Spein J Mold 2009

Experimental
Experimental Design
Design For
For
Injection
Injection Molding
Molding
Launsby
Launsby Consulting
Consulting
2009
2009
4/2/2009 1 Launsby Consulting

Bob
Bob Launsby
Launsby Bob@launsby.com
Taught
Taught experimental
experimental design
design toto several
several
thousand
thousand people
people
Participated
Participated in
in numerous
numerous actual
actual
experiments
experiments
Application
Application is
is key
key
Co-developer
Co-developer of of DOE
DOE Wisdom
Wisdom software
software
Co-Author
Co-Author of
of DOE
DOE for
for Injection
Injection Molding
Molding
www.launsby.com

Introductions
Introductions
Name
Name
Title
Title
Background
Background in
in Injection
Injection Molding
Molding
Previous
Previous Courses
Courses
Cavity
Cavity Pressure
Pressure Control?
Control?
Previous
Previous Experiences
Experiences with
with Experimental
Experimental
Design
Design and
and Statistics
Statistics

Course
Course Guidelines
Guidelines
Start
Start and
and Stop
Stop Times
Times
Breaks
Breaks
Active
Active Participation
Participation
You
You are
are Responsible
Responsible for
for Learning
Learning
Importance
Importance ofof Applications
Applications
Having Fun
Having and Learning
Fun and Learning

Module
Module One
One
Goals:
Goals:
Understand
Understand the
the Building
Building Blocks
Blocks for
for aa
Fundamentally
Fundamentally Robust
Robust Molding
Molding Process
Process
Understand
Understand the
the Need
Need forfor Modern
Modern Design
Design ofof
Experiments
Experiments Techniques
Techniques
Recognize
Recognize the
the Power
Power andand Applicability
Applicability of
of
These
These Approaches
Approaches toto Injection
Injection Molding
Molding
Understand
Understand the
the Basics
Basics

The Injection Molding
Challenge

The
The Challenge
Challenge
(Cont.)
(Cont.)
Complex
Complex Part
Part Geometry,Many
Geometry,Many Finishes
Finishes
Varying
Varying Wall
Wall Thickness
Thickness
Snap
Snap Fits,
Fits, Threads
Threads
No
No Secondary
Secondary Operations
Operations
Consistency,
Consistency, High
High Prod.
Prod. Rates
Rates
Regrind
Regrind
Tight
Tight Tolerances,
Tolerances, Cost
Cost Competition
Competition
QS
QS 9000,
9000, Process
Process Validation
Validation
The
The Process
Process Diagram
Diagram

Process
Process Diagram
Diagram
PROCESS DIAGRAM FOR

INJECTION MOLDING
Some Potential Factors Potential Responses

Material Lot Dimensions
Material Variation Color
% Regrind Black Specks
Hold Pressure Warpage
Pellet Geometry Blisters
Plastic Temperature Blush
Screw RPM Knit Lines
Injection Velocity Sinks
Basic
Basic Understandings
Understandings
Before
Before Doe
Doe
Non-Newtonian
Non-Newtonian Behavior
Behavior of
of Plastic
Plastic
Static
Static Pressure
Pressure Loss
Loss
Relative
Relative Viscosity
Viscosity Curves
Curves
Semi-Crystalline
Semi-Crystalline Vs.
Vs. Amorphous
Amorphous Materials
Materials
Hygroscopic
Hygroscopic and
and non-hygroscopic
non-hygroscopic
Materials
Materials
Shear
Shear Heating
Heating
Fountain
Fountain Flow
Flow
Four
Four Plastic
Plastic Variables
Variables
Static
Static Pressure
Pressure Loss
Loss
CAVITY SCREW
RUNNERS SPRUE
TRANSDUCERS
Where is Plastics Pressure Greatest?

Where is it the Least?
Source: RJG, Inc.

Relative
Relative Viscosity
Viscosity
THICK
High sensitivity to
machine fill speed
fluctuation
VISCOSITY
Crossover point
Low sensitivity to
machine fill speed
fluctuation
THIN
SLOW FLOW RATE FAST
4/2/2009 Source: RJG, Inc.

12 Launsby Consulting
Crystalline
Crystalline Vs.
Vs. Amorphous
Amorphous
Crystalline
Crystalline (Semi-Crystalline)
(Semi-Crystalline)
Melt
Melt is
is Amorphous
Amorphous -- Forms
Forms Crystals
Crystals on
on Cooling
Cooling
More
More Crystalline
Crystalline == More
More Shrinkage
Shrinkage
Fast
Fast Cooling
Cooling -->
--> Less
Less Time
Time to
to Form
Form Crystals
Crystals ----
>> Less
Less Crystallinity
Crystallinity -->
--> Less
Less Shrinkage
Shrinkage
Amorphous
Amorphous
Both
Both Melt
Melt and
and Solid
Solid are
are Amorphous
Amorphous
Cooling
Cooling Rate
Rate Not
Not Related
Related to
to Shrinkage
Shrinkage
Source: RJG, Inc.
Fountain
Fountain Flow
Flow
Fountain
FountainFlow,
Flow,Skin
SkinLayer,
Layer,and
andAlignment
Alignment
Source: RJG, Inc.

Four
Four Plastic
Plastic Variables
Variables
Plastic
Plastic Flow
Flow Rate
Rate
Plastic
Plastic Temperature
Temperature
Plastic
Plastic Cooling
Cooling
Plastic
Plastic Pressure
Pressure Gradient
Gradient

Before
Before Attempting
Attempting DOE
DOE
Is the materials dry?
Set
Set Melt
Melt Temps
Temps at
at Nominal
Nominal
Position
Position Transfer
Transfer Check ring leakage?
Fill
Fill Fast
Fast (But
(But No
No Faster),
Faster), Fill
Fill With
With Ample
Ample First
First
Stage
Stage Pressure
Pressure
Relative
Relativeviscosity
viscositycurve
curve
Fill
Fill 95%
95% toto 99%,
99%, Then
Then Transfer
Transfer to
to Pack
Pack
Hold
Hold Plastic
Plastic in
in Tool
Tool
Understand
Understand WhenWhen Gate
Gate Seals
Seals (gate
(gate seal
seal test)
test)
Cool Efficiently
Cool Efficiently Clogged cooling
lines???
Demold
Demold Quickly
Quickly and
and Consistently
Consistently
What
What Is
Is A
A Designed
Designed
Experiment?
Experiment?
Systematic,
Systematic, Controlled
Controlled Changes
Changes ofof the
the
Inputs
Inputs (factors)
(factors) to
to aa Process
Process in
in Order
Order toto
Observe
Observe Corresponding
Corresponding Changes
Changes in in the
the
Outputs
Outputs (responses).
(responses).

