Process Capability Improvement in Turbo Charger

Center Housing Component

Submitted in partial fulfillment of the requirements for the degree of

Bachelor of Technology
in
Mechanical Engineering

by
SHERIN THOMAS SIPRI
16BME0751

Under the guidance of

Dr.Sundaramali G

SMEC
VIT,Vellore

May, 2020
 DECLARATION

I hereby declare that the thesis entitled “Process Capability

Improvement in Turbo Charger Center Housing Component" submitted by me, for the
award of the degree of Bachelor of Technology in Mechanical Engineering to VIT is a
record of bonafide work carried out by me under the supervision of Dr.Sundaramali
G.
I further declare that the work reported in this thesis has not been submitted
and will not be submitted, either in part or in full, for the award of any other degree or
diploma in this institute or any other institute or university.

Place : Vellore
Date : 11/05/20
Signature of the Candidate
 CERTIFICATE

This is to certify that the thesis entitled “Process Capabilty Improvement in

Turbo Charger Center Housing Component” submitted by Sherin Thomas Sipri &
16BME0751, SMEC, VIT, for the award of the degree of Bachelor of Technology in
Mechanical Engineering, is a record of bonafide work carried out by him under my
supervision during the period, 01.12.2019 to 10.03.2020, as per the VIT code of
academic and research ethics.

The contents of this report have not been submitted and will not be submitted
either in part or in full, for the award of any other degree or diploma in this institute or
any other institute or university. The thesis fulfills the requirements and regulations of
the University and in my opinion meets the necessary standards for submission.

Place : Vellore
Date : 11/05/20 Signature of the Guide

Internal Examiner External Examiner

HOD

Dept. of Manufacturing Engineering

 ACKNOWLEDGEMENTS

I would like to express my profound gratefulness to everyone who collaborated with me in

executing this project. I would like to thank Prof. Sundaramali G, 5S auditor of ABI Soorai
Green Mr. Nathan S, and my project facilitator at ABI Soorai Green Mr. Raghul , whose
great incite and knowledge have helped me and my team navigate through this project.

I thank ABI Soorai Green for providing me and my team this opportunity to help
in executing this project. This project has provided for us great incite into the functioning
and workings of a factory that holds itself to the worlds standards. My thanks goes to the
workers and the engineering personnel in the quality assurance department for providing us
with the data and the constructive criticism that have helped us single out and provide
relevant solutions to the problem. They have also helped us understand how the machines
and processes, critical to our problem statement were operated and run respectfully. To add
to this, ABI Soorai Green provided for us the meals that were needed during the times we
visited the factory.
This project is the consequence of the consolidated exertion of numerous people
and associations whose help and direction were indispensable to effectively total the work.
I want to thank the Chancellor, the Dean of the School of Mechanical Engineering, HoD,
Department of Mechanical and Production and Industrial Engineering, VIT Vellore for
doing my engineering project successfully. At last, I want to thank my associates and family
for providing the constant help and consolation needed to accomplish my objectives.
Student Name
 Executive Summary

The project study involves the application of various Lean and Six Sigma tools in the
identification and solving of defects found in the turbo charger center housing component
made in the company factory of ABI Soorai Green that has been causing a rejection rate of
25%. First, the identification of the cause(s) of the hole misalignment defect that is the
reason for the current high rejection rate to try to implement a solution to the above
problem. Second, the project will also collect data on the current cycle times based on the
value and non-value added activities clubbed together. The cycle time will also be
optimised. Third, the scrap generated from various processes can also be reduced in order to
reduce the cost of wastage to company. The objective of the project is to reduce the
rejection rate from the current 30% to 5%. Tools like Pareto chart and value stream mapping
are vital for the tasks listed above. The project follows the DMAIC methodology of Six
Sigma to implement find and rectify the problem found in turbo charger center housing
component. The results obtained from these three tasks can considerably bring down costs
to the company.
CONTENTS Page
No.

Acknowledgement i

Executive Summary ii

Table of Contents Iii

List of Figures ix

List of Tables xiv

Abbreviations xvi

Symbols and Notations xix

1 INTRODUCTION 1
1.1 Objective 1
1.2 Motivation 2

1.3 Background 3

2 PROJECT DESCRIPTION AND GOALS

2.1 Literature Survey

2.2 Knowledge gained

2.3 Gaps in literature survey

2.4

3 TECHNICAL SPECIFICATION 3

4 DESIGN APPROACH AND DETAILS (as applicable) .

4.1 Design Approach / Materials & Methods .

4.2 Codes and Standards .

4.3 Constraints, Alternatives and Tradeoffs .

5 SCHEDULE, TASKS AND MILESTONES .

6 PROJECT DEMONSTRATION .

7 COST ANALYSIS / RESULT & DISCUSSION (as applicable) .

8 SUMMARY .

9 REFERENCES .

APPENDIX A .
List of Figures

Figure No. Title Page No.

