DOE Exercise Book

Shainin DOE, Version: 1.
1,Jan03
World Class Manufacturing Solutions (WCMS)
Shainin Design of Experiments (DOE)
Exercise Book
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2 Shainin DOE, Version: 1.1,Jan03
List of exercises
28-29
27
23-26
21-22
15-20
11-14
9-10
6-8
5
3-4
Page
B Vs C
Variable Search
Multi-Vari
Multi-Vari
Component Search
Product/Process search
Paired Comparison
Paired Comparison
Paired Comparsion
Phase-1 Define
Tool
375 Total time
15 Validating the cause and quantifying the
contribution
10
120 Catapult design and validation 9
60 Conducting analysis and identifying the cause 8
10 Identification of streams and constructing
stream table
7
60 Identification of Root cause using Component
search
6
20 Identification of Root cause and establishing
spec using the tool
5
5 Establishing specifications 4
45 Analysis Identification of root cause using
the tool
3
10 Selection of BOB and WOW 2
30 Problem definition 1
Time
(Mins)
Description Exercise
#
Exercise 1 Problem definition
Time: Max 30 mins
Select one problem based on CTQ or CTC or
CTS
Define the Problem using the Problem definition
sheet provided
Exercise 1 Problem definition
Time: Max 30 mins
Scratch Pad
Exercise 2 Paired Comparison
Time: Max 10 mins
! Identify the 6 BOB and 6 WOW from the data given below
BEARINGS
Tol 22 45 125 90 45 16 2 0.03 22 45 125 90 45 16 2 45
NO L1 L2 L3 L M H Wt Ri Ra L1 L2 L3 L M H Wt Re Ra Response
1(G) 36 39 10 34 14 7 2.24 1.99 0.041 38 15 6 11 20 10 0.93 2.15 0.05 44.10
2(G) 27 25 10 25 20 8 1.65 2 0.036 23 33 23 46 20 7 0.66 2.15 0.034 43.40
3(G) 26 33 7 29 14 7 1.75 2 0.045 14 9 6 9 8 7 1.34 2.15 0.067 33.10
4(G) 22 15 8 21 14 6 1.23 2.02 0.034 7 23 5 26 16 4 2.65 2.14 0.068 37.20
5(G) 28 23 11 21 16 7 0.98 1.99 0.034 25 13 6 26 9 7 0.91 2.15 0.058 31.80
6(G) 33 10 8 17 12 6 1.79 2.01 0.046 8 7 6 16 19 6 1.78 2.15 0.067 37.70
7(G) 25 5 13 16 13 8 1.08 2.02 0.04 13 9 6 14 12 6 1.49 2.14 0.043 17.40
8(G) 28 20 10 22 12 8 0.9 1.99 0.031 17 8 8 22 16 8 1.47 2.17 0.048 22.40
9(B) 356 211 100 252 127 21 1.32 1.99 0.055 12 20 6 22 14 9 3.63 2.17 0.14 426.00
10(B) 36 11 11 15 10 8 0.5 2.01 0.028 32 26 18 20 16 7 3.14 2.15 0.17 50.80
11(B) 33 25 16 22 26 17 0.61 2.02 0.055 20 15 5 14 15 11 1.79 2.13 0.047 45.70
12(B) 37 10 14 15 13 6 1.43 1.98 0.04 192 39 33 127 71 28 3.08 2.17 0.093 59.40
13(B) 121 43 35 73 42 10 1.33 1.98 0.05 12 8 5 18 33 18 2.89 2.16 0.073 124.00
14(B) 35 22 17 25 21 10 0.9 1.99 0.033 8 9 11 32 65 15 5.6 2.11 0.26 83.10
15(B) 32 17 14 18 12 7 2.49 2.01 0.055 14 7 5 10 13 9 2.1 2.13 0.1 65.20
16(B) 38 19 18 42 38 13 0.67 2 0.034 11 6 6 16 18 9 3.47 2.11 0.059 103.50
INNER RING OUTER RING
Bearing Vibration
Time: Max 45 mins
! Find the total count for each parameter of the inner ring based on 6 BOB & 6 WOW and give
your conclusions
Tol 22 45 125 90 45 16 2 0.03
NO L1 L2 L3 L M H Wt Ri Ra
Count
INNER RING
Exercise 3 (Contd..)
