Describe the design experiments method for product and process optimization

Expert Solution

Response surface methodology (RSM) is a collection of statistical and mathematical techniques useful for developing, improving, and optimizing products and processes. The most extensive applications of RSM are particularly in situations where several input variables have potentially influence on some performance measures or quality characteristics of the product or process. RSM initiates from design of experiments (DOE) to determine the factors’ values for conducting experiments and collecting data. The data are then used to develop an empirical model that relates the process response to the factors. Subsequently, the model facilitates to search for better process response, which is validated through experiments. The above procedure iterates until an optimal process is identified or the limit on experimental resources is reached. RSM is a very important tool for product and process improving in the improvement phase of Six Sigma Management.

Also there is another method called Taguchi method.This method is an alternative method to review loss due to poor quality.It's also known as robust design and seeks to minimize the sensitivity to noise for any product or process.The conventional loss function states that products may be accepted if they are within statistical tolerance limits. Taguchi's loss function states that there is a loss unless the product exactly adheres to the target.The product then, must be designed in such a way that the control factors settings are optimal and minimize sensitivity to noise.The main advantages of robust design are in design transferability and in less experiments conducted.

The advantage of RSM over taguchi method-

Taguchi designs help you determine, the parameter settings for experiments that can give best or optimal settings. However this optimal setting value depends on the number of experiment you can afford to do as experimentation itself involves great cost.

RSM on the other hand involves more experimentation, however it can take you closer to global optimum.

Thus when you have to compromise on number of experiments you can perform, Taguchi is preferred. But if rigorous experimentation is possible, RSM will always take you much closer to global optimum settings as compared to Taguchi.

samet mamat answered 2 years ago

Explain with an example the process for determining the replicates number for Design of Experiments.

An article in Solid State Technology, "Orthogonal design for process optimization and its application to plasma...

An article in Solid State Technology, "Orthogonal design for process optimization and its application to plasma etching" by G.Z.Yin and D.W. Jillie (May, 1987) describes an experiment to determine the effect of the C2F6 flow rate on the uniformity of the etch on a silicon wafer used in integrated circuit manufacturing. All of the runs were made in random order. Data for two flow rates are as follows: C2F6 Uniformity Observation Flow 1 2 3 4 5 6 125 2.7 ...

Question 3: In “Orthogonal Design for Process Optimization and Its Application to Plasma Etching”, an experiment...

Question 3: In “Orthogonal Design for Process Optimization and Its Application to Plasma Etching”, an experiment is described to determine the effect of flow rate on the uniformity of the etch on a silicon wafer used in integrated circuit manufacturing. Three flow rates are used in the experiment, and the resulting uniformity (in percent) for six replicates is shown below. Flow Observations 125 2.7 4.6 2.6 3.0 3.2 3.8 160 4.9 4.6 5.0 4.2 3.6 4.2 200 4.6 3.4 2.9...

what is the importance of product and service design and process design in an organization? and...

what is the importance of product and service design and process design in an organization? and what will happen if one of them was neglected over the other?

describe the key features of PCA design method

Briefly describe how a Design of Experiments methodology can be used when testing a new pump...

Briefly describe how a Design of Experiments methodology can be used when testing a new pump design that has three variables (number of impeller blades, channel depth, outlet diameter). Why would a factorial design of experiments be better than optimizing each variable independently?

Part I - Product Design and Service Design: Product Design Create a product design within an...

Part I - Product Design and Service Design: Product Design Create a product design within an operations management environment, using real world research to support your work. At the beginning of your paper, introduce your planned work, to include a description of the elements of the product design, that you selected to focus on, and how you plan to apply it to a real world scenario.

Q: 1. Describe THE COSMETICS product. (a) IN REGARD TO THE COSMETIC PRODUCT, design the research...

Q: 1. Describe THE COSMETICS product. (a) IN REGARD TO THE COSMETIC PRODUCT, design the research procedures that will enable data collection and analysis of the effects of the different components of the marketing mix on each other and of their importance to the customer base. (b) Nominate the sources of data (primary and/or secondary) you would choose to access and explain why you would use those sources. (C) What data would you collect? (D) What procedures would you follow...

You believe protein D is involved in the metastatic process. Describe experiments in how you would...

You believe protein D is involved in the metastatic process. Describe experiments in how you would rule out it was not involved in primary tumor growth, but it is involved in growth at the secondary site. What could be the pitfalls of your experimental set-up? (limit 2 pages; 10 pts) Please type answers, written answers are hard to read.

Kagle design engineers are in the process of developing a new “green” product, one that will...

Kagle design engineers are in the process of developing a new “green” product, one that will significantly reduce impact on the environment and yet still provide the desired customer functionality. Currently, two designs are being considered. The manager of Kagle has told the engineers that the cost for the new product cannot exceed $550 per unit (target cost). In the past, the Cost Accounting Department has given estimated costs using a unit-based system. At the request of the Engineering Department,...

Question