1 / 55

MPX Optimize Xpert

MPX Optimize Xpert. Process Optimization Detailed Overview. Table of Contents. Overview Design of Experiment (DOE) Adjusting the Process Targeting Six Sigma Summary. Direct Machine Upload. Process Setup. MPX Setup Wizard. One Good Part. CAE - MPI/MPA. Direct Machine Upload. One

shubha
Download Presentation

MPX Optimize Xpert

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. MPX Optimize Xpert Process Optimization Detailed Overview

  2. Table of Contents • Overview • Design of Experiment (DOE) • Adjusting the Process • Targeting Six Sigma • Summary

  3. Direct Machine Upload Process Setup MPX Setup Wizard One Good Part CAE - MPI/MPA Direct Machine Upload One Good Part One Good Part Process Optimization Many Good Parts No Burn No Short No Flash ü Direct Machine Upload Process Control Check Every Part MPX Software Modules

  4. Direct Machine Upload One Good Part One Good Part Process Optimization Many Good Parts Optimize Xpert • Main objective is to operate in a robust area of the processing window to consistently produce good parts when natural machine and process variation occurs • Starting conditions from either Process Setup or from existing conditions on machine

  5. Process Window : Inside = good parts Outside = bad parts Stroke Packing Pressure Injection Velocity Process Window Concept

  6. Optimize Xpert – What it does • Automated Design of Experiments used to determine size of robust processing window • Begins by measuring the normal process variation of the molding machine • Varies Velocity Stroke, Injection Velocity, and Packing Pressure • Uses short shots, sink marks, flash, burn marks, & weld lines as part visual defects criteria • Automatically shifts process parameters to a safer position within the processing window

  7. Optimize Xpert - What it does • Extendable to eliminate part defects due to warpage, weight & dimensions • Varies Packing Pressure, Packing time & Cooling Time • Automatically shifts process parameters to a safer position within the processing window

  8. Defects vs. Variables

  9. What is a DOE? • A Design of Experiment (DOE) is a structured, organized method for determining the relationship between factors (Xs) affecting a process and the output of that process (Y). • MPX uses three variable - two level - full factorial design of experiments (DOE) • In other words… • X1 = Packing Pressure • X2 = Injection velocity • X3 = …. • Y1-n = Part Quality (various criteria)

  10. Optimize Xpert - DOE • MPX DOE can be performed relatively quickly compared to days, weeks or even months that manual DOE’s can take • MPX DOE automatically selects the key parameters & calculates the variation to apply • MPX DOE automatically analyses the data & quality feedback to calculate the required adjustments to the process

  11. Optimize Xpert - DOE • Process variable states for the 8 parts produced in the DOE when eliminating visual defects

  12. Optimize Xpert – DOE • Process variable states for the 8 parts produced in the DOE when eliminating dimensional, warpage or weight defects

  13. Optimize Xpert – DOE / Six Sigma • MPX automatically calculates the high & low limits for the DOE & applies them to the molding machine during each experiment • User can define sigma difference between high & low, otherwise default is 6 sigma (+/- 3 standard deviations) • MPX calculates +/- 3 Sigma, but configuration limits can restrict the actual variation used to design the DOE • Default limits can be changed by the user

  14. What is 6 Sigma? • The goal of Six Sigma is to increase profits by eliminating variability, defects and waste that undermine customer loyalty. • Six Sigma can be understood/perceived at three levels: • Metric: 3.4 Defects Per Million Opportunities. DPMO allows you to take complexity of product/process into account. Rule of thumb is to consider at least three opportunities for a physical part/component - one for form, one for fit and one for function, in absence of better considerations. Also you want to be Six Sigma in the Critical to Quality characteristics and not the whole unit/characteristics. • Methodology: DMAIC/DFSS structured problem solving roadmap and tools. • Philosophy: Reduce variation in your business and take customer-focused, data driven decisions. • Six Sigma is a rigorous and a systematic methodology that utilizes information (management by facts) and statistical analysis to measure and improve a company's operational performance, practices and systems by identifying and preventing 'defects' in manufacturing and service-related processes in order to anticipate and exceed expectations of all stakeholders to accomplish effectiveness. http://www.isixsigma.com/dictionary/Six_Sigma-85.htm

  15. Simplified Sigma Conversion Source : The Six Sigma Way - Pande, Neuman & Cavanagh

  16. Table of Contents • Overview • Design of Experiment (DOE) • Adjusting the Process • Targeting Six Sigma • Summary

  17. What is a DOE? • A Design of Experiment (DOE) is a structured, organized method for determining the relationship between factors (Xs) affecting a process and the output of that process (Y). • MPX uses three variable - two level - full factorial design of experiments (DOE) • In other words… • X1 = Packing Pressure • X2 = Injection velocity • X3 = …. • Y1-n = Part Quality (various criteria)

