Professional Documents
Culture Documents
Quality By Design
Part 1: Quality Assessment using Quality Loss Function
Fall 2016
By
Prof. Dr. Eng. Ahmed Sherif El-Gizawy
Professor and Director Tech Development Center
University of Missouri, USA
Presentation Method
Quality by Design (QBD) is one of the most powerful quality improvement tools.
Products or services with specification on the target values give best performance .
The focus in the present seminar is on the application of the quadratic loss function
to quantify improvement opportunities in engineering industry.
Sony - USA
Sony - Japan
Noise Factors
They are the uncontrolled factors that cause Quality
characteristics to deviate from their target value.
Robustness
Product and process designs that are insensitive to noise factors
are Robust.
Minimum Variability
10
11
Robustness
System designs that are insensitive to noise factors are Robust.
12
Measurement of Quality
During Design/Development
Quality Loss
Function
Signal To
Noise Ratio
Efficient
Experimentation
Using Design of
Experiments
(ANOVA)
Analysis of
Variances
13
m + 0
L(y) = k(y-m)2
k=
0 = Tolerance (allowance)
A0 = Quality Loss at y = y0 = (m + 0)
k = Constant
(y - m) is deviation from the target value
15
Variations of the
Quality loss function
(QLF)
16
115 20 volts
The average cost of repairing is $100
a.
b.
17
L(y)
Loss ($)
Nominal the Best
0 = $100.00
0 = $100.00
0 = 20 V
95
L = ( )2
k = 02 =
0
100
20 2
115
0
135
y = voltage
= 0.25
= 0.25 ( 115) 2
18
Summary
22
Material
Data (% shrinkage)
A
0.28 0.24 0.33 0.30 0.18 0.26 0.24 0.33
B
0.08 0.12 0.07 0.03 0.09 0.06 0.05 0.03
23
Solution
Smaller the Better
k=
L= 35.55556 y2
35.55556
100
90
80
70
LOSS, $
60
50
40
30
20
10
0
0
0,2
0,4
0,6
0,8
SHRINKAGE %
1,2
1,4
1,6
1,8
Material B
k=
35.5555
L= 35.55556 y2
average B =
0.0663
L=
0.0351
1.2468
Material A
k=
35.5555
L= 35.55556 y2
average A =
0.0729
L=
0.1239
4.4050
Conclusion
A
L=4.4050
B
L=1.2468
Month
1
Deviations
-2
-2
-2
-1
-1
-2
-1
-1
-1
-2
-2
-2
-1
-3
Solution
Nominal the Best
Unsymmetrical
m=3
For (y-m)>0
K=200/7^2= 4.081633
L= 4.081633(y-3)^2
For (y-m)<0
K=200/2^2= 50
L= 50 (y-3)^2
For (y-m)>0
K=200/7^2= 4.081633
L= 4.081633 (y-3)^2
For (y-m)<0
K=200/2^2= 50
L= 50 (y-3)^2
500
450
400
350
300
250
Chui1
200
150
100
50
0
-8
-6
-4
-2
Y-m
Results
Month1
Month2
Conclusion
There is improvement in the process during month 2
because the total loss of quality in month 2 is less than
loss of quality in month 1
10.2
5.8
4.9
16.1
15.0
9.4
4.8
10.1
14.6
19.7
5.0
4.7
16.8
4.5
4.0
16.5
7.6
13.7
7.0
12.8
11.8
13.7
14.8
10.4
7.0
10.1
6.8
10.0
8.6
11.2
8.3
10.6
Solution
K=70/5^2= 2.8
L= 2.8 (1/y^2)
0,35
0,3
L, $
0,25
0,2
0,15
0,1
0,05
0
0
10
15
Y-m
QLF for Joint Resistance
20
25
Results
S1
S2
Total loss per unit $ 0.064
Total loss of manufacture cost
$ 7674
Material cost $50
Total loss of manufacture cost + material
cost $7724
Conclusion
Even thought S1 is cheaper than S2, but the
total loss of quality is higher than S2
Levels
900o
1200o
12 hr
Type 2
8 hr
Type 1
Experiment run
Response (y)
y1
2
3
4
5
6
7
8
1
1
1
2
2
2
2
1
2
2
1
1
2
2
2
1
2
1
2
1
2
y2
y3
y4
y5
y6
y7
y8
Orthogonality means that for any pair of columns, all combinations of factor levels
occur and they occur an equal number of times.
40
D.F. = N 1
D.F. (L4) = 4 - 1 = 3
(L8) = 8 - 1 = 7
42
Interaction
A x B, C x D
Select a suitable O.A.
Number of Experiments =
D.F + 1 = 11
44
Assigning Interactions
Interactions are located in specific columns to avoid confounding.
45
Exp. #
1
2
3
4
AxB
1
1
2
2
1
2
1
2
1
2
2
1
If C is significant; therefore,
C and A x B are Confound.
y1
y2
y3
y4
Linear Graphs
Interaction Table
Interaction table is presented for each orthogonal
array to determine which column must assign
interaction.
Interaction column number is found where row (the
first factor) intersects column (the second factor).
The three column combination is interchangeable.
47
Column
Expt.
