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DOE is a more formal
approach to learn about the impact of process parameters on a specific
characteristic of the product. It can be applied to any process and they say
that having only a basic knowledge about what are the major parameters and their
range will suffice to perform DOE.
This is not completely
thru. The more detailed information the one has about the process parameters,
about other models for the same or similar process, about the physical or
chemical processes taking place the better choice of experimental
plan. Materials, Metallurgical and Chemical Engineer who are
knowledgeable about materials processing and specifics handle DOE for processes
for/ with materials better then other professionals. The following are the steps
of DOE
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Learn more about your
process and process parameters from the technical literature in order to be
able to list and rank them them with their ranges of change and importance
and to also indicate the major parameters. The
more information you have , the better your decision about the plan
/experimental matrix
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Estimate the the number of experiments based
on the required accuracy and costs. Trades-off with the
model accuracy reduce the experimental work and costs but affect negatively
the accuracy. The higher model precision you want to get, the more
investments for experiments ( see samples of matrices below >
) Select a DOE plan while bear in mind that:
N= Lf
where N- # of experiments L- # of levels, f- # of factors (
See samples of matrix below > )
-
A fractional
factorial requires less experiment but is also gives a less accurate model
( See samples of matrix below > )
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The
replication is important, 3 trials at the same process parameters settings
is recommended
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Have the matrix of
the experiment selected, plan the physical experiment. Keep your experiment
in control. Make sure you change only parameters required. Take
materials/parts from one lot or package. Use the same measurement techniques
and devices for the entire experiment. Carefully record all data including
for all the parameters, make notes about the environmental conditions.
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Analyze the results
1-st from the matrix of the plan by factor e.g. by column evaluating the
impact of each parameter on the output /response. Using simple addition or
subtraction you can find out the factors of highest impact. Design graphs
displaying results. Make conclusions about the parameters impact. Use this
knowledge to set up your parameters and an experiment with the best
output.
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