2.1 Figure caption 13
2.2 Figure caption 15

(In the chapters, figure caption should come below the figure and table caption
should come above the table. Figure and table captions should be of font size 10.)
List of Tables

Table No. Title Page No.

2.1 Table caption 28
List of Abbreviations

UDL Upper Decision Limit

LDL Lower Decision Limit
USL Upper Specification Limit
LSL Lower Specification Limit
Symbols and Notations

f CFO
 NCFO
 1. INTRODUCTION

1.1 OBJECTIVE
Process Capability Improvement in Turbo Charger Center Housing Component

1.2 MOTIVATION

In recent years the manufacturing sector of India has been approaching world class standards.
Each and every rupee invested is made sure to be utilized for the production of high quality
engineered products. Each correction and finding of faults is recorded and is made sure to be
referred when the industry encounters the same fault again. This helps to create a certain “defect
awareness” environment which is vital to the survival and existence of manufacturing industries.
Though quality cannot be compromised, it must be ensured that a break even point be present
between quality and cost i.e. to say quality is not achieved at the expense of a loss to the
company. The automotive industry is a very capital intensive industry, and the most minor
mistake can prove detrimental to the consumer and the future of the company. Methodologies and
procedures have been devised to circumvent problems met during the manufacture of these
complicated products. Some of these include the Six Sigma and the lean production
methodologies. Industries in India have been quick to jump to the application of these quality
assurance tools in order to obtain a fine balance between quality of products and obtaining a
profit. The workers and the engineering personnel are made sure to be educated and well versed
in these tools.

1
1.3 BACKGROUND

1.3.1 About ABI Showatech

ABI Showatech is a subsidiary of Brakes India group. It was founded in 1991, to produce brake
components in order to cater to the demand of the US market. Broadening its capabilities, ABI set
up Light Alloy Products, an Aluminum Foundry in 1995 in order to manufacture master cylinder
castings. Since 1997 LAP and ABI have been manufacturing and machining turbo charger
components on a large scale. ABI manufactures wheel cylinders, brake cylinders, other brake
parts and turbo charger components. It caters to both domestic and international customers.ABI
consists of dedicates, skilled and qualified staff and personnel who have stayed with the
organization for atleast one decade. ABI machining division currently machines Bearing / Centre
Housings, Turbine housings, Master Cylinders, Brake Calipers, Bearing caps, Cast Compressor
wheels, Milled from solid compressor wheels and Turbine wheels.
ABI machining division specializes in high precision and safety critical which require low
tolerances. Operations include turning, drilling, porting, facing, milling, grinding, honing and
other machining operations. ABI has state of the art machines including turning centres, CNC
milling centres, assembly machines, 5-axis milling machines, honing machines and testing
machines. ABI has the ability to design their own tools/ jigs/ fixtures. The tool room is equipped
CNC milling machines, grinding machines, heat treatment and fitting facilities. In addition the
tool room is equipped with 5-axis and 6-axis tools and it also has cutter grinders for the
manufacture of cutting tools.
ABI enforces and upholds strict quality related specifications. ABI has a R&D facility that has
been recognized by the Government of India( Dept. of Scientific and Industrial Research) and
houses an advanced laboratory to facilitate various development programs. The R&D is mainly
involved in the optimization of existing processes and development of new materials, products
and processes.

2
1.3.2 About Six Sigma Methodology

Bill Smith, an engineer in Motorola formulated the Six Sigma strategy to improve the quality
level in his company in 1986. Six Sigma is a structural way of doing improvement in a process by
following data-driven approach and methodology to solve the problem or to optimize the process. Six
Sigma applies set of tools such as Shainin tools, Statistical tools and 7 Quality Control tools to solve
the problem or to optimize the process. Through Six Sigma the conventional strategies followed to
solve the problem or improve processes are replaced with statistical or analytical results which leads
to sustainable results. By implementing six sigma methodologies, improved productivity, customer
satisfaction and reduced scrap, the cycle time can be achieved. The implication of Six Sigma also
gives company financial benefits which trigger the organizations to implement it, despite the
difficulties faced in implementing them. Motorola in 1980 initially implemented Six Sigma in its
production line. Even though Six Sigma had its pilot implementation in manufacturing sector it has
also penetrated into other fields such as marketing, servicing, engineering, service-based sectors and
has shown successful improvements.

