Description of Techniques
This section addresses the benefits, project experience, DOE techniques available and typical DOE equation formats obtained.
What are the benefits
- Can save money - typically about $40k for new users
- Reduce schedule – by months
- Meet challenging requirements – not just small incremental improvements
- Reduce risk – gain product and process understanding
- Can also solve problems in manufacturing or in the field – but this should not be the primary focus of company DOE implementation to obtain maximum gain
- Robust design capability
- Identify stable process settings
- Identify design parameter settings to meet requirements
- Understand impact of tolerances – capability
- Scale solutions for other applications
- Develop company Intellectual Property
A Sample of Projects:
- Welding, web processes, heat treat, stamping
- Molding plastic and rubber, foaming (gaskets, diaphragms and piece parts)
- Adhesive in assembly, epoxy curative reaction, powder coating colorization, adhesive delivery
- Plating, vapor deposition, cleaning, soldering, polishing
- Laser cutting and surface grinding equipment
- Medical fluid sampling equipment
- Electronics, composites, food, control systems
- Seal repeatability, product durability/ reliability
- Office process flow, process waste, manufacturing simulation
- Analysis of hydraulic, thermal and molding systems
"143 of these projects saved an estimated $6,104,000."
Description of Techniques and Approach:
Perry’s Solutions, LLC, has a set of skills to improve products and processes already in manufacturing as well as to develop products and processes in the development stages. The definition of DOE promoted is “a tool to assist in the process of understanding a system.” It is important to understand how DOE fits into the overall product lifecycle and where it applies in the area of testing. DOE tools available include full and fractional factorials, central composite, Box-Behnken, Taguchi, Evolutionary Operation method of steepest ascent, mixture and D-Optimal designs. A standard, simple process will be presented which allows for improved communication and user confidence in using the tool set. This is an application-orientated course.
DOE related areas also supported include Statistical Process Control (SPC), Gage R&R, Quality Function Deployment (QFD), Risk Analysis, Failure Modes and Effects Analysis (FMEA), Project Cost Estimating, Monte Carlo and decision analysis.
Typical Equations for 3 variables A, B and C (determined via t-test):
where y is an output, z is an offset factor and the remaining small letters are coefficients.
One Factor At a Time (OFAT) typical output (main effects)
y = z + a*A + b*B + c*C
DOE Factorial typical output (main effects and interactions)
y = z + a*A + b*B + c*C + d*A*B + e*A*C + f*B*C + g*A*B*C
DOE Response Surface typical output (main effects, interactions, quadratic)
y = z + a*A + b*B + c*C + d[A]² = e[B]² + f[C]² + g[AB] +h[AC] + i[BC] + j[ABC] +p[A]³ + q[B]³ + r[C]³ + s[A²B] + t[AB²] + u[A²C] + v[AC²] + w[B²C] +x[BC²]
Contact Us
E-mail
info@perryssolutions.com
Phone
651-230-3861
Mail
2938 Marine Circle
Stillwater, MN 55082