Types
Types Of
Of Factors
Factors
Constant
Constant Factors
Factors
Control
Control Factors
Factors
Noise
Noise Factors
Factors (Robustness)
(Robustness)

What
What Do
Do We
We Learn
Learn From
From
Designed
Designed Experiments?
Experiments?
Best
Best Settings
Settings
Sensitivity
Sensitivity

Why
Why Do
Do Designed
Designed
Experiments?
Experiments?
50
50 Per
Per Cent
Cent Improvement
Improvement in
in
Efficiency
Efficiency and
and Effectiveness
Effectiveness
11 ++ 11 == 10
10

How
How To
To Be
Be Good
Good At
At ItIt
Attend
Attend Training
Training
Read
Read
510
510 Rule
Rule

Engineering
Engineering Experimental
Experimental
Design
Design
Not
Not aa Substitute
Substitute For
For Knowledge
Knowledge of
of
Technology
Technology
Incorporates
Incorporates Current
Current Understanding
Understanding
Physics
Physics First
First
IfIf You
You Do
Do Not
Not Understand
Understand the
the Basics,
Basics, You
You
Will
Will Do
Do EVIL
EVIL Things
Things With
With DOE
DOE

Examples
Examples Of
Of Poorly
Poorly Done
Done
Does
Does
Quality
Quality Digest
Digest of
of 1999
1999
Injection
Injection Press
Press
Gates
Gates
Barrel
Barrel Temps
Temps
Moisture
Moisture Content
Content
Randomization,
Randomization, Replication
Replication

An
An Example
Example
Hinged
Hinged Box,
Box, 100
100 ton
ton Press
Press
Thickness
Thickness is is .070
.070 in
in
Length
Length isis response
response
Polypropylene
Polypropylene
Single
Single Cavity
Cavity MoldMold
Set
Set Transfer
Transfer Point
Point and
and Performed
Performed Gate
Gate
Seal
Seal Test
Test
Fix
Fix Settings
Settings (except
(except mtemp
mtemp and
and hpress)
hpress)
An
An Example
Example
RUN Mtemp H Press Length

1 70 5000 15
2 70 7000 19
3 90 5000 12
4 90 7000 17

Pareto
Pareto Chart
Chart
Pareto Chart
L 4
e
n
g
t 3
h
A 2.25
v
2
g
D -1.25
e
l 1
t
a
/ 0.25
2 0
Hold press(B) Mold temp(A) AB
Factors

Main
Main Effects
Effects Plot
Plot
Main Effects
19
17.8
L
e 16.6
n
g
t 15.4
h
14.2
13
70(-) 90(+) 5000(-) 7000(+)
Mold temp(A) Hold press(B)
Factors

Transfer
Transfer Function
Function
The
The equation
equation (algebraic)
(algebraic)
ItIt comes
comes from
from MLR
MLR
Three
Three important
important assumptions
assumptions
Two
Two levels
levels
O.A.
O.A.
Variables
Variables are
are on
on orthogonal
orthogonal scale
scale
Software packages use MLR to generate transfer function

MLR
MLR Math
Math
y = b0 + b1 x1 + b2 x2 + b12 x1 x2 + .........
= [X X ] [X tY ]
1
t
y1
y 1.. 1.. 1.. 1
b0 2 1.. 1.. + 1.. + 1
b
1 y3
1.. + 1.. 1.. + 1
= b2 Y = y4 X =
1 .. + 1 .. + 1.. 1
b12 .
...
.
yn

Note: the computer does the
math, we just need to be able includes factors (assumes 4 run
to interpret the output
previous example), and
interaction effect
Contour
Contour Plot
Plot
Contour Plot
7000
18.4
17.6
H 6600
o 16.8
l
d 6200
16
p
r 5800
15.2
e
s
s 5400 14.4
13.6
12.8
5000 1
70 74 78 82 86 90
Mold temp
Length

RSM
RSM Plot
Plot
Response Surface
22
L 19.6
e
17.2
n
g 14.8
t
12.4
h
10
5000 90
5400 86
5800 82
Hold press6200 78
6600 74 Mold temp
7000 70

Example
Example Using
Using DOE
DOE Wisdom
Wisdom
click
Click on
new
Name
example 1

Example
Example Using
Using DOE
DOE Wisdom
Wisdom
Click on add
Enter info
on first
factor
Example
Example Using
Using DOE
DOE Wisdom
Wisdom
Click to add
additional
factors

Example
Example Using
Using DOE
DOE Wisdom
Wisdom
Add
response

Example
Example Using
Using DOE
DOE Wisdom
Wisdom
Click
when
done
select

Example
Example Using
Using DOE
DOE Wisdom
Wisdom
Select data
window
Enter data
Click save
when done
Example
Example Using
Using DOE
DOE Wisdom
Wisdom

Example
Example Using
Using DOE
DOE Wisdom
Wisdom

Example
Example Using
Using DOE
DOE Wisdom
Wisdom

Experimental
Experimental Objectives
Objectives

Where
Where Can
Can Molders
Molders Use
Use
Designed
Designed Experiments?
Experiments?
Problem
Problem solving
solving
Tool
Tool trials
trials
Establishment
Establishment of
of process
process windows
windows
2004 42 Launsby Consulting M1

Troubleshooting/screening

FACTORS LOW HIGH

Mold Temp 100 150
Barrel Temp Low High
Cure Time 40 50
Back Press 50 150
Inj Velocity 1 3.1
Hold Press 200 1100
Response
Response
Appearance
Appearance
Decreasing
Decreasing shape
shape
Rate
Rate as
as 1,
1, 2,
2, 33 (3
(3 is
is best)
best)
O.A.
O.A.
L8
L8 with
with 55 repetitions
repetitions

Main
Main Effects
Effects
5 Mold temp is big hitter, set at high

for best appearance. Other factors
4 appear to have little impact on
a appearance
p 3
p
e
a 2
r
moldt barrelt injvel ctime holdp bckpre

Factors

Modeling
Modeling DJ
DJ Example
Example
Toshiba ink cartridge

DJ
DJ Example
Example
FACTOR LOW HIGH
Hold Pressure (psi) 5000 8500
Pack Speed (%) 15 30

Injection Vel. (%) 30 65
Mold Temp (deg.) 100 150

Responses
Responses For
For DJ
DJ
RESPONSE LSL NOM. USL

SLOT1 31.90 31.95 32.0
SLOT2 56.68 56.83 56.98
SLOT3 38.62 38.72 38.8
SLOT4 33.60 33.65 33.70
SPLAY and FLOWLINES rated as Good, OK, Bad (3,2,1)

