PRESENTATION ONDESIGN OF EXPERIMENTS

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DESIGN OF EXPERIMENTS

TEAM MEMBERS

NAME DEPARTMENT

P.S.RAVI ENGINEERING

I.SEKAR MANUFACTURING

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I.SEKAR MANUFACTURING

PRABHAKAR MAINTENANACE

KAMALAKANNAN QUALITY CONTROL

K.SURESH ENGINEERING

EQUIPMENT WELDING MACHINE (CAPACITOR TYPE)

PROCESS WELDING

PROCESS

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COMPONENTS TUBE & BRACKET

PROCESS OUTPUTS

NO PARAMETERS SPEC.

1 PULL-OFF LOAD 500Kg Min

2 SPATTER MARKS NOT

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2 SPATTER MARKS NOT ALLOWED

3 LEAK NOT ALLOWED

OBJECTIVE

PROBLEMIN ORDER TO MAINTAIN THE PULL-OFF LOAD

SAFELY, WE INVITE SPATTER MARKS AND LEAKAGE

PROBLEM. THIS IS BECAUSE, WE HAVE DETECTION

MECHANISM FOR LEAKAGE AND SPATTER BUT FOR

PULL-OFF LOAD WE HAVE TO DO DESTRUCTIVE

TESTING.

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OBJECTIVE1. REDUCE LEAK2. REDUCE SPATTER3. MAINTAIN PULL-OFF LOAD AT

OPTIMUM LEVEL WITH LESS VARIATION.

PAST DATA - LEAKQUALITY CONTROL DEPATRMENTQUALITY CONTROL DEPATRMENTQUALITY CONTROL DEPATRMENTQUALITY CONTROL DEPATRMENT

EMXI- MONTHLY PPM TREND CHART - LEAKEMXI- MONTHLY PPM TREND CHART - LEAKEMXI- MONTHLY PPM TREND CHART - LEAKEMXI- MONTHLY PPM TREND CHART - LEAK

100

1000

10000

100000

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MONTH JAN FEB MAR APR MAY JUNPROD 18815 20000 20794 15180 11435 23321LEAK 113 55 320 128 120 350PPM 6006 2750 15389 8432 10494 15008

1

10

100

JAN FEB MAR APR MAY JUN

PPM

PAST DATA - SPATTERQUALITY CONTROL DEPATRMENTQUALITY CONTROL DEPATRMENTQUALITY CONTROL DEPATRMENTQUALITY CONTROL DEPATRMENT

EMXI-MONTHLY PPM TREND CHART - SPATTER EMXI-MONTHLY PPM TREND CHART - SPATTER EMXI-MONTHLY PPM TREND CHART - SPATTER EMXI-MONTHLY PPM TREND CHART - SPATTER

100

1000

10000

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MONTH JAN FEB MAR APR MAY JUNPROD 18815 20000 20794 15180 11435 23855SPATTER 1 10 120 105 79 135PPM 53 500 5771 6917 6909 5659

1

10

JAN FEB MAR APR MAY JUN

PPM

BRACKET

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TUBE

TUBE

FACTORS & LEVELS

SN NOTATION

FACTORS LEVELS

HIGH(2) LOW(1)1 A VOLTAGE 275 250

2 B DOME THICK 2.5 1.9

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2 B DOME THICK 2.5 1.9

3 C RAM PRES. 40 35

4 D DELAY TIME 2 1

L827

8 TREATMENTS

2 LEVELS &

7 FACTORS

A1

B2

C4

D76

5

3

EXPERIMENT DATAEXP_NO TREAT 1 2 3 4 5 6 7 8 9 10

1 LLLL 750 825 549 593 756 764 552 799 560 7642 LLHH 736 739 653 808 825 670 781 723 680 5933 LHLH 786 825 828 797 862 562 859 872 772 9224 LHHL 754 742 706 456 794 772 593 806 747 7585 HLLH 803 839 756 777 802 822 781 806 767 741

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5 HLLH 803 839 756 777 802 822 781 806 767 7416 HLHL 828 811 803 802 748 759 790 776 800 7787 HHLL 866 810 844 784 797 829 808 824 842 8408 HHHH 823 839 827 821 798 815 836 818 757 849

VALUES ARE PULL-OFF LOAD IN Kg

TREATMENT COMBINATIONTREAT 1 2 4 6 3 5 7 SpatMENT A B C AD AB AC D ter

1 LLLL A1 B1 C1 AD1 AB1 AC1 D1 691 15.75 No2 LLHH A1 B1 C2 AD2 AB1 AC2 D2 721 19.90 No3 LHLH A1 B2 C1 AD2 AB2 AC1 D2 809 18.36 No4 LHHL A1 B2 C2 AD1 AB2 AC2 D1 713 16.38 No

Avg SNRSN

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Total 6155 189

4 LHHL A1 B2 C2 AD1 AB2 AC2 D1 713 16.38 No5 HLLH A2 B1 C1 AD1 AB2 AC2 D2 789 28.28 No6 HLHL A2 B1 C2 AD2 AB2 AC1 D1 790 30.20 No7 HHLL A2 B2 C1 AD2 AB1 AC2 D1 824 30.42 Yes8 HHHH A2 B2 C2 AD1 AB1 AC1 D2 818 30.04 Yes

