DOE Application - Roadmap&Examples RKR
DOE Application - Roadmap&Examples RKR
DOE Application - Roadmap&Examples RKR
Ranjit k. Roy
Nutek, Inc.
3 829 Quarton Road,Bloomfield Hills, MI 48302. USA.
Email: Support@Nutek-us.com www.Nutek-us.com
Content:
- Project Identification
- System definition
- Experiment planning
- Etc.
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-Chinese Proverb
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Slide # 4
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4. Review Process
Review Process Flow and Define
Flow System for Study
Form Team
• First-hand knowledge
5. Form Team
• Customer/supplier
• Stake holders
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Identify Project
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Define System
- Outputs (Objectives)
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Input Output
System
Note: OUTPUT of previous sub-process is INPUT to the next. For example: Batter is output
of MIXING process, but input to the BAKING process.
The process flowchart was first introduced by Frnak Gilbreth in 1921. He used it
show as a graphical and structured method for documenting process activities.
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Agenda
- Project Logistics
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Analyze Test
Project Team & Advisor 3 Results and
Prescribe
Carry Out Solutions
Planned Tests
and Collect
2 Results
Design and
1 Describe Test
Recipes
Hold
Experiment
Planning
Discussions
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C1: Taste 0 8 B 60
C2: Moistness 25 – 70 gms 40 gms. N 25
C3: Voids/Smoothness 6 0 S 15
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OEC formulation require that (1) All criteria have the same direction of desirability, (2) Readings are
expressed in ratios, and that (3) Each criteria gets include its own weighting.
C1 C2 – C2-nom C3
OEC = x Wt1 + ( 1 - ) x Wt2 + (1 - )x Wt2
C1range C2b – C2-nom C3range
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Plan Experiment
Agree on a Title
Define objectives Design Experiment
◦ Evaluation criteria &QC Select appropriate orthogonal
Analyze Results
◦ Relative weighting array Compute average and
◦ Table of Eval. Criteria Assign factors to the columns standard deviation
Brainstorm for factors Readjust array selection if Calculate grand average
◦ Long LIST necessary Calculate factor averages
◦ Qualified List (Ordered) Describe trial conditions Plot factor average effects
◦ Study List Establish number of samples Analyze results
tested in each trial condition
Establish Factor levels ִ Factor influence
Create DATA COLLECTION
◦ How many levels ִ Optimum condition
sheet
◦ 2-level strategy ִ Predicted performance
Prepare any special
◦ 3-level strategy improvement
instruction for test and data
Identify Interactions handling
◦ Two factor interaction Determine other
recommendations and
◦ Strategy
conduct CONFIRMATION
Consider Robust Design TESTS
◦ Noise factors
Assign TASKS for project
completion
◦ Who does what?
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Project Title
• Contains process description (Spells out goals)
• Brief description of problem – PROBLEM STATEMENT
Objectives
• What we are after (one or more)
• How are they evaluated
• What is the units of measurement
• What direction is the results desired
• If multiple objectives, details of each and their relative weights
Data Reduction Scheme for Multiple Objectives
• Pareto chart for objectives
• Need for a single index (OEC)
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Materials Machine
• Natural Gas • Furnace
• Filters
• Propane • Humidifies
• Oil/Hot water
Method Man
• Duct Cleanliness • Temperature Setting
• Fireplace
• Vents Open & Close • Late night Stay
• Space Heaters • Lack of Worm Clothes
• Insulation • Excessive door open/close
• Window Glass
Mother Nature
Measurement • Too many clod days
• Meter Reading Error • Windy nights
• Leaky Gas Tube • Storm and Rain
• Thermostat Control
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Ref. Page 9 - 32
Create Process Diagram (or P-Diagram)
Double-click here to start defining
DC parameters (shows first screen
below).
System Configuration or Process Diagram (P-Diagram)
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1 x x x x x x
2 x x x x x x
1 x x x x x x
2 x x x x x x
1 x x x x x x
2 x x x x x x
1 x x x x x x
2 x x x x x x
Details of Activities in
Step 3
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Details of Activities in
Step 4
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Details of Activities in
Step 5
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Identify Projects Appoint Leader Set Objectives Define System Form Team
- Higher ROI - Project - Achievable - Clear boundary - First-hand
- Can be done ownership - Implementable - Relates to knowledge
- Value to - Process - Team consensus issues - Customer &
stakeholders knowledge - Keeps focus supplier
- Work as team - Narrower - Stakeholders
Plan Experiment Design Expts Run Tests Analyze Results Confirm Recmd.
-Results & QC - Array - Order of tests - Main effects - Sample size
- Criteria of - Test description - Sample size - ANOVA - Validation
evaluations - Samples/trial - Results - Optimum & C.I. - Lessons learned
- Factors & Levels - Data collection recordings - Improvement - Future tasks
- Interaction - Multiple criteria - Loss/Savings
-- Noise factors
-- Logistics
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Testimonials: http://nutek-us.com/wp-q4w-eval.html
Nutek Client List: http://nutek-us.com/wp-nut.html
Nutek, Inc.
