MPX Optimize Xpert Process Optimization Detailed Overview Table

MPX Optimize Xpert Process Optimization Detailed Overview

Table of Contents § § § Overview Design of Experiment (DOE) Adjusting the Process Targeting Six Sigma Summary MANUFACTURING SOLUTIONS

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

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 Direct Machine Upload Process Optimization MANUFACTURING SOLUTIONS One Many Good. Part Good Parts

Process Window Concept Process Window : Stroke Inside = good parts e g n ki Pr Outside = bad parts ur ss e c Pa Injection MANUFACTURING SOLUTIONS Velocity

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 MANUFACTURING SOLUTIONS

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 MANUFACTURING SOLUTIONS

Defects vs. Variables MANUFACTURING SOLUTIONS

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… § X 1 = Packing Pressure § X 2 = Injection velocity § X 3 = …. § Y 1 -n = Part Quality (various criteria) MANUFACTURING SOLUTIONS

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 MANUFACTURING SOLUTIONS

Optimize Xpert - DOE § Process variable states for the 8 parts produced in the DOE when eliminating visual defects MANUFACTURING SOLUTIONS

Optimize Xpert – DOE § Process variable states for the 8 parts produced in the DOE when eliminating dimensional, warpage or weight defects MANUFACTURING SOLUTIONS

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 MANUFACTURING SOLUTIONS

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: 1) 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 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. 2) Methodology: DMAIC/DFSS structured problem solving roadmap and tools. 3) 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 MANUFACTURING SOLUTIONS

Simplified Sigma Conversion Source : The Six Sigma Way - Pande, Neuman & Cavanagh MANUFACTURING SOLUTIONS

Table of Contents § § § Overview Design of Experiment (DOE) Adjusting the Process Targeting Six Sigma Summary MANUFACTURING SOLUTIONS

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… § X 1 = Packing Pressure § X 2 = Injection velocity § X 3 = …. § Y 1 -n = Part Quality (various criteria) MANUFACTURING SOLUTIONS

Process Parameters Cushion e i ck ng Pr u ss re Pa MANUFACTURING SOLUTIONS Injection Velocity

Measure Process Variation GO 1 2 Cushion 3 4 c Pa n ki MANUFACTURING SOLUTIONS g Pr r su e 5 es Measured Process Variation Injection Velocity

Cushion Design of Experiments c Pa n ki MANUFACTURING SOLUTIONS g Pr r su e es Injection Velocity

DOE Variation MANUFACTURING SOLUTIONS

Design of Experiments MANUFACTURING SOLUTIONS

Design of Experiments GO 1 2 Cushion 3 4 ng Pr r su e 5 es i k ac 6 P 7 8 MANUFACTURING SOLUTIONS Injection Velocity û û û û

Judge Part Quality MANUFACTURING SOLUTIONS

Judge Part Quality MANUFACTURING SOLUTIONS

Process Window 1 Cushion Process window for parts with acceptable quality ss i k ac ng e Pr e ur 2 3 4 5 6 P 7 8 MANUFACTURING SOLUTIONS Injection Velocity û û û

Cushion Adjust Process Window c Pa n ki g Pr r su e es MANUFACTURING SOLUTIONS Injection Velocity

Repeat DOE GO 1 2 Cushion 3 4 c Pa n ki g Pr r su e 5 es 6 7 8 MANUFACTURING SOLUTIONS Injection Velocity

Table of Contents § § § Overview Design of Experiment (DOE) Adjusting the Process Targeting Six Sigma Summary MANUFACTURING SOLUTIONS

How Does MPX Shift the Process? § Simple case § Short shot when velocity stroke is low MANUFACTURING SOLUTIONS

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 MANUFACTURING SOLUTIONS

Conflicts Resolution § Some defects require conflicting actions § These are partly resolved by the nature of vector summation Shift Matrix MANUFACTURING SOLUTIONS

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 MANUFACTURING SOLUTIONS

Additional DOE’s MANUFACTURING SOLUTIONS

Additional DOE’s MANUFACTURING SOLUTIONS

Additional DOE’s MANUFACTURING SOLUTIONS

Judge Part Quality MANUFACTURING SOLUTIONS

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 MANUFACTURING SOLUTIONS

DOE History MANUFACTURING SOLUTIONS

DOE History MANUFACTURING SOLUTIONS

Table of Contents § § § Overview Design of Experiment (DOE) Adjusting the Process Targeting Six Sigma Summary MANUFACTURING SOLUTIONS

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: 1) 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 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. 2) Methodology: DMAIC/DFSS structured problem solving roadmap and tools. 3) 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 MANUFACTURING SOLUTIONS

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 MANUFACTURING SOLUTIONS

Reducing Experiment Size Stroke Small Process Window re u ss e ng i k Pr c Pa Injection MANUFACTURING SOLUTIONS Velocity

Reducing Experiment Size Stroke 6 Sigma DOE re u ss e ng i k Pr c Pa Injection MANUFACTURING SOLUTIONS Velocity

Stroke Reducing Experiment Size 4 Sigma DOE re u ss e ng i k Pr c Pa Injection MANUFACTURING SOLUTIONS Velocity

Increasing Experiment Size Stroke Large Process Window re u ss e ng i k Pr c Pa Injection MANUFACTURING SOLUTIONS Velocity

Increasing Experiment Size Stroke 6 Sigma DOE re u ss e ng i k Pr c Pa Injection MANUFACTURING SOLUTIONS Velocity

Increasing Experiment Size Stroke 12 Sigma DOE re u ss e ng i k Pr c Pa Injection MANUFACTURING SOLUTIONS Velocity

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

Saved Record File § All details of the Optimise Xpert DOE runs are saved in a readable trace file § Documented evidence of experiments performed, quality feedback, condition changes, final conditions and execution times § Navigate to Program Files Moldflow MPX Job Mold Run OXCycles MANUFACTURING SOLUTIONS

Saved Record File MANUFACTURING SOLUTIONS

Table of Contents § § § Overview Design of Experiment (DOE) Adjusting the Process Targeting Six Sigma Summary MANUFACTURING SOLUTIONS

Summary: Optimize Xpert § Automated Design of Experiments used to determine a robust processing window § Begins by measuring the normal process variation of the molding machine § Varies the most important process parameters for the experiment § Uses visual, dimension, warpage and weight defects as part quality criteria Direct Machine Upload Process Optimization No Burn No Short MANUFACTURING SOLUTIONS No Flash One Many Good. Part Good Parts

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