  18. Cushion Packing Pressure Injection Velocity Process Parameters

  19. GO 1 2 3 Cushion 4 5 Packing Pressure Measured Process Variation Injection Velocity Measure Process Variation

  20. Cushion Packing Pressure Injection Velocity Design of Experiments

  21. DOE Variation

  22. Design of Experiments

  23. GO û 1 û 2  3 û Cushion 4  5 Packing Pressure  6  7 û 8 Injection Velocity Design of Experiments

  24. Judge Part Quality

  25. Judge Part Quality

  26. 1 2 3 Cushion 4 5 Packing Pressure 6 7 8 Injection Velocity Process Window û Process window for parts with acceptable quality û  û    û

  27. Cushion Packing Pressure Injection Velocity Adjust Process Window

  28. GO  1  2  3  Cushion 4  5 Packing Pressure  6  7  8 Injection Velocity Repeat DOE

  29. Table of Contents • Overview • Design of Experiment (DOE) • Adjusting the Process • Targeting Six Sigma • Summary

  30. How Does MPX Shift the Process? • Simple case • Short shot when velocity stroke is low

  31. Shift Vector Calculations • Every “Bad” = 1 , Every “Good” = 0 Process parameter shift = {(all “highs”)-(all “lows”)}/4 Packing pressure shift = (2 - 2)/4 = 0 Velocity stroke shift = (0 - 4)/4 = -1

  32. Conflicts Resolution • Some defects require conflicting actions • These are partly resolved by the nature of vector summation Shift Matrix

  33. Conflicts Resolution (Cont.) • Some knowledge of the process is used to prioritize the importance of the different shifts Shift Matrix Process “knowledge” matrix Weighted matrix Summed shifts Normalized shifts Actual shifts

  34. Additional DOE’s

  35. Additional DOE’s

  36. Additional DOE’s

  37. Judge Part Quality

  38. Dimensions, Warpage & Weight Feedback • Feedback can be entered 24+ hours later if required • Save & re-open run or leave dialog open • NB. If Visual Defects DOE also selected then visual defects must be eliminated before progressing to DOE’s on Dimensions, Warpage or Weight

  39. DOE History

  40. DOE History

  41. Table of Contents • Overview • Design of Experiment (DOE) • Adjusting the Process • Targeting Six Sigma • Summary

  42. What is 6 Sigma? • The goal of Six Sigma is to increase profits by eliminating variability, defects and waste that undermine customer loyalty. • Six Sigma can be understood/perceived at three levels: • Metric: 3.4 Defects Per Million Opportunities. DPMO allows you to take complexity of product/process into account. Rule of thumb is to consider at least three opportunities for a physical part/component - one for form, one for fit and one for function, in absence of better considerations. Also you want to be Six Sigma in the Critical to Quality characteristics and not the whole unit/characteristics. • Methodology: DMAIC/DFSS structured problem solving roadmap and tools. • Philosophy: Reduce variation in your business and take customer-focused, data driven decisions. • Six Sigma is a rigorous and a systematic methodology that utilizes information (management by facts) and statistical analysis to measure and improve a company's operational performance, practices and systems by identifying and preventing 'defects' in manufacturing and service-related processes in order to anticipate and exceed expectations of all stakeholders to accomplish effectiveness. http://www.isixsigma.com/dictionary/Six_Sigma-85.htm

  43. Optimize Xpert • If 8 good shots cannot be produced then DOE can be repeated with a lower sigma size or lower variation limits • This then defines the size of the available processing window • Equally if 8 good shots are obtained then DOE can be repeated with a higher sigma size or higher variation limits to determine the size of the available processing window

  44. Stroke Packing Pressure Injection Velocity Reducing Experiment Size Small Process Window

  45. Stroke Packing Pressure Injection Velocity Reducing Experiment Size 6 Sigma DOE

  46. Stroke Packing Pressure Injection Velocity Reducing Experiment Size 4 Sigma DOE

  47. Stroke Packing Pressure Injection Velocity Increasing Experiment Size Large Process Window

  48. Stroke Packing Pressure Injection Velocity Increasing Experiment Size 6 Sigma DOE

  49. Stroke Packing Pressure Injection Velocity Increasing Experiment Size 12 Sigma DOE

  50. HTML-Based document Automatically created & formatted at end of DOE run Saves... Velocity & Pressure profiles Temperature profiles Back pressure & screw speed profiles On-line Process Setup Sheet

More Related