Use of Six Sigma Tools in the Commercial Scale-up of a Novel PPE Copolymer

Poly(phenylene ether) is an engineering thermoplastic known for its excellent hydrolytic stability, dimensional stability and inherent flame retardancy. A block copolymer  produced by the oxidative coupling polymerization of 2,6 xylenol and a comonomer, has been developed to deliver significant improvements in mechanical properties and flame retardancy.

Process development for new technology to culminate in production in an existing operating commercial chemical plant requires conscientious planning and risk mitigation efforts. This presentation illustrates the evolution of this commercial scale up effort as a Six Sigma project. Special emphasis is done on the application of Six Sigma tools and their impact on the planning of the project requirements, risk mitigation, and implementation analysis and control.