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GOLDEN
ALUMINUM Increases Production Effectiveness “I must tell you that most people in our
plant are very impressed with ULTRAMAX®. I have been able to reduce
a particular quality defect (edge cracks off the Hot Mill) by 78%. No
one including myself has been able to do that in 20 years of operating this
plant.” Larry Hopkins, Perpetual
Improvement Manager Golden Aluminum, Fort
Lupton, CO. March 26, 2007. Procter & Gamble
Optimizes Manufacturing Operations Using ULTRAMAX® Technology “The decision to integrate ULTRAMAX
sequential optimization method and technology into Procter & Gamble manufacturing
processes underscores our commitment to accelerating cost reduction,”
says Cy Wegman, Optimization Specialist, P&G Corporate Engineering
Technical Laboratory. “Our past experience using the ULTRAMAX method
and technology has shown substantial improvements in operating performance
and bottom line profits.” ULTRAMAX dynamic optimization technology
adjusts process settings to improve performance according to defined
objectives and operational constraints. The process operates reliably within
safety, capacity and regulatory constraints, achieving continuous
improvements in product quality and throughput while reducing energy and raw
material consumption, emissions and waste. The Procter & Gamble Co., headquartered in Founded in 1982, the Ultramax Corporation, also
headquartered in For public release, P&G Alpharma Increases Fermentation Yield by 20% with ULTRAMAX “I consider ULTRAMAX to be the best system
one could employ to make rational process control adjustments, with those
changes quickly resulting in measurable (predefined) improvements. Of equal importance, these changes
will result in a more robust, profitable and predictable process. “I am responsible for improvements in our
large-scale fermentation process.
Over the years, I have tried various non-linear modeling methods to
make the necessary improvements in the process, as well as attempt to
establish a higher level of predictability. Before ULTRAMAX, process improvements
were frustratingly slow in coming and the results offered low predictability
for two reasons: 1) a change in one or more uncontrolled inputs occurred
during the course of obtaining the data that required additional tests to be
run, and, 2) the control (decision) input changes had to be small so as to
not cause a process failure, thus the outputs had very low signal to noise
ratios. “The moment I was introduced to the ULTRAMAX
concepts I knew deep down that this was the answer for which I had been
searching. In the few years I
have used it, my fermenter yield (on a near 50-year-old process) has
increased by over 20%, with variability decreasing by over 50%. The decrease in variability has
allowed me to "see" other variables that were impacting our
process, and when changed, increased the robustness of the process.” Dr. Michael Barder,
Alpharma IBM Accelerates Process
Design and Improves Production
Performance with ULTRAMAX “ULTRAMAX … has been effectively used
by IBM to rapidly model and optimize existing processes, as well as
efficiently develop (from zero knowledge) high performance processes to
standards not previously experienced.
Successful applications have been encountered in photolithography, dry
etching, film deposition, thermal processing and ion implantation, with no
failure of the software or its sequential optimization methodology
observed. Final process yield
improvement and process variability reduction are to be expected via this
technology.” Bob McCafferty, IBM. |
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