Runs
Runs For
For DJ
DJ
moldtemp injvel packspd holdpress
Note: here are
1 100 30 15 4000 the trials, 4
cavity tool, did
2 100 30 30 8000
5 shots per run.
3 100 65 15 8000
Response
4 100 30 30 4000 values are not
5 100 65 25 8500 shown, only
6 100 65 15 4000 some of the
7 100 30 15 4000 simple analysis
8 150 65 30 4000 (follows)
9 150 30 15 8500
10 150 65 15 8500
11 150 30 30 8500
12 150 30 15 4000
Main
Main Effects
Effects Plot
Plot
Slot
Slot 11
Main Effects
31.92
31.91
s
l 31.9
o
31.89
t
31.88
1
31.87
31.86
100(-) 150(+) 30(-) 65(+) 15(-) 30(+) 4000(-)8500(+)
moldtemp(A) injvel(B) packspd(C) packpress(D)
Factors
Main
Main Effects
Effects Plot
Plot
Slot
Slot 22
Main Effects
56.82
56.81
s
l 56.8
o
56.79
t
56.78
2
56.77
56.76
100(-) 150(+) 30(-) 65(+) 15(-) 30(+) 4000(-)8500(+)
Factors
Main
Main Effects
Effects Plot
Plot
Slot
Slot 33
Main Effects
38.72
38.7
s
l 38.68
o
38.66
t
38.64
3
38.62
38.6
100(-) 150(+) 30(-) 65(+) 15(-) 30(+) 4000(-)8500(+)
Factors
Main
Main Effects
Effects Plot
Plot
Slot
Slot 44
Main Effects
33.63
33.62
s
l 33.61
o
33.6
t
33.59
4
33.58
33.57
100(-) 150(+) 30(-) 65(+) 15(-) 30(+) 4000(-) 8500(+)
Factors
Main
Main Effects
Effects Plot
Plot
Splay
Splay
Main Effects
3.4
3.2
s 3
p
l 2.8
a
y 2.6
2.4
2.2
100(-) 150(+) 30(-) 65(+) 15(-) 30(+) 4000(-) 8500(+)
Factors

Main
Main Effects
Effects Plot
Plot
FLOWLINES
FLOWLINES
Main Effects
3
f
l
o 2
w
l
i
n 1
e
s
0
100(-) 150(+) 30(-) 65(+) 15(-) 30(+) 4000(-) 8500(+)
Factors
What
What Is
Is The
The Best
Best Trade-
Trade-
off?
off?
Response Surface**packspd(C)=15.0000,packpress(D)=7920.00
Operate in this region
D
0.4
(
c
o 0.3
m
p 0.2
o
s
0.1
i
t
e 0
) 30 150
37 140
44 130
injvel 51 120
58 110 moldtemp
65 100
PICTURAL
PICTURAL View
View Of
Of Trade-
Trade-
off
off (means)
(means)
. Slot 1
.Slot 2
. Slot 3
. Slot 4
Note: slot 1 and slot 2 work the opposite of slots 3 and 4. If

we attempt to increase slot 1 and slot 2, slots 3 and slots 4
decrease. Good time to find this out is during tool trial

How
How About
About Variation?
Variation?
Monte Carlo Simulation can be used to predict
variation about a process mean
DOE Wisdom Analysis of Variance
Dependent Variable: response 4

Number Runs(N): 12
Multiple R: 0.999807
Squared Multiple R: 0.999614
Adjusted Squared Multiple R: 0.995757
Standard Error of Estimate: 0.000848528 How closely can the factors be
Variable Coefficient best setting controlled in production?
Constant 33.5985
Mold Temp(A) 0.00506435 150
Inj Vel(B) -0.00941707 47
Pack Spd(C) -0.00507645 15
Pack Prs(D) -0.00436898 7920
AB 0.00572135
AC 0.00363698
AD -0.000393981
BC -0.00360833
BD -0.00193009
CD -0.00225509
Results
Results of
of Monte
Monte Carlo
Carlo
Simulation
Simulation

ROBUST
ROBUST DESIGN
DESIGN
Product
Product Level
Level
What
What itit Means
Means
Products
Products Perform
Perform Intended
Intended Functions
Functions at
at
Varying
Varying Usage
Usage Conditions
Conditions
Wide
Wide Range
Range Customer
Customer Usage
Usage
Product
Product Deterioration
Deterioration
Variation
Variation in
in Subsystems/Components
Subsystems/Components

Robustness
Robustness At
At The
The
Process
Process Level
Level
Lot-to-Lot
Lot-to-Lot Variation
Variation in
in Resin
Resin
Regrind
Regrind
Machine
Machine
Room
Room Temperature
Temperature
Moisture
Moisture Content
Content
Operator
Operator

Robust
Robust Design
Design
(Cont.)
(Cont.)
Robust
Robust Design
Design Recognizes
Recognizes ThatThat Variability
Variability
Exists
Exists and
and is
is the
the Enemy
Enemy of of High
High Quality
Quality
Products
Products and
and Processes
Processes
Employs
Employs DOE
DOE as as aa Strategic
Strategic Weapon
Weapon
Accomplished
Accomplished by by Selecting
Selecting the
the Best
Best Levels
Levels
for
for Control
Control Factors
Factors so so That
That Performance
Performance
Insensitive
Insensitive to
to Noise
Noise Factors
Factors

Robust
Robust Design
Design
(Examples)
(Examples)
Caramel
Caramel Candy
Candy Example
Example
Industry
Industry Examples
Examples (HP
(HP Ink
Ink Cartridgesee
Cartridgesee
following
following slides)
slides)

HP
HPweld
weldexample
example

HP
HP Weld
Weld Example,
Example, The
The Part
Part
Ink
Cartridge
Energy director
on base
Hp
Hp Ireland
Ireland
EDH is energy director height,

MFI is melt flow index. They
are both noise factor in this
example
Robust
Robust Design
Design Example
Example
FACTORS C/N LOW HIGH
APRESS C 25 40
COL DIST C .004 .006
AMP C 65 85
DWN SPD C 2.6 4.0
MFI N LOW HIGH
EDH N LOW HIGH
HP
HPIreland
Ireland
Review
Reviewfactors,
factors,levels,
levels,responses,
responses,Desirabilities
Desirabilities
Any
Anyfactor
factorsettings
settingsminimize
minimizevariation?
variation?
What
Whatare areoptimal
optimalsettings?
settings? Desirability functions allow us to trade-
off multiple simultaneous responses (we
will learn details later)

The
The Data
Data
Eight run
inner OA
Run press dist amp spd
1 25 0.004 65 2.6
2 25 0.004 85 4
3 25 0.006 65 4
4 25 0.006 85 2.6
5 40 0.004 65 4
6 40 0.004 85 2.6
7 40 0.006 65 2.6
8 40 0.006 85 4
MFI high high low low

