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Step-4
Percent
Count
1000 60
40
500
20
0 0
Potential Causes of Failure Mod e y t x l x r
u um tu r ti t r ke f l u an o fl u CM th e
c a a n a r e h e
r by S O
r v a per q u t m in met ng
l a s r i n
de t em n o ty los y o
f
du giv
e
u n on t ha bil i ol t ly s
A ti M e a ila a n g q pe r ec
TE ac v t h n o s p
ig ng R
e
al a M e Wro pr ng
ar ri ed o
h ate a in Wr
C M
a int
o tm
n
p
m
Te
UCL=0.7599
0.75
0.70
Individual Value
_
X=0.6633 Target yield: 0.75
0.65
0.60
LCL=0.5666
0.55
2 4 6 8 10 12 14 16
Observation
Past data analysis shows that the average yield in the plant was
0.6633 with base - methanol route batches as against a minimum
yield of 0.75 with Base IPA route.
DOE: First set of Improve
Step-1
experiments
StdOrder RunOrder MeOH Vol Reflux temp yield purity
•Design – Multilevel full
6 1 2.5 65-70 0.515 85.03
factorial design
2 2 1.5 65-70 0.57 84.5
4 3 2 65-70 0.624 90.82 •Number of factors – 2
1 4 1.5 60-65 0.586 83.9
•Total number runs - 12
5 5 2.5 60-65 0.52 81
3 6 2 60-65 0.628 86.5
11 7 2.5 60-65 0.548 84.6
7 8 1.5 60-65 0.56 85.5
8 9 1.5 65-70 0.55 86
9 10 2 60-65 0.624 86.8
12 11 2.5 65-70 0.53 87
10 12 2 65-70 0.65 89.5
Responses
(Y’s)
DOE:Analysis of first set of Improve
experiments
Main Effects Plot (data means) for yield
Step-2
0.62
0.60
Mean of yield
Measure
0.52
Analyze 1.5 2.0 2.5 60-65 65-70
Improve
•DOE
Interaction Plot (data means) for yield
•Control 60-65 65- 70
0.65
M eO H
Vol
1.5
0.60 2.0
2.5
Me OH Vol
1.5 2.0 2. 5
DOE:Analysis of first set of Improve
experiments
Main Effects Plot (data means) for purity
Step-2
88
Mean of purity
87
86
85
Define
Measure 84
Analyze 1.5 2.0 2.5 60-65 65-70 Main effects and interaction effects
Improve shows that the purity is higher when the
•DOE setting is kept at 2 vol methanol with 65-
Interaction Plot (data means) for purity
•Control 60-65 65-70
70 deg C
90 MeOH
Vo l
1.5
88
2.0
2.5
MeOH Vol 86
84
82
90 Reflux
temp
88 60-65
65-70
86 Reflux temp
84
82
1.5 2.0 2.5
DOE:Analysis of first set of Improve
experiments Step-2
Factor Type Levels Values
MeOH Vol fixed 3 1.5, 2.0, 2.5
Reflux temp fixed 2 60-65, 65-70
•DOE
MeOH Vol = 2.02363
•Control 63 Reflux temp = 67.4690
purity = 89.6119
The contour plot also shows that purity of oxime is more at 2.023
vol of methanol at 67.5 deg C temperature (65-70)
DOE: First set of Improve
Step-3
experiments
Learning
•From the first set of DOE it is clear that methanol setting at 2 volume
and temperature setting at 65-70 deg C (reflux) gives the maximum
yield and purity.
•From earlier plant/R&D trials kit is clear that with more volume of
methanol yields are low.
Path forward
•Based on the result of first set of DOE it is decided to have a
confirmatory runs at the critical values to firm up the process as CCD is
not possible for temp range settings of 65-70 deg C.