1.3.3 About lean production

The lean production is a methodology taken from the Toyota’s 1930 operating model “The Toyota
Way”. The production models sole focus is to improve quality by putting the minimum effort,
negating human error. It mainly encompasses the following five ideas i.e. specifying the value of the
product, identify the required value stream for the product and challenge the wasteful steps, make the
product flow through the value added steps present in the vale stream, introducing pull between all
steps so that continuous flow is possible and finally seek perfection in the way that the number of
steps, time needed and information to be provided for the customer falls.

3
 1. PROJECT DESCRIPTION AND GOALS

2.1 Literature Survey

Table 2.1 Literature survey

Title of the paper Journal and Published Authors Description/ Remarks

year
Production lessening   Journal of Project Pankaj Kumar, In this paper, the lean six
analysis of Management, 2019 Mahipal Singh, sigma DMAIC approach was
manufacturing unit in
India : Lean Six Sigma
Gurpreet Singh used to reduce wastage in a
perspective Phull automotive part manufacturing
Reduction of rejection of facility.
an automobile part using
six sigma approach

A methodical Australian Journal of Amitkumar This paper, apart from describing the
literature review on Mechanical Engineering Dhanjibhai various six sigma tools that can be
implemented for our project, also
application of Lean Makwana, Gajanan lists comprehensively the various
and Six Sigma in Shankarrao Patange papers from different journals that
various industries make use of lean principles.

Elimination of International Journal Rateesh Nair, S.A. This paper deals with the
Sporadic defects of Engineering Sonawane elimination of defects in the
in Polyurethane
Lining Process
Research and polyurethane lining process by
by using Quality Technology, 2016 the identification of defects
Maintenance using tools like pareto chart
Methodology and 4M + T method.

Application of Int. J. Six Sigma and Kumbhar Mahesh This paper applies the design
design for Six Competitive Advantage, Suresh, for six sigma by applying the
Sigma Vol. 10, No. 1, 2016
methodology to
P. Asokan and S. methodology of Identify,
an automotive Vinodh design, Optimize and validate
component for an automotive seal
component.

4
 Using Six Sigma Procedia - Social and Monika This paper deals with the
DMAIC to Behavioral Sciences Smętkowska, Beata detailed application of the
improve the
quality of
238 ( 2018 ) 590 – Mrugalska design, measure, analyze,
the production 596 improve and control phases in
process: a case a company on a a machine
study Kolbus BF 511.

The effects of tool edge CIRP Annals - K.S. Woona, A. This paper discusses the effect
radius on drill deflection Manufacturing Chaudhari , M. of drill edge radius on drill
and hole misalignment in
deep hole gundrilling of
Technology 63 Rahman , S. Wanc, misalignment leading to hole
Inconel-718 (2014) 125–128 A. Senthil Kumar misalignment especially in
high length to diameter ratios,
while taking into account
cutting forces, drill deflection
and wall deformation
equations.

Experimental 10th CIRP conference Stefan Klot, Andreas

This paper experiments the
investigation of on Intelligence Lepold, Fredrik
influence of clamping systems
clamping systems and
the resulting change of
Computaion in Zanger, Volker
on cutting conditions. A
cutting conditions while Manufactturing Schulze relationship between deflection
drilling carbon fiber Engineering – CIRP and axial force was
reinforced plastics ICME ‘16 determined. They also show
that cutting conditions vary
during the entire drilling
process.
A novel approach in Precision Afzaal Ahmed, M.T. This paper explores the
high performance deep Engineering 56 Lew, P. Diwakar, A. effectiveness of coolant
hole drilling of Inconel
718
(2019) 432–437 Senthil Kumar, M. pressure and rotation speed
Rahman during deep hole drilling . The
second phase pf the study
involves fabrication of a
straight guide hole which
considerably reduces thrust
force.

An analysis of the Six Int. J. Production Jeroen de Mast, This paper presents
Sigma DMAIC method Economics 139 Joran Lokkerbol comprehensively the
from the perspective of
problem solving
(2012) 604-614 methodology the application of
DMAIC technique for solving
problems along with its
limitations.

5
 2.2 Knowledge gained

• Working of Industry, how the component flows through the factory, inspection and quality
control, and packaging.
• Understood how the presence of a single defect can affect the rejection rate of the component
i.e., the scrap generated is high.
• The application of lean and Six Sigma principles such as 4M, Pareto chart, X bar - R chart and
p-chart.
• The applications of above methods to identify causes of defects, and how to solve them, to
reduce cycle time and to reduce rejection rate.

