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1、DOE ApplicationsDOE ApplicationsDOE ApplicationsDOE Applications Oct 16th 2002 ASQ Section 702 San Gabriel Valley by Dr Raj Palanna Objective of Talk Give a flavor for actual applications of DOE in industry Provide an insight into how complex theoretical concepts are applied in real world situations
2、 Build on the ASQ 702 September presentation DOE Basic Concepts by Dr Kurt Palmer Agenda Deep Dive 2 Examples Quick High Level Overview Few More Applications Q A These examples are taken from applications at different companies Some of the data and facts have been coded to protect proprietary inform
3、ation 1 ECS Pack Switch Failure Investigation Starting February 2002 until April 2002 a total of 21 switches have been rejected at XXX Aircraft Company s aircraft test line for failure to open at max 200 deg F Shipments of multi million dollar aircraft are at risk Key Planning Aspects Immediate cont
4、ainment actions taken Teams working at 3 tiers of supply chain Evaluate the usual suspects Testing setup and process Manufacturing process Application at system level etc Different schools of quality uses slightly different methods for this exercise This presentation will concentrate only on the DOE
5、 aspect of the problem DOE Problem Statement Parts that failed at customer passed at supplier test process Test method is a suspect A DOE was set up to understand the sensitivity of switches to the test parameters 6 Parts were chosen for DOE 3 New 3 Rejected DOE Pre planing A complex DOE THOUGHT MAP
6、 was developed Factor Selection Response Selection Measurement Repeatability Studies Noise Impact Confounding Randomization Resource Logistics Management Approvals Observation Copious Notes etc DOE Orthogonal Matrix Building Exercise You Have Been Tasked to Optimize Gas Mileage on Your Car Team Need
7、s to Test 4 Factors Has Resources for 8 Runs Res IV Confounded Design in Acceptable Don t worry if you don t understand this bullet What is the DOE Matrix DOE Matrix Factor AFactor BFactor CFactor DResponse Run Test Depth of Switch Plate Ramp Rate Oil Type Viscosity Flow Mounting Technique Output SN
8、 1 Output SN 2 Output SN 3 Output SN 4 Output SN 5 Output SN 6 Average Good Average Rejected Average Total 11Submerged2 DC 200 10CSTThreaded188 2187 9187 9191 8191 6191 8188 0191 7189 9 72 Not Submerged2 DC 200 10CSTSet On190 3188 5188 4213 3219 4220 2189 1217 6203 4 63Submerged10 DC 200 10CSTSet On
9、188 8188 7188 0203 2207 5209 1188 5206 6197 6 84 Not Submerged10 DC 200 10CSTThreaded188 7188 0187 3195 3200 6200 5188 0198 8193 4 35Submerged2 DC 210 100CSTSet On192 8190 6190 8215 6222 0222 0191 4219 9205 6 56 Not Submerged2 DC 210 100CSTThreaded190 9189 9191 0207 8212 7212 9190 6211 1200 9 27Subm
10、erged10 DC 210 100CSTThreaded189 0187 9189 3204 4213 7213 8188 7210 6199 7 48 Not Submerged10 DC 210 100CSTSet On199 6191 6195 4253 1246 4250 8195 5250 1222 8 24 1ResIV 01020 AC AB B AD A C D Pareto Chart of the Effects response is REJECTED Alpha 30 A Plate B Ramp Rat C Oil Type D Mounting 20 100102
11、0 1 5 1 0 0 5 0 0 0 5 1 0 1 5 Effect Normal Score C D Normal Probability Plot of the Effects response is REJECTED Alpha 30 A Plate B Ramp Rat C Oil Type D Mounting DOE Analysis Rejected Switches Average Trigger Temperature PlateRamp RateOil TypeMounting Not Submerged Submerged 2 10 DC 200 10CST DC 2
12、10 100CST Set On Threaded 204 209 214 219 224 REJECTED Main Effects Plot Boeing Rejected Switches F Type of TESTING OIL C influences test results and Type of MOUNTING D influences test results 2 10 DC 200 10C DC 210 100 Set On Threaded 190 200 210 190 200 210 190 200 210 Plate Ramp Rate Oil Type Mou
13、nting Not Submer Submerged 2 10 DC 200 10C DC 210 100 Interaction Plots Boeing Rejected Switches F DOE Analysis New Switches Average Trigger Temperature 0123 B AD AC AB A D C Pareto Chart of the Effects response is GOOD Alpha 30 A Plate B Ramp Rat C Oil Type D Mounting 3 2 10123 1 5 1 0 0 5 0 0 0 5
14、1 0 1 5 Effect Normal Score C Normal Probability Plot of the Effects response is GOOD Alpha 30 A Plate B Ramp Rat C Oil Type D Mounting 2 10 DC 200 10C DC 210 100 Set On Threaded 188 0 190 5 193 0 188 0 190 5 193 0 188 0 190 5 193 0 Plate Ramp Rate Oil Type Mounting Not Submer Submerged 2 10 DC 200
15、10C DC 210 100 Interaction Plots Good Switches F PlateRamp RateOil TypeMounting Not Submerged Submerged 2 10 DC 200 10CST DC 210 100CST Set On Threaded 188 5 189 3 190 1 190 9 191 7 GOOD Main Effects Plot Good Switches F No Impact of Factors A B C and D on New Switches 180185190195200205 LSLUSL Test
16、 Parameters Outside ATP Trigger Temp Spread 14353 USL Target LSL Mean Sample N StDev ST StDev LT Cp CPU CPL Cpk Cpm Pp PPU PPL Ppk PPM USL PPM Total PPM USL PPM Total PPM USL PPM Total 200 000 180 000 191 037 8 2 81155 3 90992 1 19 1 06 1 31 1 06 0 85 0 76 0 94 0 76 0 00 0 00 0 00 43 23 716 94 760 17 2379 21 10945 68 13324 89 Process Data Potential ST Capability Overall LT CapabilityObserved PerformanceExpected ST PerformanceExpected LT Performance ST LT 185187189191193 LSLUSL Test Parameters Ou
