Design of experiments

Lecture 4: Introduction-Applications of DOE (Ch

1 DAE)
Nitin Padhiyar
IIT - Gandhinagar
 APPLICATION-1:
CHARACTERISING A PROCESS
 FLOW SOLDERING MACHINE
⚫ A flow solder machine is used in the manufacturing
process for printed circuit boards. The machine cleans
the boards in a flux, preheats the boards, and then moves
them along a conveyor through a wave of molten solder.
⚫ The process engineer responsible for this area would like
to use a designed experiment to determine which
machine parameters are influential in the occurrence of
solder defects and which adjustments should be made to
those variables to reduce solder defects.
 FACTORS AFFECTING THE
PROCESS
Controllable factors [x] affecting the process
1. Solder temperature
2. Preheat temperature
3. Conveyor speed
4. Flux type
5. Flux specific gravity
6. Solder wave depth
7. Conveyor angle.
 FACTORS AFFECTING THE
PROCESS
Uncontrollable factors [z] affecting the process
1. Thickness of the printed circuit board
2. Types of components used on the board
3. Layout of the components on the board
4. Operator
5. Production rate.
 POSSIBLE OUTCOME
⚫ Screening experiment
⚫ Estimate the magnitude and direction of factors effects
⚫ OFAT
⚫ Factorial design

⚫ This helps identify the critical factors

⚫ Can be used for control chart

⚫ Characterization: We are usually interested in

determining which process variables affect the
response.
APPLICATION 2: OPTIMIZING A
PROCESS

- to determine the region in the important factors that leads

to the best possible response.
 DEFINITION
⚫ Suppose that we are interested in
improving the yield of a chemical
process.
⚫ Two most important process
variables: operating temperature
and reaction time [How can we
find it?].
⚫ The process currently runs at
145°F and 2.1 hours of reaction
time, producing yields of around
80 percent. How to arrive to the
maximum yield?
 Second
Optimization
FACTORS Experiment

⚫ Temperature and Time Path leading

⚫ 2 factorial design 9
to higher
yield
⚫ What should be the 5
direction of movement?
⚫ We can do finer search after
arriving to the upper square!
⚫ Here we can perform more 8 7
Initial 2 8
precise exps and make a Optimization 8
data based model Experiment 0
⚫ Use this model to get the 7 7
max yield 0 5

⚫ Last two steps: Response Current

surface methodology Operating
Condition
APPLICATION 3: DESIGNING A
PRODUCT
 Designing a New Pump for the
Intravenous Delivery of a Drug
⚫ The pump should deliver a constant quantity or
dose of the drug over a specified period of time.
⚫ She (biomedical engineer) must specify a
number of variables or design parameters
⚫ Diameter and length of the cylinder
⚫ Fit between the cylinder and the plunger
⚫ Plunger length
⚫ Diameter and wall thickness of the tube
connecting the pump and the needle inserted into
the patient’s vein
⚫ Material to use for fabricating both the cylinder
and the tube
⚫ Nominal pressure at which the system must
operate.
Designing a New Pump for the
Intravenous Delivery of a Drug

⚫ A prototypes can be built in which these factors can be

varied over appropriate ranges
⚫ Experiments can then be designed and the prototypes
tested to investigate which design parameters are most
influential on pump performance
⚫ Analysis of this information will assist the engineer in
arriving at a design that provides reliable and
consistent drug delivery.
APPLICATION 4: FORMULATING
A PRODUCT
Formulating a Product
⚫ A biochemist is formulating a diagnostic product
to detect the presence of a certain disease.
⚫ The product is a mixture of biological materials,
chemical reagents, and other materials that when
combined with human blood react to provide a
diagnostic indication.
⚫ Mixture experiment: Various ingredients that are
combined to form the diagnostic make up 100
percent of the mixture composition
Formulating a Product
⚫ The response is a function of the mixture
proportions that are present in the product
⚫ Other applications of mixture experiment: in
designing biotechnology products,
pharmaceuticals, foods and beverages, paints and
coatings, consumer products such as detergents,
soaps, and other personal care products, and a wide
variety of other products.
Thank You