2.3 Gaps in literature survey

 One defect of our objective is to identify the root cause of and solve is the misalignment of
holes on the turbocharger housing component.
 Since the root cause of the problem has not been identified, i.e., whether it is due to defect
in the machine, or due to vibrations caused due to improper clamping etc.
 The problem lies in the fact that around 70% of the components are produced defect free so
it is difficult to identify the cause of the problem.

2.4 Objective of the work

• To identify the cause of the defect (Hole misalignment in the turbocharger housing
component), and solving of the identified problem.

• To collect data on present cycle times and identify possible ways to efficiently optimize
6
 cycle time by eliminating or reducing non value added activities.

2.5 Outcome of the project

• To reduce the current rejection rate of 30% to 5%.

• To reduce scrap.
• Continuous improvement.

2. TECHNICAL SPECIFICATION

3.1 Product Description

The product being manufactured at ABI Soorai Green is the Turbocharger center housing

7
component, which lies between the compressor and turbine and houses the shaft supported by a
bearing system. Of the many models made at the factory we worked on the Fiat 2.2L model. Since we
were not allowed to take pictures inside the factory we have shown below an example figure of a
turbocharger center housing.

Fig 3.1 Turbocharger center housing

The material is GG25, a commonly used cast iron alloy, because of its combination of high strength
and ease of machining.

8
3.2 Process layout

Fig 3.2 Process layout of the component

3.3 Brief description of DMAIC Methodology

 Once we have classified the problem as specific (if the problem that is going to be solved is
clear) and not a generic one, we can proceed to improvement projects.
 Then we proceed to the classification of the problem as a type 1/2/3 or 4 problem depending
on whether the solution and cause are known or unknown as illustrated by the below figure.

9
 Fig 3.3 Conditions for specifying problem type

 For type 4 problem, the entire DMAIC methodology is applicable, but for the other three,
only Improve and Control are applicable.
 Define: Definition and understanding of the problem definition of target production quantity
(usually reduction to 80% of current value is taken.)
 Measure: Identification of SSV’s along with checking the accuracy of measurements be it
attribute or variable type of measurements.
 Analyze: Use of tools like Paired comparison, Product/Process Search, Variable Search,
Factorial analysis etc. to analyze and pinpoint causes depending on whether it is a design of
variation SSV and whether the cause is attribute or variable.
 Improve: Using the tool B vs C to validate the already pinpointed causes and also to find out
how much improvement has taken place and if it can be concluded that improvement will be
sustained at 90% current limit.
 Control: Here the tool variation analysis is used to determine the control methods such as
Xbar-R chart or Pre-control chart.

10
 3. DESIGN APPROACH AND DETAILS
4.1 Design Approach/Material and Methods

Fig 4.1 DMAIC approach

 The Six sigma approach is internationally accepted and has been for many years. The approach is
divided into 5 phases, DMAIC, where the output from one phase is treated as input for the next phase.

5. SCHEDULE, TASKS AND MILESTONES

5.1 Gantt chart of our project

11
 Fig 5.1 Gantt chart of the project
6. PROJECT DEMONSTRATION

6.1 Methodology

• After understanding of the problem and a thorough review of literature and discussion with
engineers, we decided to go ahead with Define, Measure, Analyse, Improve and Control
(DMAIC) methodology.

• First, for the purpose of our project, we have identified the problem as specific type and not
generic type as the problem which is going to be solved is very clear.

• Second, the categorization of this specific problem into Type 1/2/3/4 is necessary in
order to proceed further.

Fig 6.1 Categorization of our

problem

• Since our problem falls into type 4 problem we are able to proceed with DMAIC
methodology for our project. For the other three types of problems, only Improve and
Control phases are required.
12
6.1 Define Phase:

• The current rejection rate in the manufacture of turbocharger center housing component is
very high and leads to high costs in the form of wastage for the company. This rejection
rate is primarily due to a hole misalignment problem that occurs in the Makino machine
which is explained in the measure phase.

• Our goal is to reduce the rejection rate to a specific target and try to work towards
that target.

• Ideally in problem solving in DMAIC, a target reduction of 80% is set. For that reason
our target is set to 5% from the current rate of 25%. This target is what our project
ultimately hopes to achieve.

6.2 Measure Phase:

The measure phase involves the mapping of the process along with the manufacturing stage
where the problem is generated. Then, the variation in measurement is analyzed and abnormal
fluctuations in rejection rate, if any are found. Then, this phase ends with the identification of
the Suspected Sources of Variation (SSV’s).