EDH high low high low
strength STD % strength STD % strength STD % strength STD %
0.0067 0.00148 0 0.00707 0.00088 0 0.00694 0.00116 0 0.00719 0.00111 0
0.00941 0.00056 100 0.00985 0.00079 100 0.00929 0.00044 100 0.00977 0.00088 98
0.00906 0.0006 87 0.00932 0.00101 74 0.00899 0.00068 80 0.00931 0.00112 74
0.01129 0.0005 100 0.01152 0.00086 99 0.01143 0.0004 100 0.01143 0.00077 100
0.00703 0.00098 1 0.00703 0.00098 6 0.00697 0.00096 4 0.00718 0.0011 7
0.00941 0.00067 100 0.00991 0.00095 100 0.00932 0.00065 100 0.00953 0.00098 93
0.00911 0.00572 45 0.0085 0.00093 56 0.00862 0.00052 59 0.00859 0.00078 53
0.01136 0.00047 100 0.01177 0.0008 100 0.01121 0.00068 100 0.01182 0.00079 100
4/2/2009
File hp robust 1 69 Launsby Consulting
Robust
Robust Design,
Design, Strength
Strength
Main Effects
0.012
Average
0.011
s 0.01
t
r
e
n 0.009
g
t
h
0.008
0.007
0.006
25(-) 40(+) 0.004(-) 0.006(+) 65(-) 85(+) 2.6(-) 4(+)
press(A) dist(B) amp(C) spd(D)
Factors

Robust
Robust Design
Design (Cont.)
(Cont.)
Students:
Students: What
What is
is the
the best
best trade-off?
trade-off?
Mean (Weld Str) Stand Dev (Weld Str) % Good Welds D(composite)
0.0116059 0.00044375 122.25 1
95% CI: 0.000498452 0.00193891 39.7551
Constant 0.00924781 0.000975 66.75
Air Pressure(A) -3.78E-05 0.0001475 -2.75 25
Collapse Distance(B) 0.000960313 6.44E-05 16.1875 0.006
Amplitude(C) 0.00127219 -0.000275625 32.625 85
Down Speed(D) 8.78E-05 -0.0001725 3.9375 4
Here are the predicted

optimal setting for factors

RSM
RSM Plot
Plot
Response Surface**Air Pressure(A)=25.0000,Down Speed(D)=4.00000
D
( 1
c
o 0.8
m
0.6
p
o 0.4
s
i 0.2
t
0
e
0.004 85
)
81
77
0.005
Collapse Distance 73
69 Amplitude
0.006 65

Knowledge
Knowledge Of
Of The
The Technology
Technology
To
To Enhance
Enhance Robustness
Robustness
Viscosity
Viscosity vs.
vs. Shear
Shear Curves
Curves
Cavity
Cavity Pressure
Pressure Sensors
Sensors
Cavity pressure changes are a major source of dimensional

and appearance variation
Conventional
Conventional Molding
Molding
Fill
Fill and
and Pack
Pack are
are Done
Done on
on First
First Stage
Stage
Time
Time isis Usually
Usually Used
Used to
to Transfer
Transfer From
From
Boost
Boost toto Hold
Hold

Typical
Typical Pressure
Pressure Profile
Profile
From Plastic Part Design by R.A. Malloy

Hydraulic
Hydraulic Pressure
Pressure Is
Is
Misleading
Misleading
Hydraulic Injection Pressure
Mold Cavity Pressure
Source: RJG, Inc.

Decoupled MOLDINGTM
Decoupled MOLDINGTM
DECOUPLED MOLDINGTM is a registered trademark of RJG, Inc.

Cavity
Cavity Pressure
Pressure Impact
Impact
4/2/2009
Source: RJG, Inc.
Cavity
Cavity Control
Control Impact
Impact
MOLDING GATE END EOF MOLD
TECHNIQUE MOLD PRESS (s.d.)
PRESS (s.d.)
Traditional 514 860
Totally 21.4 205

Decoupled
Source: RJG Associates, Decoupled Molding is a Trademark of RJG in Traverse City,

MI

Box
Box And
And Bubble
Bubble Chart
Chart
Planning
Planning
Select
Select an
an Orthogonal
Orthogonal Array
Array
Conduct
Conduct
Analysis
Analysis
Confirmation
Confirmation

Planning
Planning
Who
Who Are
Are the
the Customers?
Customers?
How
How Will
Will Customers
Customers UseUse Products?
Products?
What
What are
are the
the Functions?
Functions?
Objectives?
Objectives?
Time
Time Requirements
Requirements
Responses,
Responses, Factors,
Factors, Money
Money

Orthogonal
Orthogonal Array
Array
AA Set
Set of
of Experimental
Experimental Conditions
Conditions (runs)
(runs)
Where
Where the
the Levels
Levels ofof Each
Each Factors
Factors are
are
Balanced
Balanced Over
Over the
the Levels
Levels of
of the
the Other
Other
Factors,
Factors, Both
Both Horizontally
Horizontally and
and Vertically
Vertically
AA Balanced
Balanced Family
Family ofof Tests
Tests Which
Which Allows
Allows
For
For Fast,
Fast, Efficient,
Efficient, Simple,
Simple, and
and Powerful
Powerful
Analysis
Analysis
Example-----Golf
Example-----Golf

Orthogonal
Orthogonal Vs
Vs What?
What? An
An
Example
Example

Factor
Factor Assignments
Assignments
FACTOR LEVELS
Carbon Black (C) 1.2, 2.1
Sulfur (S) 2, 2.5
Filler (F) 30, 33
Accelerator Type (A) Dupont, Allied
Polymer Type (P) 1, 2, 3, 4, 5

Full
Full Factorial
Factorial
Approach
Approach
Advantages
Advantages
Disadvantages
Disadvantages

One-factor-at
One-factor-at
A
A Time
Time
Advantages
Advantages
Disadvantages
Disadvantages

Best
Best Guess
Guess Approach
Approach
Advantages
Advantages
Disadvantages
Disadvantages

Experimentation
Experimentation In
In
The
The 00s
00s
Full
Full Factorials,
Factorials, Taguchi
Taguchi O.A.s
O.A.s
Fractional-Factorials
Fractional-Factorials
Plackett-Burman
Plackett-Burman
Hadamard
Hadamard Matrices
Matrices
Box-Behnken,
Box-Behnken, Central
Central Composite
Composite
D-optimal
D-optimal Designs
Designs

Module
Module #2
#2
Goals
Goals
Understand
Understand the
the Steps
Steps Required
Required for
for Success
Success
Set-up
Set-up and
and Analyze
Analyze aa Simple
Simple Design
Design
Learn
Learn When
When Analysis
Analysis is
is Unsuccessful
Unsuccessful and
and
Grasp
Grasp How
How to
to Recover
Recover
Apply
Apply Desirability
Desirability Functions
Functions (using
(using software).
software).

