Yield Of Chemical Product Improvement Based On Zero Defect Management

Production of tri-sodium citrate (TSC) is a kind of continuous chemical production. In order to improve the yield of TSC, Chemical process controlling base on zero defect management was researched. Zero waste would be achieved through management and technical approach.The research has three aspects:Firstly, the factors which influence yield were given the rank through FMEA, and big factors were corrected. We reduced the losses which were caused from all kinds of failure. Yield was improved from 86% to 88%.Secondly, one of the DOE--Orthogonal design was carried out in the decomposition process.Through the orthogonal design we got the best factors combination: Sodium carbonate ratio, reaction temperature and reaction time. Thirdly, we used SPC (statistic process control) approach to prevent production from the deviation after DOE. Several control charts were set up in the key process of tri-sodium citrate production for process control and capacity evaluation. The whole production line was always at good controlled status.After implementation of the FMEA, DOE and SPC, the loss was reduced step by step, Zero defect management improved the yield from 86% to 91%.