Design of Experiments, Case Study

Design of Experiments

Project	Our client, an automotive supplier, approached SQPS with an assembly problem. Their customer experienced occasional adhesion problems on their part when it was mounted on a larger assembly at the customer's site. The objective of this study was to identify all failure modes of assembly (both internal and at the customer's site). Our client was also interested identifying the best process settings so no failures could occur.
Approach	Our approach can be summarized as follows: We assembled a team of our client's engineers, technicians and production associates All possible process variables were investigated. This included controlled and noise variables 3 internal factors and one external (customer-controlled) factor were identified An experimental design was planned. A factorial design was generated (3 factors at two levels and one factor at 3 levels). The client's customer provided the necessary samples to complete the experiment under controlled conditions The experiment was run and analyzed A report was issued with the findings.
Results	The results showed that The "Testing Distance" factor was the most significant. This meant that most of the failures that occurred in the experiment were attributed to this factor. Interestingly enough, this is the factor that was controlled by the client's customer. Results were confirmed Another factor, "Promoter Applied" was found not to be significant. This meant that no difference was observed whether the promoter was applied or not. However, since the promoter was being applied in the process, significant savings from not using it could be realized. All factors were set at their best levels

			S Q P S, Ltd.

			.....Solutions for quality since 1997