The
The Box
Box And
And Bubble
Bubble Details
Details
Who
Who isis the
the customer?
customer?
How
How will
will product
product be
be used?
used?
Consider
Consider applicability
applicability of
of functional
functional
analysis
analysis
What
What isis the
the objective?
objective? What
What are
are the
the
detailed
detailed questions
questions to
to be
be answered?
answered?
When
When cancan wewe start?
start? When
When do do we
we need
need an
an
answer?
answer?
The
The Box
Box And
And Bubble
Bubble
Details
Details (Cont)
(Cont)
Responses
Responses
Name,
Name, how
how measured?,
measured?, MSA?,
MSA?, shape,
shape, critical
critical
values,
values, weight
weight
Factors
Factors
Name,
Name, qualitative
qualitative oror quantitative?
quantitative? Range
Range of
of
interest,
interest, levels,
levels, propensity
propensity for
for interactions
interactions
Costs
Costs
Approximate
Approximate cost
cost per
per run,
run, time
time per
per run
run

The
The Box
Box And
And Bubble
Bubble
Details
Details
Select
Select OA
OA
Determine
Determine number
number of of samples
samples perper run,
run,
Discuss
Discuss replication,
replication, randomization,
randomization, and and
repetitions
repetitions
Conduct
Conduct trials,
trials, record
record set
set points
points for
for
constant
constant factors
factors
Analysis
Analysis
Confirm
Confirm predictions
predictions

Four
Four Types
Types Of
Of Factors
Factors
Effect
Effect Location
Location
Effect
Effect Variation
Variation
Effect
Effect Both
Both
No
No Effect
Effect

Statistical
Statistical Analysis
Analysis
Golf
Golf Ball
Ball Example
Example

Introduction
Introduction To
To Simple
Simple
Analysis
Analysis
Run TEMP PIN PACKT PACKP DURA. WT
1 1 -20 5 600 45 44.8
2 1 -20 15 900 47 45.3
3 1 10 5 900 64 45.3
4 1 10 15 600 69 44.8
5 2 -20 5 900 49 45.4
6 2 -20 15 600 49 44.9
7 2 10 5 600 69 44.9
8 2 10 15 900 74 45.4

Main
Main Effects
Effects
Main Effects
90
D
U 80
R
A 70
B
60
I
L 50
I
T 40
Y
30
1(-) 2(+) -20(-) 10(+) 5(-) 15(+) 600(-) 900(+)
TEMP(A) PIN(B) PACKT(C) PACKP(D)
Factors
Main
Main Effects
Effects
Main Effects
45.4
45.3
W
E 45.2
I
45.1
G
H 45
T
44.9
44.8
1(-) 2(+) -20(-) 10(+) 5(-) 15(+) 600(-) 900(+)
Factors
Stats
Stats Analysis
Analysis
Weight
Weight
Dependent Variable: WEIGHT

Number Runs(N): 128
Adjusted Squared Mu 0.925969
Standard Error of Esti 0.067707
Variable Coefficient Std Error 95% CI Tolerance T P(2 Tail)
Constant 45.1056 0.005985 0.0118460 7537.012 0

TEMP(A) 0.048281 0.005985 0.011846 1 8.068 0
PIN(B) -0.0025 0.005985 0.011846 1 -0.418 0.677
PACKT(C) 0.007656 0.005985 0.011846 1 1.279 0.203
PACKP(D)
4/2/2009 0.23375 0.005985 0.011846
98 1 39.059 0
Launsby Consulting
Stats
Stats Analysis
Analysis
Durability
Durability
Dependent Variable: DURABILITY

Number Runs(N): 128
Constant 58.4063 1.10992 2.19701 52.622 0

TEMP(A) 2 1.10992 2.19701 1 1.802 0.074
PIN(B) 10.5938 1.10992 2.19701 1 9.545 0
PACKT(C) 1.375 1.10992 2.19701 1 1.239 0.218
PACKP(D) 0.0625 1.10992 2.19701 1 0.056 0.955
Source Sum of Sq DF Mean SquaF Ratio P
Regression 15119.63 4 3779.906 23.9713 0

Residual 19395.25 123 157.685
Example
Example
Run temp acid time time time time time time time
1 1 0 67 79 71 73 69 65 70
2 1 1 66 71 81 67 68 73 61
3 2 0 17 22 18 19 17 17 17
4 2 1 26 26.5 25.5 27 28 27 26.6

Example
Example (Cont.)
(Cont.)
Main Effects
80
70
60
t
i
50
m
e
40
30
20
1(-) 2(+) 0(-) 1(+) -1(-) 1(+)
temp(A) acid(B) AB
Factors

Example
Example (Cont.)
(Cont.)
Main Effects
6
5
S
4
t
3
i
m
2
e
1
0
1(-) 2(+) 0(-) 1(+) -1(-) 1(+)
temp(A) acid(B) AB
Factors

Example
Example (Cont.)
(Cont.)
t
Pareto Chart
i 4
m
e
3
l
n
2
S -1.4787
D 1
-0.58861
e
-0.25787
l
t 0
temp(A) AB acid(B)
a
Factors
R.O.T.: If absolute value of Ln S effect (Delta) is equal to or greater

than 1.0, this is a strong reason to believe you have a factor which
influences variation

Example
Example #3
#3
QUESTION: How The Tabled Taguchi Designs Differ From

Fractional-Factorials?

Example
Example ## 44
Important
Important terms
terms
Interaction
Interaction Columns
Columns
Aliasing
Aliasing
Resolution
Resolution

Tabled
Tabled Taguchi
Taguchi Designs
Designs
See pages 52 thru 58 (Experimental Design for Injection

Molding for L4, L8, L9, L16,..)

D-optimal
D-optimal Designs
Designs
Advantages
Advantages
Disadvantages
Disadvantages

How
How Many
Many Samples?
Samples?
R.O.T.
R.O.T.
Response Type
Pass/Fail Visual (G,M,E) Quantitative
Np 10 10 to 20 Per 40 or More Per

Run Experiment
Note: These are rules of thumb

How
How Many
Many Samples?
Samples?
Easy
Easy to
to provide
provide if:
if:
You
You have
have an
an estimate
estimate ofof the
the standard
standard deviation
deviation
for
for response
response being
being studied
studied
Know
Know what
what is
is aa practically
practically significant
significant difference
difference

Statistical
Statistical Significance
Significance
People
People talk
talk aa great
great deal
deal about
about statistical
statistical
significance;
significance; yet
yet spend
spend almost
almost no
no time
time regarding
regarding
practical
practical significance
significance
Reality
Reality
Any
Anyeffect
effect(as
(aslong
longasasititisisnot
notzero)
zero)will
willbe
beshown
shownas
as
statistically
statisticallysignificant
significantififenough
enoughsamples
samplesare
areused
used
You
Youcancanmathematically
mathematicallyjustify justifyany
anysample
samplesize
sizeby
by
tweaking
tweakinginputs
inputsto toformula
formula