! Find the total count for each parameter of the outer ring based on 6 BOB & 6 WOW and give
your conclusions
22 45 125 90 45 16 2
L1 L2 L3 L M H Wt Re Ra
OUTER RING
Time: Max 45 mins
Scratch Pad
Time: Max 5 mins
! Establish the tolerance for the SSV"s having count >=6 for the Inner ring
Tol 22 45 125 90 45 16 2 0.03
NO L1 L2 L3 L M H Wt Ri Ra
Count
INNER RING
Time: Max 5 mins
! Establish the tolerance for the SSV"s having count >=6 for the Outer ring
22 45 125 90 45 16 2
L1 L2 L3 L M H Wt Re Ra
OUTER RING
Exercise 5 Product/Process search
Time: Max 30 mins
! Establish whether L3 after grinding is the root cause for L3 variation after honing. Establish
specification for L3 after grinding
No
L3 (after
grinding)
L3 (after
honing)
1 90 7
2 71 5
3 93 6
4 161 7
5 108 7
6 106 8
7 56 7
8 116 6
9 94 8
10 124 6
11 116 6
12 158 11
13 78 7
14 99 7
15 113 10
16 69 9
17 151 10
18 106 10
19 140 15
20 159 10
21 89 8
22 95 6
23 145 6
24 84 5
25 127 12
26 154 13
27 161 9
28 155 11
29 110 9
30 129 11
31 139 6
32 111 4
33 138 8
34 106 7
35 126 8
36 108 10
37 176 12
38 128 12
39 85 5
40 150 8
41 113 6
42 73 7
43 90 6
44 93 8
45 106 9
46 119 12
47 72 6
48 91 8
49 98 10
50 92 7
Time: Max 30 mins
Scratch Pad
Time: Max 30 mins
Scratch Pad
Time: Max 30 mins
Scratch Pad
Exercise 6 Component Search
Time: Max 60 mins
! The data for the component search done on a Motor assembly for Noise is
given below. The following is the Stage # 1 data. Unit of Noise is in dB
24 5 Second
reassembly
27 6 First reassembly
25 4 Initial value
WOW BOB
D =
d =
D/d =
Conclusion: Is it an assembly process problem or not
Exercise 6 Contd..
Time: Max 60 mins
! Stage #2 data is given below. Draw the graph and conclude
which component is creating the problem
6
21
22
8
D-R+
C-R+
B-R+
A-R+
D+R- 8
C+R- 7
B+R- 6
Decision A+R- 21
Exercise 6 Contd..