No
1
2
3
4
5
6
7
8
Column
1
1
1
1
1
2
2
2
2
2
1
1
2
2
1
1
2
2
3
1
1
2
2
2
2
1
1
4
1
2
1
2
1
2
1
2
5
1
2
1
2
2
1
2
1
6
1
2
2
1
1
2
2
1
7
1
2
2
1
2
1
1
2
Factor Assignment
Column
1
2
3
4
5
6
7
1
(1)
2
3
(2)
3
2
1
(3)
4
5
6
7
(4)
5
4
7
6
1
(5)
6
7
4
5
2
3
(6)
7
6
5
4
3
2
1
(7)
48
Main Effects
Estimation of Factor Effects
= Response (measurement of quality characteristic y or
signal to noise ratio S/N)
Overall mean value of response:
n = number of experiments
Quality Characteristic y
Smaller the better
Larger the better
Nominal the best
2.
51
52
(ANOVA, contd)
(= ( ) + ( )+ )
= mean square due to factor =
(where = d.f of that factor = L 1)
Percentage contribution =
53
(ANOVA, contd)
Errors
If only one experiment is conducted at each experimental
condition, the error term is identically zero for each experiment.
(pooling method)
2
Error variance = =
54
(ANOVA, contd)
55
F distribution table
56
L(Y) = K(MSD) = K
= -10 log ( + )
= mean =
= variance =
L(Y) = K(MSD) = K
(correct)
=( )
58
L(Y) = K(MSD) = K (
= K [( ) + ]
Where: t = target value
= mean value
= variance =
=( )
59
60
Questions:
1. Which input affects the 2. What is the relationship
output parameter y?
between the important
inputs and the output
parameter y?
3. How can y be
controlled?
Input
raw materials,
components,
and subassemblies
Measurement
Evaluation
Control
Product
Process
Output product
y = Quality
characteristic
Determine optimum levels of the Control Factors and predict performance under
these levels (regular analysis and S/N analysis)
Conduct verification experiment and plan future actions
62
Exercise:
In order to optimize the process capability of an injection molding
process, the following factors were considered.
Control Factors:
A: Cool Time
B: Mold Temperature
C: Melt Temperature
D: Holding Pressure
E: Injection Speed
F: Holding Time
G: Injection Pressure
Noise Factors
H: Material Batch
I: Machine Type
J: Ambient Temperature
Level 1
A1
B1
C1
D1
E1
F1
G1
Level 2
A2
B2
C2
D2
E2
F2
G2
Level 1
Level 2
H1
I1
J1
H2
I2
J2
63
Quality Characteristic:
Percentage shrinkage
(smaller the better)
64
Results
Control Factor
A
1
2
3
4
5
1
1
1
1
2
1
1
2
2
1
1
1
2
2
2
1
2
1
2
1
1
2
1
2
2
1
2
2
1
1
1
2
2
1
2
Noise Factors
1
1
2
1
2
1
1
2
2
2.20
2.10
2.30
0.30
2.50
2.70
0.50
3.10
0.40
2.00
1.90
1.80
3.00
3.10
3.00
2.10
4.20
1.00
3.10
7
8
2
2
2
2
1
1
1
2
2
1
2
1
1
2
4.00
2.00
1.90
1.90
4.60
1.90
2.20
1.80
H
I
J
2
2
1
2.30
0.30
2.80
2.00
3.00
L(Y) = K(MSD) = K
= -10 log ( + )
= mean =
= variance = =( )
Exercise Solution
Control Factor
1
2
3
4
5
6
7
8
1
1
1
1
2
2
2
2
1
1
2
2
1
1
2
2
1
1
2
2
2
2
1
1
1
2
1
2
1
2
1
2
1
2
1
2
2
1
2
1
1
2
2
1
1
2
2
1
1
2
2
1
2
1
1
2
Level
Noise Factors
H
1
1
I
1
2
J
1
2
2.20 2.10
0.30 2.50
0.50 3.10
2.00 1.90
3.00 3.10
2.10 4.20
4.00 1.90
2.00 1.90
S/N
2
1
2
2.30
2.70
0.40
1.80
3.00
1.00
4.60
1.90
2
2
1
2.30
0.30
2.80
2.00
3.00
3.10
2.20
1.80
Response Table
C
D
1
2
67
Solution, contd
Control Factor
1
2
3
4
5
6
7
8
1
1
1
1
2
2
2
2
1
1
2
2
1
1
2
2
1
1
2
2
2
2
1
1
1
2
1
2
1
2
1
2
1
2
1
2
2
1
2
1
1
2
2
1
1
2
2
1
1
2
2
1
2
1
1
2
Noise Factors
H
1
1
I
1
2
J
1
2
2.20 2.10
0.30 2.50
0.50 3.10
2.00 1.90
3.00 3.10
2.10 4.20
4.00 1.90
2.00 1.90
S/N
2
1
2
2.30
2.70
0.40
1.80
3.00
1.00
4.60
1.90
2
2
1
2.30 -6.95
0.30 -5.88
2.80 -6.98
2.00 -5.70
3.00 -9.62
3.10 -9.36
2.20 -10.73
1.80 -5.58
2.225
1.45
1.7
1.925
3.025
0.0092 1.77
2.1
0.0092
0.0025
2.6
3.175
1.9
Response Table
Level
-8.82381
-7.25
-7.9145
69
Final Solution
= 4.477
Y = 1.68 %
71
72
73
74
75
76