Statistical/Practical
Statistical/Practical
Significance
Significance If the difference is
not greater than 4, it
20
Main Effects is not of practical
importance
19
b 18
u
m
p 17 All are
h
16
statistically
t
significant
15
14
A(-) B(+) 1(-) 2(+) 3(-) 5(+) 2(-) 4(+)
(A) (B) (C) (D)
Factors
Constant
tech(A):A
17.0505
1.06016
0.201485
0.209227
0.464627
0.482480
84.624
5.067
0
0.001 Not a big
tech(A):B
(B)
-1.06016
0.689843
0.209227
0.209227
0.482480
0.482480
0.888
0.888
-5.067
3.297
0.001
0.011 deal
(C) 0.796313 0.226216 0.521657 0.908 3.52 0.008
(D) -0.915697 0.249362 0.575030 0.875 -3.672 0.006
4/2/2009 111 Need both before you get veryLaunsby

excitedConsulting
Sample
Sample Size
Size For
For Mean
Mean Shift
Shift
(one
(one approach)
approach)
16 2
n= n = (t + t ) 2 2 / 2
2
= .02
2n =
Total number of samples in
experiment = .02
2n 30
= Minimum practical difference we wish to find as
significant n (2 + 2) 2 2 / 2
= Error standard deviation
Example: We decide to conduct an L8. We decide that = 4 and estimate the

error standard deviation as 4. The number of samples for the experiment is 32.
We need to run the L8 4 times.

Confirmation
Confirmation
Recommended
Recommended ## of
of Tests
Tests
Graphical
Graphical Approach
Approach

Why
Why You
You May
May Not
Not Confirm
Confirm
Data
Data Entry
Entry
Did
Did Not
Not Conduct
Conduct Per
Per Plan
Plan
Measurement
Measurement System
System NotNot Reliable
Reliable
Large
Large Variation
Variation in
in the
the Response
Response
Wrong
Wrong About
About Interactions
Interactions
Model
Model is
is Inadequate
Inadequate
Something
Something Changed
Changed (Viscosity)
(Viscosity)
Computer
Computer On/Brain
On/Brain Off
Off
Golf
Golf Example
Example
Analysis
Analysis Of
Of Diameter
Diameter
Which
Which Factors
Factors Appear
Appear to to be
be Influencing
Influencing the
the
Average?
Average?
Do
Do Any
Any Factors
Factors Appear
Appear toto be
be Influencing
Influencing
the
the Variation
Variation in
in the
the Diameter?
Diameter?
How
How Should
Should WeWe SetSet the
the Process
Process to to
Achieve
Achieve aa Target
Target Response
Response of of 1.682?
1.682?
Note: please use following graphs to
answer above questions

Main
Main Effects
Effects
Diameter
Diameter
Main Effects
1.692
1.69
1.688
S
I
1.686
Z
E
1.684
1.682
1.68
1(-) 2(+) -20(-) 10(+) 5(-) 15(+) 600(-) 900(+)
Factors
Variance
Variance Analysis
Analysis
Diameter
Diameter
S
Pareto Chart
I 0.8
Z
E
0.6 -0.54953
l
n
0.4
S -0.28592
D 0.2
e 0.061876
l 0.018528
t 0
PACKP(D) TEMP(A) PIN(B) PACKT(C)
a
Factors

Stats
Stats Analysis
Analysis
Diameter
Diameter
Dependent Variable: SIZE

Number Runs(N): 128
Constant 1.68614 0.000136 0.000268335 12438.2 0

TEMP(A) 0.000874 0.000136 0.000268 1 6.447 0
PIN(B) -0.00023 0.000136 0.000268 1 -1.709 0.09
PACKT(C) 8.33E-05 0.000136 0.000268 1 0.614 0.54
PACKP(D) 0.003378 0.000136 0.000268 1 24.916 0
Source Sum of Sq DF Mean SquaF Ratio P
Regression 0.001566 4 0.000391 166.417 0

Residual 0.000289 123 2.35E-06
Contour
Contour Plot
Plot
Diameter
Diameter
Contour Plot**TEMP(A)=1.00000,PIN(B)=10.0000
15
13
P
A 11
1.6824 1.6856 1.6872
C 1.684 1.6864
1.6832 1.6848 1.688
K 9
T
7
816
5
600 660 720 780 840 900
PACKP
4/2/2009
SIZE
Residual
Residual Analysis
Analysis
What
What is
is it?
it?
AA method
method for
for evaluating
evaluating errors
errors in
in model
model
predictions
predictions
What
What are
are the
the benefits?
benefits?
Check
Check of
of model
model assumptions
assumptions
Evaluation
Evaluation of
of model
model adequacy
adequacy
Increased
Increased understanding
understanding of
of technology
technology
What
What patterns
patterns should
should emerge?
emerge?

Example
Example
Epsoon
Epsoon (full-factorial,
(full-factorial, single
single cavity,
cavity, 10
10
shots
shots per
per run)
run)
Factors Levels
Mtemp 90, 130
Injection Velocity 60, 80 %
Pack Press 30, 60%
Responses
Dimension E
Total run out

Main Effects
13.07
Dim
Dim E
E d
i
13.06
m 13.05
e
n
s 13.04
i
o
n 13.03
E
13.02
13.01
90(-)130(+)60(-)80(+)-1(-) 1(+) 30(-)60(+) -1(-) 1(+) -1(-) 1(+) -1(-) 1(+)
mtemp(A) vel(B) -AB pack(C) -AC -BC ABC
Factors

Main Effects
0.052
TIR
TIR T 0.051
o
t
a 0.05
l
r 0.049
u
n
0.048
o
u
t 0.047
0.046
90(-)130(+)60(-)80(+)-1(-) 1(+) 30(-)60(+) -1(-) 1(+) -1(-) 1(+) -1(-) 1(+)
mtemp(A) vel(B) -AB pack(C) -AC -BC ABC
Factors

EPSOON
EPSOON Dim
Dim E
E Student
Student
Residual
Residual

Dim
Dim E
E Student
Student Residual
Residual
Plot
Plot
R e s i d u a l S c a tte r P lo t
d 6
i
m
4
E
s
t 2
u
0
r
e
s
-2
-4
1234567891011121314151617181920212223242526272829303132333435363738394041424344454647484950515253545556575859606162636465666768697071727374757677787980
R u n O r d e r

