Together, Bayer Crop Science & Stanwick shift six sigma into a higher gear

Bayer Crop Science & Stanwick

With (6 sigma) improvement projects we try to identify the most important process parameters in order to understand a process and thus to be able to steer and control it. The execution of experiments is inevitable in this respect and the Design of Experiment (DoE) approach has proven to be a very handy method.

Until recently, however, a “relatively” large number of experiments were needed, especially when many process parameters were to be studied. The invention of Definitive Screening Designs (B. Jones and Nachtheim) brings DOE within easy reach of every company, even in production environments. In the article (Chemical Engineering), we describe a comparison between a classical Response Surface Method design (RSM= typical optimisation design)  and a Definitive Screening Design performed in the labs of Bayer Crop Science (formerly Monsanto). The results are astonishing. Using the DSD only 13 experiments were needed to study 6 process variables. The results of this DSD were almost identical to the results of the 90 experiments requested by the classical RSM.

With the Definitive Screening Designs, we have already achieved good results in the textile, pharmaceutical, biochemistry and metal industries, both in the laboratory and in the production environment. The DSD approach will accelerate the 6 sigma approach.

Project team: Bart Peeters (Bayer), Marc Roels (Bayer), Sam Van Aeken (Bayer) & Guido Desmarets (Stanwick)

Read the full article here: link


Problem solving

Are you facing issues in the production process that sometimes pop-up while not knowing the root cause of it? Many different problem-solving methodologies were developed with at least four logical steps as common ground: define the problem, search for root causes, find solutions for the root causes and secure the solutions in the organization.
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