•Experiments planned with both TiOC Methanol and Base Methanol at
R&D with new process parameter obtained from DOE
Improve
Actions taken Step 6
•First 6 batches demo given to plant with different batch sizes over a period of
time (TiOC : MeOH Rt)
•Next 10 batches were done by plant independently
0.61
Individual Value
0.60
_
X=0.59272
0.59
0.58
Define 0.57
Measure 0.56 LCL=0.55828
Analyze
0.55
Improve 2 4 6 8 10 12 14 16
Observation The plant demo batches ( TiOC
MeOH) shows that the mean yield is
I Chart of HPLC purity 0.592 with a average purity of
Control 96 87.92%
UCL=94.58
94
92
Individual Value
90
_
88 X =87.92
86
84
82
LCL=81.26
80
2 4 6 8 10 12 14 16
Observation
Improve
Actions taken Step 6
S ummar y for Y ield at plantTiOC Methanol
A nde rson -D arlin g N orm alit y T est
A -S q uared 0. 47
P -V a lue 0.2 14
M ea n 0. 592 72
S tD e v 0. 015 38
V aria nce 0. 000 24
S kew ne ss -0.7 804 60
K urto sis -0.1 844 92
N 16
M inim um 0. 560 00
1 st Q ua rtile 0. 581 20
Define M ed ian 0. 597 40
3 rd Q ua rtile 0. 603 80
Measure 0.56 0.57 0.58 0.59 0.60 0.61
M axi mu m 0. 613 60
Analyze 95 % C on fide nce In terv al f or M ea n
0 .58 453 0. 600 91
Improve 95% C onf iden ce Inte rv a l fo r M edi an
0 .58 694 0. 603 39
The graphical summary shows that with 95% confidence interval the
average yields will be between 0.584 to 0.601
Improve
Actions taken Step 6
Following batches were from Base MeOH route in the plant
AZD1
AZD1 Out put In Purity by
SL.NO Batch Size Potency Methanol TEA HAH Yield
Batch No Kg Hplc
Kg
1 078 100 954 200 53 47.5 77.5 0.775 90.94
2 082 100 954,951 200 53 47.5 75.2 0.752 93.95
5 091 100 967 200 53 47.5 72.2 0.722 92.79
6 092 200 967 400 106 95 152 0.76 91.25
7 104 100 967 200 53 47.5 77 0.77 90.78
8 105 200 967 400 106 95 154 0.77 92.3
Define
Measure Summary for Y ield Base MeOH Plant
A nderson-D arling N orm ality T est
Analyze A -S quared 0.50
P -V alue 0.123
Improve M ean 0.75817
S tD ev 0.01956
V ariance 0.00038
S kew ness -1.58170
K urtosis 2.51166
Control N 6
M inim um 0.72200
1st Q uartile 0.74450
M edian 0.76500
3rd Q uartile 0.77125
0.72 0.73 0.74 0.75 0.76 0.77 M axim um 0.77500
95% C onfidence I nterv al for M ean
0.73764 0.77869
95% C onfidence I nterv al for M edian
0.73271 0.77321
Median
•Two-Sample T-Test clearly shows the difference of the yields Before and after
modification of the process.
•After modification of process the yield is more than before modification of the
process
Improve
Actions taken Step 6
0.70
0.65
0.60
Before After
Case
The box plot shows the yield improvement after the process
change in the Base-Methanol Rt. and also the reduction in
yield variation
Control
Control Plan Step-1
Month Batch No Input Output yield Month Batch No Input Output yield Month Batch No Input Output yield
Oct-05 238 125 75 0.600 Nov-05 277 125 73.75 0.59 Dec-05 285 125 75 0.600
Oct-05 239 250 145 0.580 Nov-05 278 125 75 0.6 Dec-05 286 125 74 0.592
Oct-05 240 125 75 0.600 Nov-05 279 125 74 0.592 Dec-05 287 250 147 0.588
Oct-05 241 125 74 0.592 Nov-05 280 250 150 0.6 Dec-05 288 125 73 0.584
Oct-05 242 250 145 0.580 Nov-05 281 125 75 0.6 Dec-05 290 125 75 0.600
Oct-05 243 125 76 0.608 Nov-05 282 125 73.75 0.59 Dec-05 291 125 75 0.600
Oct-05 244 125 75 0.600 Nov-05 283 125 76 0.608 Dec-05 293 125 73 0.584
Oct-05 245 250 145 0.580 Nov-05 284 250 152 0.608 Dec-05 294 125 74 0.592
Oct-05 246 125 75 0.600 1250 749.5 0.600 Dec-05 298 125 75 0.600
Oct-05 247 125 76 0.608 Dec-05 299 125 75 0.600
Oct-05 248 250 145 0.580 Dec-05 301 125 75 0.600
Oct-05 249 125 75 0.600 Dec-05 302 125 75 0.600
Oct-05 250 125 75 0.600 Dec-05 304 125 75 0.600
Oct-05 251 250 145 0.580 Dec-05 305 125 77 0.616
Oct-05 252 125 75 0.600 Dec-05 310 125 77 0.616
Oct-05 253 125 75 0.600 Dec-05 311 125 76.6 0.613
Oct-05 254 250 150 0.600 2125 1271.6 0.598
Oct-05 255 125 75 0.600
Oct-05 257 250 150 0.600
Oct-05 263 125 74 0.592
Oct-05 264 125 76 0.608
Oct-05 265 250 152 0.608
Oct-05 266 250 151 0.604
4000 2379 0.595
The above data shows the yield of Q3 taken after three months of the
completion of the project for TiOC-MeOH
Control
Control plan Step-1
UCL=0.62195
0.62
0.61
Define
Individual Value
Measure
0.60 _
Analyze X=0.59772
Improve
0.59
Control
Control plan 0.58
LCL=0.57350
0.57
5 10 15 20 25 30 35 40 45
Observation
Individual Va lue
_
0.60 X=0.59772
0.58
LC L=0.57350
5 10 15 20 25 30 35 40 45 0.58 0.59 0.60 0.61 0.62
0.015
__
MR=0.00911
0.000 LC L=0
5 10 15 20 25 30 35 40 45 0.58 0.60 0.62
0.60
Cp 1.44 Overall
Pp 1.24
C pk 1.14 Ppk 0.98
C C pk 1.44 C pm *
0.58 Specs
25 30 35 40 45
Observation