Manufacture of plasticizer. Normally, the product is made in batches, and the reaction is allowed to continue until a certain viscosity is obtained. The unit manager desired that this reaction take from seven to nine hours. The plant was experiencing other problems, which led to the reaction proceeding too fast. The fast reaction time resulted in batches that were difficult to control and product of unacceptable viscosity. The purpose of the experiment was to find a combination of the percentage of a key Ingredient X and the reaction temperature that would result in a reaction that proceeded at the desired rate.

The response variable was the reaction time necessary to reach the desired viscosity. There were two factors under study: the percentage of Ingredient X and the reaction temperature. The levels for the ingredient were chosen at 42% and 48%. The temperature levels were chosen at 175°C and 195°C.

Several background variables were considered. The experiment was initially conducted in the laboratory, so confirmation of the results in the plant would be necessary. The rate of heat-up was controlled by a temperature programmer. One laboratory operator was used. The difference in blends of X was handled by completing the experimental pattern using only one blend of X.

For this experiment, two replications of the experimental pattern were run. An adequate amount of Ingredient X was obtained and mixed so that the four combinations of the two factors needed for one replication of a 22 pattern could be performed using a homogeneous blend of Ingredient X. The second replication of the pattern was performed using a blend of Ingredient X from a different shipment. The order of the four runs in each replication was randomized separately, using a table of random permutations.

The data collection form for the experiment follows.

1. Use the information above to complete a documentation form for a planned experiment.
2. Analyze the data to determine the cause-and-effect system at work.
3. Recommend settings for running the process and give your reasons for suggesting the settings.
4. Would you recommend another PDSA Cycle? What would it be?

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Data Collection Form for the Plasticizer Experiment Batch ID Percentage of X Temperature Reaction time Replication 1 (Blend 1 of X) 1 42 195 5.5 2 42 175 9.0 3 48 175 9.0 4 48 195 1.5 Replication 2 (Blend 2 of X) 5 42 195 6.5 6 48 195 1.0 7 42 175 9.5 8 48 175 8.0