Design for Six Sigma (DFSS) Approach to Copolymer Process Development

The SABIC Innovative Plastics LEXAN* polycarbonate business has introduced several new copolymer platforms into existing resin manufacturing assets in the past decade.   These new copolymers expand the application space of traditional polycarbonates and allow business growth into new applications.  Commercialization of new copolymers involves developing processes that address challenges due to copolymer chemistry, new product requirements, and fit with existing assets and investment constraints. Having a systematic and proactive methodology that provides “designed in” process capability and product quality is critical to successful process and product scale-up. The Design for Six Sigma (DFSS) methodology provides such a framework and set of tools to ensure success by design. This paper will survey critical tools for managing scale-up and product performance requirements.  An example of development and scale-up of one of these copolymers will be reviewed.

* LEXAN is a registered trademark of SABIC Innovative Plastics LLC