TIR
TIR Student
Student Residuals
Residuals
Residual Histogram
10
9 9 9
8
8
7
C 6
6
o 5
u
n 4 4
t 4
3 3
2 2 2 2 2
2
1 1 1
0 0
0
-2.2 -2 -1.8-1.6-1.4-1.2 -1 -0.8-0.6-0.4-0.2 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8
T otal run out Studentized Residual

TIR
TIR Student
Student Residuals
Residuals
R e s i d u a l S c a tte r P lo t
3
r
u
n
2
o
u 1
t
s
0
t
u
d
-1
r
e
s
-2
l
-3
12345678910111213141516171819202122232425262728293031323334353637383940414243444546474849505152535455 657585960616263646566 768697071727374757677 87980
R u n O r d e r

Case
Case Study
Study Hockey
Hockey
Sticks
Sticks
Responses of Interest:
Trim part for saddle bags of
Length of the left
motorcycle
Length of the right
Gap on left
Gap on right
Sinks on left
Sinks on right
Factors Studied:
Mold Temperature (150 and 190)
Injection Velocity (2 and 4 in/sec.)
Hold Pressure (5000 and 14000 psi plastic)

Case
Case Study
Study (cont.)
(cont.)
Two cavity tool for left and
right part

Case
Case Study
Study (cont.)
(cont.)
Relative
Speed Visc.
Decided to run DOE at
2 and 4 in/sec
0.5 18,720
20,000
1 10,070 15,000
10,000
1.5 7,225
5,000
0
2 5,715
0.5 1 1.5 Rel. Visc.
2 3 4 5
3 4,270 speed
4 3,540
5 2,950

Case
Case Study
Study (cont.)
(cont.)
Hold Time Part Weight
2 Less than .088
3 .088
A hold time of 6 seconds
was selected. Appear to
4 .089 provide ample time for gate
seal
5 .089
6 .089
7 .089

Case
Case Study
Study (cont.)
(cont.)
Run mold temperature velocity hold pressure
1 150 2 5000
2 150 2 14000
3 150 4 5000 Conducted

five shots
4 150 4 14000
per run
5 190 2 5000
6 190 2 14000
7 190 4 5000
8 190 4 14000

Case
Case Study
Study (cont.)
(cont.)
Main Effects
0.4
l
e
0.16
n
g
t -0.08
h
r -0.32
i
g
-0.56
h
t
-0.8
150(-) 190(+) 2(-) 4(+) 5000(-) 14000(+)
mold temp(A) velocity(B) hold press(C)
Factors
Main Effects
0.2
l
0.1
e
n
g 0
t
h -0.1
l -0.2
e
f
-0.3
t
-0.4
150(-) 190(+) 2(-) 4(+) 5000(-) 14000(+)
Factors
Case
Case Study
Study (cont.)
(cont.)
Main Effects
3.6
3.4
g
a
p 3.2
r 3
i
g 2.8
h
t
2.6
2.4
150(-) 190(+) 2(-) 4(+) 5000(-) 14000(+)
Factors
Main Effects
3.2
3
g
a 2.8
p
2.6
l
e
f 2.4
t
2.2
2
150(-) 190(+) 2(-) 4(+) 5000(-) 14000(+)
Factors
Case
Case Study
Study (cont.)
(cont.)
Main Effects
2.8
s
i
2.6
Student question:
n 2.4
k does it make sense
2.2
r
i that these two
2
g
h responses display
t 1.8
1.6
dramatically different
150(-) 190(+)
mold temp(A)
2(-) 4(+)
velocity(B)
5000(-) 14000(+)
hold press(C)
main effects plots for
2.4
MainFactors
Effects
Hold Press?
2.3
s
i
n 2.2
k
l
2.1
What could
e
f
2
account for this
t
1.9
difference?
1.8
150(-) 190(+) 2(-) 4(+) 5000(-) 14000(+)
Factors
Case
Case Study
Study (cont.)
(cont.)
Dependent Variable: length right

Number Runs(N): 40
Constant -0.1625 0.012447 0.0253545 -13.055 0

mold temp -0.083 0.012447 0.0253545 1 -6.668 0
velocity(B) 0.006 0.012447 0.0253545 1 0.482 0.633
hold press( 0.3135 0.012447 0.0253545 1 25.186 0
AB -0.0045 0.012447 0.0253545 1 -0.362 0.72
AC -0.03 0.012447 0.0253545 1 -2.41 0.022
BC 0.029 0.012447 0.0253545 1 2.33 0.026
ABC 0.0215 0.012447 0.0253545 1 1.727 0.094

Case
Case Study
Study (cont.)
(cont.)
Dependent Variable: length left

Number Runs(N): 40
Multiple R: 0.95219
Constant -0.13575 0.009998 0.0203662 -13.577 0

mold temp -0.03575 0.009998 0.0203662 1 -3.576 0.001
velocity(B) -0.00275 0.009998 0.0203662 1 -0.275 0.785
hold press( 0.17175 0.009998 0.0203662 1 17.178 0
AB -0.01175 0.009998 0.0203662 1 -1.175 0.249
AC -0.00325 0.009998 0.0203662 1 -0.325 0.747
BC 0.01075 0.009998 0.0203662 1 1.075 0.29
ABC -0.00525 0.009998 0.0203662 1 -0.525 0.603

Case
Case Study
Study (cont.)
(cont.)
Dependent Variable: gap right

Number Runs(N): 40
Constant 2.9575 0.013579 0.0276584 217.808 0

mold temp -0.2575 0.013579 0.0276584 1 -18.964 0
velocity(B) -0.0225 0.013579 0.0276584 1 -1.657 0.107
hold press( 0.4825 0.013579 0.0276584 1 35.534 0
AB -0.0175 0.013579 0.0276584 1 -1.289 0.207
AC 0.0175 0.013579 0.0276584 1 1.289 0.207
BC 0.0225 0.013579 0.0276584 1 1.657 0.107
ABC 0.0175 0.013579 0.0276584 1 1.289 0.207

Case
Case Study
Study (cont.)
(cont.)
Dependent Variable: gap left

Number Runs(N): 40
Constant 2.5975 0.008478 0.0172689 306.384 0

mold temp -0.0475 0.008478 0.0172689 1 -5.603 0
velocity(B) -0.0175 0.008478 0.0172689 1 -2.064 0.047
hold press( 0.4575 0.008478 0.0172689 1 53.964 0
AB -0.0025 0.008478 0.0172689 1 -0.295 0.77
AC -0.0075 0.008478 0.0172689 1 -0.885 0.383
BC 0.0025 0.008478 0.0172689 1 0.295 0.77
ABC -0.0025 0.008478 0.0172689 1 -0.295 0.77