LEAKAGE % = 0

SNR CALCULATIONEXP_NO X ΣΣΣΣ x ΣΣΣΣ x2 Sm=(ΣΣΣΣ x)2/10 Variance SNR

1 691 6912 4891808 4777574 12693 15.752 721 7208 5243354 5195526 5314 19.903 809 8085 6622435 6536723 9524 18.364 713 7128 5185730 5080838 11655 16.385 789 7894 6239850 6231524 925 28.28

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5 789 7894 6239850 6231524 925 28.286 790 7895 6238463 6233103 596 30.207 824 8244 6801902 6796354 616 30.428 818 8183 6702119 6696149 663 30.04

SUM OF SQUARESFROM AVG DATA1 2 1~2 (1~2)2/8

A 2933 3222 288 10390B 2991 3164 173 3745C 3114 3041 72 650D 3018 3137 119 1773

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D 3018 3137 119 1773AB 3055 3100 46 259AC 3108 3047 60 452AD 3012 3143 132 2162

ANOVA TABLEFROM AVG DATA

SOURCE OF Nota Mean Sqr. F RatioVARIATION tion SS/DF SS/EMSVoltage A N 1 10390 10390 22.92Thickness B N 1 3745 3745 8.26Volt x Thick AxB Y 1 259 259 0.57Ram Pre. C Y 1 650 650 1.43

Pool D.F. S.S

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From F TableF1,3 (1%) = 34.12F1,3 (5%) = 10.13

Ram Pre. C Y 1 650 650 1.43Volt x Ram Pre AxC Y 1 452 452 1.00Delay D N 1 1773 1773 3.91Volt x Delay AxD N 1 2162 2162 4.77Error (Pooled) 3 1360 453Total 19430

SUM OF SQUARESFROM S/N DATA

1 2 1~2 (1~2)2/8A 70.39 118.94 48.56 294.73B 94.12 95.21 1.08 0.15C 92.81 96.52 3.71 1.72

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C 92.81 96.52 3.71 1.72D 92.75 96.58 3.83 1.83

AB 96.11 93.22 2.88 1.04AC 94.34 94.99 0.65 0.05AD 90.45 98.88 8.42 8.87

ANOVA TABLEFROM S/N DATA

SOURCE OF Nota Pool D.F. S.S Mean Sqr. F RatioVARIATION tion SS/DF SS/EMSVoltage A N 1 295 294.73 317.29Thickness B Y 1 0.15 0.15 0.16Volt x Thick AxB Y 1 1.04 1.04 1.12Ram Pre. C Y 1 1.72 1.72 1.85

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Ram Pre. C Y 1 1.72 1.72 1.85Volt x Ram Pre AxC Y 1 0.05 0.05 0.06Delay D Y 1 1.83 1.83 1.97Volt x Delay AxD N 1 8.87 8.87 9.55Error (Pooled) 5 4.64 0.93Total 308.4

From F TableF1,5 (1%) = 16.26F1,5 (5%) = 6.61

RESPONSE TABLEFROM AVG DATA

FACTOR CODE LEVEL RESPONSE Diff1 733.332 805.40 721 747.732 791.00 43

Voltage

Thickness

A

B

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2 791.00 431 778.38 182 760.351 754.482 784.25 30

Thickness

Ram Pre.

Delay

B

C

D

Preferred CombinationA2-B2-C1-D2

RESPONSE TABLEFROM S/N DATA

FACTOR CODE LEVEL RESPONSE Diff1 17.602 29.74 121 23.532 23.80 0.3

Voltage A

Thickness B

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2 23.80 0.31 23.202 24.13 0.91 23.192 24.15 1.0

Ram Pre. C

Delay D

Preferred CombinationA2-B2-C2-D2

SUMMARY OF RESULTSOPT. COMB. FACTOR SIG. OPTIMAL COMB. FACTOR SIG.(AVE. TABLE) (AVE. TABLE) (SNR TABLE) (SNR TABLE)

Voltage-A A2 A A2 AThick-B B2 B B2(Marginal) Not SignificantRam Pre-C C1 Not Significant C2(Marginal) Not SignificantDelay-D D2 Not Significant D2(Marginal) Not Significant

FACTORS

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1. VOLTAGE SHOULD BE MAINTAINED AT 275.

2. SINCE THICKNESS VALUE IS NOT

SIGNIFICANT, THE PRESENT TOLERANCE OF

1.9~2.5 CAN BE MAINTAINED.

3. RAM PRESSURE, 40 IS BETTER THAN 35

4. DELAY TIME 2 IS BETTER THAN 1. BUT 1 CAN

BE TRIED FOR PRODUCTIVITY PURPOSE.

CONCLUSION

1. CONSIDERING PULL-OFF LOAD ALONE, HHHH

COMBINATION IS BETTER.

2. CONSIDERING PULL-OFF LOAD AND SPATTER

MARKS, HLHL COMBINATION IS BETTER.

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MARKS, HLHL COMBINATION IS BETTER.

3. CONFIRMATORY TRIALS TO BE CONDUCTED WITH

HLHL & HHLH TO COMPARE THE RESULTS. HLHL IS

BETTER IN TERMS OF PRODUCTIVITY.

THANK YOU !!!

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THANK YOU !!!