Use DMAIC To Stop Yield Drift
Apply DMAIC phases to a chemical manufacturing yield drift problem.
Esterification yield fell from 94.6 percent average to 92.8 percent average over six weeks, with no approved recipe change. DMAIC: Define the problem, Measure the process, Analyze likely causes, Improve with a targeted change, and Control the gain. Adding reaction time immediately because it appears to recover yield, while hiding the real cause and creating new impurity and capacity risks. Define Problem: yield down 1.8 points on product E-14 since May 3. Scope: esterification step only. Target: restore yield to at least 94.3 percent without increasing impurity A or cycle time. A good definition sets boundaries and protects against solving…
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