Case
Case Study
Study (cont.)
(cont.)
Dependent Variable: sink right

Number Runs(N): 40
Constant 2.275 0.025 0.0509233 91 0

mold temp -0.225 0.025 0.050923 1 -9 0
velocity(B) 0.225 0.025 0.050923 1 9 0
hold press( 0.475 0.025 0.050923 1 19 0
AB 0.225 0.025 0.050923 1 9 0
AC -0.025 0.025 0.050923 1 -1 0.325
BC 0.025 0.025 0.050923 1 1 0.325
ABC 0.025 0.025 0.050923 1 1 0.325

Case
Case Study
Study (cont.)
(cont.)
Dependent Variable: sink left

Number Runs(N): 40
Constant 2.1 0.053033 0.108025 39.598 0

mold temp -0.15 0.053033 0.108025 1 -2.828 0.008
velocity(B) 0.05 0.053033 0.108025 1 0.943 0.353
hold press( 0 0.053033 0.108025 1 0 1
AB -0.2 0.053033 0.108025 1 -3.771 0.001
AC 0.15 0.053033 0.108025 1 2.828 0.008
BC -0.05 0.053033 0.108025 1 -0.943 0.353
ABC 0.1 0.053033 0.108025 1 1.886 0.068

Case
Case Study
Study (cont.)
(cont.)
l
e
f Residual Scatter Plot
t 6
S 4
t
u
2
d
e
0
n
t
i -2
z
e -4
d
-6
R 1 2 3 4 5 6 7 8 9 10111213141516171819202122232425262728293031323334353637383940
e Run Order
s
i
d

Case
Case Study
Study (cont.)
(cont.)
Response Surface**velocity(B)=2.00000
1
D
(
c 0.8
o
m 0.6
p
o 0.4
s
i
t 0.2
e
) 0
190
182
174
mold temp 166
14000
158 12200
10400
8600
6800
150 5000 hold press

Case
Case Study
Study Best
Best Set
Set Points
Points
Mold temperature = 173 degrees

Injection velocity = 2 inches/sec
Hold pressure = 14000 psi. plastic
(Note that this setting was not actually one of the eight trials conducted in the
orthogonal array)
From these settings the following values were predicted:
Length right = .0965 +/- .1684

Length left = .0247 +/- .1352
Gap right = 3.404 +/- .183
Gap left = 3.063 +/- .115
Sink right = 2.43 +/- .34
Sink left = 2.11 +/- .717
5 confirmation runs were conducted. All parts fell

4/2/2009
into above confidence Intervals
Desirability
Desirability Functions
Functions
What
What are
are They?
They?
Why
Why are
are They
They Needed?
Needed?
What
What are
are the
the Steps
Steps Required?
Required?
For
For Each
Each Response,
Response, Determine
Determine aa Shape
Shape
For
For Each
Each Response,
Response, Determine
Determine an
an Importance
Importance
Weight
Weight
Analyze
Analyze Composite
Composite D
D

Composite
Composite D
D Example
Example
FACTOR LOW HIGH
A 1 2
B 1 2

Composite
Composite D
D Example
Example
RESP TYPE MIN. NOM. MAX. WT.
Tensile Tent 1500 2000 2500 1
Hard. Decr. 20 50 2
Elong. Inc. 500 600 4

Example
Example

Tensile
Tensile Contour
Contour
Contour Plot
2 00
1950
1.8 1900
1850
1.6
1800
b
1750
1.4 1700 1650
1.2
1
1 1.2 1.4 1.6 1.8 2
a
4/2/2009
Tensile
Hardness
Hardness Contour
Contour
Contour Plot
2
1.8 32
1.6
34
b
1.4 36
38
1.2 40
42
44
1
1 1.2 1.4 1.6 1.8 2
a
4/2/2009
Hardness
Elongation
Elongation Contour
Contour
Contour Plot
2 580
510 570
1.8 520 560
1.6 530 550

b
540
1.4
1.2
540
530
1
1 1.2 1.4 1.6 1.8 2
a
4/2/2009
Elongation
Desirability
Desirability Contour
Contour
Contour Plot
2 0.1
0.2 0.6
1.8 0.3
0.5
1.6
b
1.4
0.4
1.2
1 0
1 1.2 1.4 1.6 1.8 2
a
4/2/2009
D(composite)
Summary
Summary
Understand
Understand the
the Technology
Technology of
of Molding
Molding
Use
Use the
the Four
Four Plastic
Plastic Variables
Variables as
as the
the
Foundation
Foundation for
for DOE
DOE
Physics
Physics First
First
510
510 Rule
Rule

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Experimental

4/2/2009 1 Launsby Consulting

4/2/2009 2 Launsby Consulting

4/2/2009 3 Launsby Consulting

4/2/2009 4 Launsby Consulting

4/2/2009 5 Launsby Consulting

4/2/2009 6 Launsby Consulting

4/2/2009 8 Launsby Consulting

PROCESS DIAGRAM FOR

Some Potential Factors Potential Responses

Where is Plastics Pressure Greatest?

Source: RJG, Inc.

SLOW FLOW RATE FAST

4/2/2009 Source: RJG, Inc.

Source: RJG, Inc.

4/2/2009 15 Launsby Consulting

4/2/2009 17 Launsby Consulting

4/2/2009 18 Launsby Consulting

4/2/2009 19 Launsby Consulting

4/2/2009 20 Launsby Consulting

4/2/2009 21 Launsby Consulting

4/2/2009 22 Launsby Consulting

4/2/2009 23 Launsby Consulting

RUN Mtemp H Press Length

4/2/2009 25 Launsby Consulting

4/2/2009 26 Launsby Consulting

4/2/2009 27 Launsby Consulting

4/2/2009 28 Launsby Consulting

4/2/2009 30 Launsby Consulting

4/2/2009 31 Launsby Consulting

4/2/2009 32 Launsby Consulting

4/2/2009 34 Launsby Consulting

4/2/2009 35 Launsby Consulting

4/2/2009 36 Launsby Consulting

4/2/2009 38 Launsby Consulting

4/2/2009 39 Launsby Consulting

4/2/2009 40 Launsby Consulting

4/2/2009 41 Launsby Consulting

2004 42 Launsby Consulting M1

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FACTORS LOW HIGH

4/2/2009 45 Launsby Consulting

5 Mold temp is big hitter, set at high

moldt barrelt injvel ctime holdp bckpre

4/2/2009 46 Launsby Consulting

Toshiba ink cartridge

4/2/2009 47 Launsby Consulting

Hold Pressure (psi) 5000 8500

Pack Speed (%) 15 30

2004 48 Launsby Consulting M1

RESPONSE LSL NOM. USL

SPLAY and FLOWLINES rated as Good, OK, Bad (3,2,1)

2004 55 Launsby Consulting M1

Operate in this region

Note: slot 1 and slot 2 work the opposite of slots 3 and 4. If

2004 58 Launsby Consulting M1

Dependent Variable: response 4