 26101

    A. Berzinis

    W. Morris

    D. Olson

    B. Pomeroy

    R. PotyrailoE. Pressman

    T. Repoff

    C. Sabourin

    A. Schmidt

    R. Shaffer

    K. Shalyaev

    O. Siclovan

    J. Silva

    G. Soloveichik

    J. Spivack

    C. Stanard

    J. Teetsov

    J. Webb

    J. Wetzel

    D. WhisenhuntB. Williams

    R. Wroczynski

    GE Plastics

    Highway 69 South

    Mt. Vernon, IN 47620

    S. Cooper

    J. DeRudder

    D. Whalen

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    J.N. Cawse Application of Six Sigma Quality Tools to High Throughput and Combinatorial 2001CRD055

    R. Wroczynski Materials Development April 2001