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DOE case study – example of fractional factorial design analysis

Gravity Casting of Aluminum Brake Calipers – Reduction of a Rare Surface Defect Using DOE The manufacturer of aluminum brake calipers was in the final phase of designing the casting process of a new caliper. Serial production was taking place on two semi-automatic prototype machines and on one fully automatic casting line. Ultimately, the prototype […]

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From apparent knowledge to conscious ignorance

What Deming really meant Deming observed that the greatest barrier to improvement is not a lack of knowledge, but the belief that we already have it. Organizations operate for years in a state he called apparent knowledge – a set of practices, procedures, and beliefs that “work” because the system has not yet collapsed. Results […]

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Process capability indexes Cp Cpk Pp ppk – sample size matters

Process behavior charts and histograms with specification limits superimposed allow us to compare the voice of the process with the voice of the customer. Numerical summaries (this is how process capability indexes should be described) complement these graphical comparisons, but they are not able to replace them. The main problem with numerical summaries is not […]

Jan

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Case Study – 50% Reduction in Coating Thickness Variation of 3D Fence Panels

The fence panel manufacturer had a problem with excessively high variation in enamel coating thickness. The five-year anti-corrosion warranty offered to customers requires ensuring a minimum coating thickness of 80 microns, confirmed by salt spray chamber tests. High variation in thickness within the manufactured panels results in significantly higher consumption of enamel powder than assumed […]

Jan

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What’s worse than a bar chart?

What’s worse than a bar chart? A 3D bar chart Every chart has only one purpose: to show the truth contained in the data—and to do it as quickly as possible. And that’s precisely where the classic chart struggles. A bar chart looks innocent: it shows a single number as the height of the bar. […]

Jan

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Design of Experiments (DoE) – DOE Analysis, Part 6/6

You can find the first parts of the article here: PART 1 PART 2 PART 3 PART 4 PART 5 It’s time for the final conclusions, i.e. the DoE analysis We’ll begin with the Y3: scale analysis, which is a visual assessment of the yolk set level on a scale of 1 to 16. The […]

DOE case study – example of fractional factorial design analysis

From apparent knowledge to conscious ignorance

Process capability indexes Cp Cpk Pp ppk – sample size matters

Case Study – 50% Reduction in Coating Thickness Variation of 3D Fence Panels

What’s worse than a bar chart?

Design of Experiments (DoE) – DOE Analysis, Part 6/6

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