3 829 Quarton Road
Bloomfield Hills, MI 48302. Tel : 1-248-812-2071
Email: Support@Nutek-us.com www.Nutek-us.com
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-Chinese Proverb
Slide # 45
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I. Experiment Planning
Project Title - Adhesive Bonding of Car Window Bracket
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I. Experiment Planning
Project Title - Die-Casting Process Parameter Study (CsEx-01)
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I. Experiment Planning
Project Title - Clutch Plate Rust Inhibition Process Optimization Study
(CsEx-05)
The Clutch plate is one of the many precision components used in the
automotive transmission assembly. The part is about 12 inches in
diameter and is made from 1/8-inch thick mild steel.
Objective & Result - Reduce Rusts and Sticky
(a) Sticky Parts – During the assembly process, parts were found to be
stuck together with one or more parts.
(b) Rust Spots – Operators involved in the assembly reported
unusually higher rust spots on the clutch during certain period in the
year.
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I. Experiment Planning
Project Title - Piston Bearing Durability Life Optimization Study
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I. Experiment Planning
Project Title - Adhesive Bonded Joint Strength Study
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I. Experiment Planning
Project Title - Study of Tenacity of Staple Viscose Fiber
Viscose is the man made fiber with excellent properties that can be engineered and
optimized for different textile and non-woven applications. The name was adopted
(1924), in preference to "artificial silk", by the U.S. Dept. of Commerce and various
commercial associations. Cellulose from wood pulp, washed, bleached, and pressed
into sheets, is dissolved by chemicals, then forced under pressure through minute
holes in a metal cap (spinneret), emerging as filaments that unite to form one
continuous strand solidified by passage through a suitable liquid or warm air.
Various stages of viscose fiber offer opportunities for process optimizations.
Objective & Result - Increase tensile strength of fiber
Quality Characteristics - Bigger is better (B)
The tensile strength of individual fiber is measured in terms of gram force/denier
(typically 2.5 - 2.7 gm weight/denier). A denier is a measure of weight of 9000 meter
long strand of fiber in grams (typically 1.2 - 1.5 gm/9000m).
Factors and Level Descriptions
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I. Experiment Planning
Project Title - Study of In Vitro Strength of CORTOSS Bone Void Filler
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I. Experiment Planning
Project Title - Wound Care Product Design Study
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I. Experiment Planning
Project Title - Bow & Arrow Tuning Study
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I. Experiment Planning
Project Title - Race Car Suspension Parameter Optimization
Factors and Level Descriptions: (Source: USA Today, February 15, 2002)
A:Right Front Tire Pressure (23 - 55 psi) Green = Superspeedway
B:Left Front Tire Pressure (15 - 30 psi)
C:Right Rear Tire Pressure (20 - 50 psi)
D:Left Rear Tire Pressure (15 - 30 psi)
E:Right Front Spring Rate (1,900 - 800 lbs/in)
F:Left Front Spring Rate (700 - 800 lbs/in)
G:Right Rear Spring Rate (225 - 350 lbs/in)
H:Left Rear Spring Rate (15 - 30 lbs/in)
I:Rear Spoiler Angle (0 - 55 degrees)
II. Experiment Design & Results
Up to 11 factors as shown above can be studied by designing an
experiment using an L-12 array.
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Key observations:
1. The combination of parameters (Optimum Condition) which is likely to produce
minimum variation in pad flatness is
OPTIMUM CONDITION (2000 rpm, 4mm nose radius, .008/in feed, and 2 passes at
.010in)
OPTIMUM CONDITION (2000 rpm, 4mm nose radius, .008/in feed, and 2 passes at .010in)
2. The influential factors are (four factors tested are shown in order of their influence):
Feed Rate (63.4%)
Check Speed (12.7%)
Tool Nose Radius (7.3%)
Finish Passes (4.3%)
The percentages within the parentheses represent the influence of the factors to the
variation of the result.
3. Chuck Speed (1000, 1500, and 2000 rpm) affects results in a nonlinear manner. For
both Range and Std. Deviation, 1500 rpm is worse than either of 1000 or 2000 rpm. All
other factors appear to influence results in a linear manner (see plot of Main effects).
4. When the new process design is implemented, the reduced variation will result in less
number of wheel require rework (or rejected). Using the average (of all 9 trial condition)
performance as a reference, the cost savings expected is,
Expected Savings = 80 %
The above represents savings in cents for every dollar that would be spent when the
performance is at a level equal to the average of all the 9 trial conditions
Recommendation:
To confirm the prediction based on the experimental results, please setup the process
condition identified above (optimum condition) and fabricate 7 or more wheels in the
same manner as the original samples. Evaluate and record results as before (Range and
std. deviation).
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Type of Analysis
Standard and S/N analysis performed.
Both types of analyses confirmed the conclusion about the optimum
condition.
The expected values (Std. Dev. And Range) at the optimum condition are
specified based on conservative estimate from both analyses.
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Notes:
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