Dow Theory_Sameer_Tushar_Sanjiv (1)

576153f67bc572d0687f52fdbcee58f13a5598eb.xlsx 11/15/2023 22:00:47 Versions (clock) (in hours) Version Date Type Description Time Duration Update By Contributors 3 April 12, 2023 Review meeting 9:00 AM 1.5 hr Sameer gharat 4 April 7, 2023 Zoom meeting 3:00 PM 1.4hr Tushar Patel Total Investigation Hours 2.90 Review the final group project sheet in the file attached. Then, with Prof.'s guidance, revise the precise specification. Tushar.s, sanjiv tivari , sameer gharat, Professor underlying issues, solutions, and standards of conduct Tushar.s, sanjiv tivari , sameer gharat The "versions" feature is useful for tracking the progress of ongoing investigations that involve multiple iterations. It allows you to keep a record of the different versions, as well as the type and level of involvement of each participant. While it is not required, you may also choose to include information about the timing and duration of each iteration. Example: (clock) (in hours) VersionDate Interaction TypeDescription Time DurationUpdate By Contributors 1 JApril 5, 2023 Conference Call first information gathered 1.00 tushar.s Tushar.s, sanjiv tivari , sameer gharat 2 JApril 7, 2023 Meeting (in person) one-on-one with operator, initial map construction, revised timetable 1:00 PM 0.40 sanjiv Sameer Gharat. 3 JApril 8, 2023 Remote Map Cleanup 0.80 sameer 4 JApril 13, 2023 Meeting (in person) Discussion with Operations: Added and extended Cause Map Action Points 7:00 AM 1.50 sanjivh Operations Team - sameer, tushar, tivari

Problem Notification 1. Consult the plant manager of a different production site (Y is a raw material provider). Has the manufacturing or availability of chemicals changed recently? delivered filtered goods? If not, why didn't the process involve filtration? 2. Speaking with the plant manager at the location of the ABC product How frequently did they maintain the machinery used in production? Was there anything that required to be taken into account in terms of laws, rules, or regulations? ABC Goods: Does climate change have an impact on it? Has the required filtration been performed on the X raw material? Did they switch to X as the raw material provider? Does the reactor have a leak that permits materials to enter it? Does the reactor get enough gaseous ammonia to produce the best? 3. Ask lower-level personnel (Operators) questions. Did they notice any recent adjustments to the manufacturing process or raw material feedrate? Were they functioning according to protocol? 4. Additional observation Inspections aid in identifying problems at work and recording them for future attention. Analyse any potential effects on the environment and the economy caused by this issue. Examine the area surrounding the drums where the material is deposited. Analyse the drums to find out what toxins are inside of them. 5. Check further records and information to pinpoint the issue . Compare and classify the problem by review organisational assets and check history for other plant issues in the past. Who are the people who had been affected by this Product issue? Who are stakeholders?

Process or Function Name: Production of Dow Corning’s Product ABC SIPOC Diagram Suppliers Inputs Processes Operating a pump. Pressurised material X Filtration Another location for manufacturing. Prefiltered material Y Pump the material into Operating a reactor. Processed material XY external vendor. Material X Pump the material in Another location for manufacturing. Prefiltered material Y Pump the material into Operating a pump. Material XY Reactor Condenser operator Waste material from reactor Condensing Bulk Storage Gaseous Ammonia Pressurize the rea Scope: Make recommendations for factors that the study team should consider while examining the primary processes' suppliers, inputs, improvement areas, outputs, and clients who will be getting those outputs. Who supplies the process inputs? What inputs are required? What are the m steps in the proc Pumping to fill in final into drums

Problem Analysis (Is - Is not) Specify the problem: IS IS NOT Distinction Causes WHAT WHERE WHEN SCOPE Problem Identification : Black specks are an issue that Dow Corning Corporation is having when producing ABC. What is the root cause of this issue, and why? The drums of product ABC included black particles. On the other goods created from the same two raw materials, X and Y, no black specks were discovered. For each product, there is a distinct feed ratio of the raw material. The flow rate changed, and the operator lacked training. Waste is unable to condense in the condenser. discovered black specks at the bottom of an ABC product drum. Except for the bottom section, the drum was completely free of any black flecks. Product ABC is a fluid that is very viscous and challenging to filter. Product ABC is a fluid that is difficult to filter due to its high viscosity. When the internal customer used it 3.5 months later, the issue was discovered. After three months of production, the internal client used it before the issue was discovered. Recent developments in the maintenance and time difference fields pollutants in the final product material within three months. and the maintenance of plant machinery. To locate and eliminate the difficult-to-filter black particles that were discovered during the manufacture of Product ABC. to find and get rid of the problematic black particle Product ABC, which had been produced three months earlier, had a problem. Where the material is poured into the barrels has an impact on the environment in the surrounding places.

Timeline Date Time Description January 20, 2023 3:30 PM February 22, 2023 6:00 PM March 28, 2023 11:30 AM April 1, 2023 3:00 PM April 3, 2023 1:00 PM April 6, 2023 10:00 AM checked to see if the drums were unclean or not. April 8, 2023 2:00 PM April 8, 2023 9:00 AM A group was established to address issues. Problem with leaky valves and broken pumps Broken Teflon was the problem, and strong graphite was used in its place. ABC product's production procedure discovered black specks in the drum's bottom. Another batch of ABThe production of ABC continued. C was produced has been verified that product ABC contains black flecks of contamination. Used this tab to capture details of the sequence of events leading up to the problem in chronological order.