Time: Max 60 mins
! What you will do for Stage #3
! Do a factorial analysis for the components
identified in Stage #2.and tell your conclusions
about the contribution of each component to
noise and the interactions contribution to noise
Time: Max 60 mins
Scratch Pad
Time: Max 60 mins
Scratch Pad
Time: Max 60 mins
Scratch Pad
Exercise 7 Multi-Vari analysis
Time: Max 10 mins
! For the process depicted below identify the following:
Type of stream:
Level of streams:
Number of streams:
Is it Process/Product stream:
Three nut runners are tightened
with a single 3 socket air driver
Assembly is index to
tighten other 3 sets of nut
runners
Time: Max 10 mins
! Make a stream table for the process given
Time: Max 60 mins
! For the data given below do the analysis and find out the highest type of variation
Side-A Side-B Side-A Side-B Side-A Side-B Side-A Side-B
1 41.2 46.6 46.4 45.3 46.1 44.2 39.9 38.6
2 44.2 45.3 46.9 45.6 43.3 44.6 41.2 39.3
3 44.5 46.2 45.4 44.4 40.6 44.6 38.8 36.3
1 50.9 53.8 49.5 50.2 40.7 46.5 37.6 34.6
2 54.9 60.9 46.2 51.4 41.9 43.3 35 36.2
3 55.5 61.3 46.9 43.1 39.2 44.2 39.4 36.8
1 11.4 15.5 14.1 16.2 24.7 27.1 19.3 16.6
2 14.5 12.8 12 13.1 20.4 18.3 14 21.9
3 12.9 14.2 14.5 17.2 17 15.4 20 20.9
1 15.1 16.7 16 21.6 22.5 23.6 22.9 31.1
2 19.7 16.1 16.4 18.2 23.3 18 17.9 22.8
3 15.1 17.7 20 19.8 16.8 21.6 18.9 23.6
RHS
SET1 SET2
4:30 AM
LHS
SET1 SET2
11:00pm
1:30 AM
2:45 AM
Parameter: L3 band, Unit of measurement: Microns/sec, Spec: 25 max, Process: Honing
Time: Max 60 mins
Scratch Pad
Time: Max 60 mins
Scratch Pad
Time: Max 60 mins
Scratch Pad
! Catapult Design
! Refer the training material
Exercise 9 Variable Search
Time: Max 120 mins
Phase 2 Variable search - Exercise
A DOE team is working on an application problem in Paint. There are some inconsistencies in the application process
for which the team suspects the Design of the Process. The team decides to do a Variable search on the Application
parameters. The following application parameters are selected to redesign the process
A) Paint temperature
B) Flash off time
C) Number of coats
D) Application pressure
E) Air flow (Automization)
F) Substrate temperature
Viscosity of the Paint
The following parameters and the levels are identified for doing the Variable search
G. Viscosity of paint
F. Substrate temp
E. Air flow
D. Appln pressure
C. Number of coats
B. Flash off time
A. Paint temp
Parameter
19 secs 23 secs
Ambient 10 deg
Full knob Half knob
4 kg/sq cm 3 kg/sq cm
4 2
3 min 1 min
Ambient 10 deg
+ -
Since the response is a visual appearance, it is graded on a scale of 0-1
The results of the step 1 of variable search are given below:
All + All -
2 10
1 10
3 10
Conclude whether the levels and parameters are
identified correctly
Calculate the Control limits
UCL (+) =
LCL (+)=
UCL (-)=
LCL(-)=
Results of Step : 2
Exp No Setting Response Setting Response Significant or
Not
1 A-R+ 1 A+R- 8
2 B-R+ 5 B+R- 9
3 C-R+ 7 C+R- 10
4 B-C-R+ 8 B+C+R- 8
5 D-R+ 5 D+R- 10
6 B-C-D-R+ 8 B+C+D+R- 3
7 E+R- 9 E-R+ 4
8 B-C-D-E-R+ 10 B+C+D+E+R- 0
Do a Factorial analysis for the factors B, C & D
B C D Response Median BC CD BD BCD
1 - - -
2 + - -
3 - + -
4 + + -
5 - - +
6 + - +
7 - + +
8 + + +
Total
effect
Avg.
effect
Exercise 10 B Vs C
Time: Max 15 mins
! A DOE team working on Bearing vibration problem has identified Inner ring
#L3" band as the root cause for problem. To validate their findings they did B
Vs C for 6B and 6C. The results are given below
C B
1 56.5 13.7
2 64.5 26.9
3 46.8 22.8
4 41 19.7
5 37.6 25.8
6 34.5 19.8
Response: L Band , Unit: Microns/sec
Exercise 10 B Vs C
Time: Max 15 mins
! Find out whether the cause they have identified is correct
! If correct, how much is the contribution of the cause towards the response

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Shainin DOE, Version: 1.

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