Chemical deviation management: how to effectively deal with the problem of unqualified quality

in the chemical production process, quality control is always the top priority. Due to various reasons such as unstable quality of raw materials, fluctuations in process parameters, and differences in operator skills, chemical deviations occur from time to time, which may lead to unqualified final products. Faced with the problem of unqualified quality, how to quickly locate the source of deviation, effectively deal with deviation, and prevent future recurrence has become an urgent problem for chemical practitioners to solve. This paper will analyze how to build an effective deviation management mechanism from three aspects: the source of chemical deviation, the treatment process and the prevention strategy.

Analysis of the Source of 1. Chemical Deviation

the generation of chemical deviation is often closely related to multiple links, the specific reasons mainly include the following aspects:

1. the quality of raw materials is unstable: the fluctuation of raw material quality is an important cause of chemical deviation. If the raw materials contain impurities, impure components or changes in physical and chemical properties, they may directly affect the key indicators in the production process.

2. Process parameter control is not strict: chemical production involves a number of process parameters, such as temperature, pressure, flow and so on. If these parameters do not fluctuate within the set value range, it may cause the chemical reaction to deviate from the expected, resulting in product performance changes.

3. As of release time: July 1, 2024, operator skill difference: the proficiency and professional skills of operators directly affect the stable operation of the production process. Errors in the operation of new workers or temporary workers can lead to deviations.

4. Equipment aging or maintenance is not in place: The aging or long-term operation of the equipment will cause performance degradation, affect the control of reaction conditions, and cause chemical deviations.

5. Missing or inadequate implementation of management measures: the lack of effective quality control and deviation handling mechanisms may lead to accumulation and amplification of deviations.

For these sources of deviation, the establishment of a comprehensive quality control system is essential. By installing an online analyzer and real-time monitoring equipment, the changes of key parameters can be detected in time, and the deviation signal can be effectively captured. Regularly train operators to improve their skills and reduce deviations caused by human factors.

2. deviation processing flow

once the chemical deviation is confirmed, taking the correct treatment measures in time is the key step to reduce the loss and ensure the product quality. The following is a common deviation handling process:

1. analysis of Deviation Reasons:

• data analysis: By collecting and analyzing deviation data, find out the time, frequency, trend and other information of deviation occurrence, and provide a basis for deviation positioning.
• backward analysis: Starting from the result of the final product failure, reverse the possible causes and gradually narrow the deviation range.
• causal analysis: The causal analysis method is used to establish the causal relationship between deviation and operating parameters and equipment status, and to clarify the key control points.

1. Deviation Data Record:

• record the deviation in detail: including the time, location, cause and degree of impact of the deviation.
• Record processing measures: Record the deviation treatment measures and their effects in detail to provide a basis for future deviation prevention.

1. Adjust and optimize process parameters:

• parameter optimization: According to the deviation analysis results, adjust the process parameters, optimize the reaction curve, and improve the stability of the production process.
• Validation Validation: After adjusting the parameters, process verification is carried out to ensure the effectiveness of the optimization measures.

1. Summary of the double disk:

• summary of experience: Analyze the experience and lessons learned in the process of deviation handling, and summarize the successful practices and failures.
• Develop an improvement plan: According to the summary results, formulate practical improvement plans to ensure that similar deviations do not occur again.

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prevention and Management Strategy of 3. Deviation Management

in order to fundamentally solve the problem of unqualified quality, the prevention and management strategy of deviation management is very important. The following are common prevention strategies:

1. strengthen supplier management:

• supplier Audit: Strictly audit the qualification of raw material suppliers to ensure that the quality of raw materials meets the standards.
• Building supplier relationships: Establish long-term and stable cooperative relations, sign quality agreements with suppliers, and jointly improve the quality of raw materials.

1. Optimize process flow:

• process optimization: Regularly optimize the process to reduce the impact of fluctuations in process parameters on product performance.
• Equipment calibration: Regularly calibrate and maintain the equipment to ensure that the equipment is in good condition and reduce the deviation caused by equipment aging.

1. Strengthen quality control:

• establish quality traceability system: Establish a full life cycle traceability system from raw materials to finished products to detect and handle quality abnormalities in time.
• Implement QC sampling plan develop a scientific QC sampling plan to ensure that each key parameter is monitored and tested on a representative basis.

1. Perfect management measures:

• develop a deviation management plan according to the actual situation of the enterprise, formulate a feasible deviation management plan and clarify the responsibilities of various departments and personnel.
• Strengthen management training: Organize regular management training to improve the quality management awareness and ability of managers.

Through the above measures, chemical deviation can be effectively prevented to ensure the stability of the production process and the reliability of product quality. Only by establishing a perfect deviation management mechanism can we achieve sustainable development in chemical production.