Problem Containment The containment area should cover: 1. Production (In-transit) Additional visual control. This task is carried out during the manufacturing phase, when problems are more likely to arise. In order to accomplish the following objectives of the business, visual control refers to the techniques, tools, or procedures used to manage or control activities (processes): > Products made by ABC must stop being produced right away. > Put every batch of ABC products that is impacted into quarantine and mark it as tainted. > Customers need to be informed and told to quarantine any ABC products they may have obtained.To pinpoint the root of the contamination, thoroughly examine the production process. > Check for any indications of damage, wear and tear, or malfunction on any machinery and components involved in the production process, such as valves, pumps, reactors, and condensers. > Gather samples of the ABC products, the X and Y raw ingredients, and the products for laboratory testing. letting the operators know about the issue (Quality alert). The operators are informed that the customer-supplied item has flaws and is scuffed. In order to assure thorough product quality checks before finishing the project from that day forward, they were more careful, which allowed the m to do the following: - Provide greater monitoring. 1. Provide more supervision. > They will ensure that the necessary quality standards are followed. >- Operators monitor the equipment they employ in the procedure. 2. Customer (Keysight). Customer notification of the issue - With the submission of the 8D, the investigation process will become more open by including all the details regarding the flaws and the efforts we took to fix them. 3. Supplier Containment • Isolate/segregate the nonconforming product. • Quarantine the complete supplier value stream – WIP, stock, in transit, on delivered product. • Clearly identify the suspect material or parts. 1. Make contact with the supplier(s) to alert them to the contamination problem and suggest that they take prompt action to resolve it. 2. Ask the supplier(s) to look into their own manufacturing procedure to locate any potential sources of contamination and then submit a thorough report of their findings. 3. Take appropriate action after assessing the supplier(s)' response, which may include: a. Rejecting further shipments from the supplier(s) until the problem is fixed.b. 4. Asking the supplier(s) for extra quality control methods or documents.c. Taking legal action, if required, to recoup expenses or losses brought on by the pollution. 4. 100% screening is done for below area: Finished good inventory (FGI), warehouse inventory, Keysight inventory (includes manufacturing), incoming material (receiving areas), Results : From of a total of xx PCs, xx PCs are determined to have similar reject. There are xx% rejections. confirmed that date number x is the impacted one. Material that is rejected is returned for further Failure Analysis. Details required:a) Screening type used in the region that was chosen above b) Results: Reject amount and rate c) the identity of the person in charged) the day that the action was taken. 5. Shipping areas Inspection before delivery: The orders placed by an internal client will be examined, and shipping will not begin until the problem's root cause has been found. 6. Lessons learned database: An organization strives to continuously improve its operations and processes by implementing a system that focuses on preventing problems, enhancing performance, and reducing costs. By doing so, the organization can learn from past mistakes and use that knowledge to better its future performance.

Work Process Process step Decision point Notes Opportunity, gap, potential failur Text label Notes: #1 The individual failure points can be found by recording the exact actions taken during the labour process. You may record the process from the "people closest to the work" by using the shapes to the right. Determine the probable points of failure. YES Decision NO Label (no border) Label (border) From a third party source, raw material X is delivered in bulk containers. To eliminate pollutants, it is then filtered as it is injected into the process. Drums of pre-filtered raw material Y are delivered from another production facility. The reactor is subsequently given a direct injection of raw material Y. To pressurise the reactor, gaseous ammonia is supplied from a bulk storage tank. Following that, the products are sent to the receiver after being condensed in the condenser. The receiver then gathers the liquid so that it may securely dispose of it. After that, the finished product is poured into drums for use in subsequent steps. 1 2 3 Process of Material X and Y Reaction in Reactor

AND OR AND/OR Possible Solution: Evidence: recognisable in the item ABC Carbon-based particles that resemble wood Gasket has a crack. top-level graphite gasket that is flaking Cause Map Version Black specks DRAFT Black specks found in the product ABC Verify the presence of pollutants in the drums. well-controlled chemical reaction. Schedule maintenance for the gasket and accessories and repair the gasket with the proper fixings. Case study question's answers Dow Corning Case Study Case study question's answers Dow Corning Case Study When processing, check the raw materials and finished goods. mixing of carbon particles during a reaction well contained reaction process. Case study question's answers

Solutions Possible Solutions for Consideration Ref. Possible Solution Root Cause Controlled 1 In the ABC product, it is mentioned. 2 3 damaged gasket. 4 top gasket made of flaking graphite. 5 6 Carbon atoms leaving the reactor. 7 Upkeep of the reactor. the reactor's malfunction. Inspect both the raw materials and the completed product throughout the production process. Look over any pollutants in the drums. Particles that are carbon-based and resemble wood. replacing the gasket with a more resilient graphite. Fix the gasket with the required fittings, and plan maintenance for the gasket and its accessories. procedure with a completely closed boundary. During the reaction process, carbon- based components were combined. when the finished product is removed from the reactor, adding a sensor. 1. Co effor 2. Ev an en 1. Specific causes are controlled by potential remedies presented on the Cause Map. 2. Prevention efforts need alterations to your work process. Describe the process that the suggested solution will alter or have an impact on.

Solutions Matrix A comprehensive a benefit-cost analysis technique that may be used to analyse possible remedies is the alternatives matrix. Copy your potential solutions from the Cause Map and arrange them on the structure in relation to one another to utilise the tool. Symbols or digits might be used to symbolise your many possibilities if you are contemplating a big number of answers. High Low Payback Benefit Effort Cost Medium High Medium A B C E F G 1 2 3 4 5 6 7

uct throughout the production process. r the gasket and its accessories. a sensor.