Reflection Final Paper

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IE 490/590

Lean Tools in Systems Engineering

Dr. Delia Valles-Rosales

Industrial Engineering Department

Lean Six Sigma-Tools

Project Selection, NPV, SIPOC Diagram, VOC, CTQ, Pareto Chart, Process Mapping

C&E Analysis, Process Capability Analysis, Sampling, Basic Statistics

Hypothesis Test, Correlation, Regression, Multi-Vari, CI’s, ANOVA

DOE, Poka-Yoke, FMEA, RSM

Control Plans, SPC, SOP’s

Outline

Intro to Design of Experiments in Lean Six Sigma

Definitions

Block Designs

Full Factorial Experiments

Examples

Example #1

What are the effects of the material type and temperature in the life of a battery?

Is there any material selection that maximizes its life?

Example #2

Response: the performance of a chemical process is studied.

It is thought that the two most important variables: pressure and temperature. Three levels of each factor are selected and performed a factorial experiment with two replicates. Performance data are:

	Pressure
Temperature	200	215	230
150	90.4	90.7	90.2
	90.2	90.6	90.4
160	90.1	90.5	89.9
	90.3	90.6	90.1
170	90.5	90.8	90.4
	90.7	90.9	90.1

Example #3

The percentage of the concentration of hardwood pulp in gross, pressure, and cooking time of pulp are examined for their effects on paper strength. Three levels of concentration of hardwood are selected. Three levels of pressure and two cooking times. Carry out a factorial experiment with two replicates.

	Time 3 hours			Time 4 hours
Percentage	Pressure			Pressure
concentration	400	500	650	400	500	650
2	196.6	197.7	199.8	198.4	199.6	200.6
	196	196	199.4	198.6	200.4	200.9
4	198.5	196	198.4	197.5	198.7	199.6
	197.2	196.9	197.6	198.1	198	199
8	197.5	195.6	197.4	197.6	197	198.5
	196.6	196.2	198.1	198.4	197.8	199.8

Example #4

An engineer is interested in the effects of cutting speed (A), the geometry of the tool (B) and the cutting angle (C) on life (in hours) of a machine tool. Two levels of each factor are chosen and run three replicates in a factorial design 2³. The results were:

				Replication
A	B	C	Treatment	I	II	III
-	-	-	[1]	22	31	25
+	-	-	a	32	43	29
-	+	-	b	35	34	50
+	+	-	ab	55	47	46
-	-	+	c	44	45	38
+	-	+	ac	40	37	36
-	+	+	bc	60	50	54
+	+	+	abc	39	41	47

Example #5

A machine is used to make grooves on a printed circuit board. The vibration level at the surface of the card when the slots are made is considered a major source of dimensional variation of the grooves. Two factors are thought to influence the vibration: the size of the grooves (A) and the cutting speed (B). two sizes of grooves (1/16 and 1/8 inch) and two speeds (40 and 90 rpm) are selected, and four grooves are made with each card set of conditions. Variable vibration response is measured as the resultant vector of three accelerometers (x, y, z) on each test card.

			Replication
A	B	Treatment	I	II	III	IV
-	-	[1]	18.2	18.9	12.9	14.4
+	-	a	27.2	24	22.4	22.5
-	+	B	15.9	14.5	15.1	14.2
+	+	ab	41	43.9	36.3	39.9

Example #6

Four factors, each with two levels were studied in a study of the performance of a process: time (A), the concentration (B), pressure (C) and the temperature (D). one replicate was run a design 2⁴ and data obtained are shown in the following table:

						Yield		Factor Levels
Run order	Real order	A	B	C	D	lbs.		Low	High
1	5	-	-	-	-	12	A(h)	2.5	3
2	9	+	-	-	-	18	B(%)	14	18
3	8	-	+	-	-	13	C(psi)	60	80
4	13	+	+	-	-	16	D(ᴼC)	225	250
5	3	-	-	+	-	17
6	7	+	-	+	-	15
7	14	-	+	+	-	20
8	1	+	+	+	-	15
9	6	-	-	-	+	10
10	11	+	-	-	+	25
11	2	-	+	-	+	13
12	15	+	+	-	+	24
13	4	-	-	+	+	19
14	16	+	-	+	+	21
15	10	-	+	+	+	17
16	12	+	+	+	+	23

Thank you!!!