 In this analysis data for 3 parts are collected simultaneously.

 The parameter is measured at identified locations on the product.
 The above is done for 1-time block and the same process has to be repeated for
minimum 15 time blocks covering a minimum of 2 hours of production.
 The highest variation has to be Part-to-Part variation, else there is a problem in the
process.

6.2.1 Part-to-part/ Time-to-time/ Stream-to-Stream Variation analysis

Table explains the data collected for the drilling process done in the makino machine of inlet
and outlet thin hole covering minimum 2 hours of production. There are three locations in the
pallet represented in the table as L1, L2 and L3 respectively and the events represent minor
adjustments done by the operator in the machine during the process. When ever there is an
adjustment in the time block, that time block is split into two and the adjustment is recorded as
the event carried out for the next process.

13
 Table 6.2.1 Multivariation analysis
TIME part L1 L2 L3 events average
12:05 1 65 10 98
2 29 42 14 39.66667
3 36 2 61
36 40 84 48
12:17 1 40 31 82
2 3 28 105 50.88889
3 73 86 10
70 58 95 37
12:29 1 35 60 55
2 14 97 37 37.77778
3 16 2 24
21 95 31 74
BREAK
1:50 1 31 47 41
2 19 16 83 42.66667
3 29 28 90
12 31 49 37
2:02 1 48 86 16
2 48 74 73 66.55556
3 87 110 57
39 36 57 21
2:14 1 95 19 9
2 11 23 54 31.44444
3 15 37 20
84 18 45 66
2:26 1 5 57 18
2 21 125 18 39.88889
3 43 35 37
38 90 19 71
2:38 1 52 58 39 49.66667
52 58 39 -5 19
2 33 11 3 21
3 38 35 6
5 24 3 21
2:40 1 21 19 12

14
 2 21 15 97 44.55556
3 85 21 110
64 6 98 92
2:52 1 2 57 15
2 36 60 53 34.22222
3 6 40 39
34 20 38 18
3:04 1 44 36 10
2 13 27 13 22.22222
3 16 18 23
31 18 13 18
3:16 1 4 29 12
2 87 34 15 34.77778
3 35 12 85
83 22 73 61

Form the analysis we have concluded the following:

• Part-to-part variation - 98 microns.

• Time-to-time variation - 45.55 microns.
• Stream-to-stream variation - 92 microns.
• Since highest variation is in part to part so the problem is there in machine not in the
process.
• Average part to part variation is – 44.3 microns.
• Upper control Limit = 2.575(constant) * 44.3 = 114.15 microns.
Since all part-to-part variations lie within the upper control limit, this confirms that the problem is in
the machine and not in the process.

15
Cause and Effect Diagram (Plotted on Minitab Software)

Fig 6.2.1 Fishbone/ Cause and effect

diagram

 The fishbone / cause and effect diagram identifies many possible causes for any problem that
occurs.
 The suspected causes are sorted into useful categories, making them easier to sort through
when trying to identify SSV’s.
 This is one of the seven basic quality tools.
 In our case, we divided the suspected causes into the categories for the problem of hole
misalignment after thoroughly analyzing the process on the factory floor.

16
Identification of Suspected Sources of Variation

Table 6.2.1(II) The SSV’s in

our problem

 Design causes – Operational causes that will not change or vary from part to part or time
to time or batch to batch.
 Variation causes – Operational causes that can vary from part to part or time to time or
batch to batch.

6.3 Analyze Phase:

this is the 3rd phase in the DMAIC process this phase helps to pinpoint the suspected sources
of variation which were identified in the measure phase by using either statistical or non-
statistical methods.

6.3.1 Paired Comparison

• Variation SSV’s can be analyzed using paired comparison method.

• Paired comparison is used when the SSV’s can be verified on good/bad parts selected based
on the required response i.e., the suspected cause can be measured on both the accepted and
rejected components, which is possible in our case, where the drill deflection in terms of
theta is known and can be verified for both the accepted and rejected components.
• First, collect 8 Good parts and 8 Bad parts from the suspected cause.
• Then list the Good parts and Bad parts along with the corresponding column of the values.
• Table.5 depicts how the good and bad parts are listed and how we arrive at the theta value
based on hole misalignment and total drill depth.
• We then proceed to arrange the values in ascending order
• After arranging them in ascending order, draw a line where the first change from bad to
good occurs.
• After arranging them in ascending order, draw a line where the first change from bad to
good occurs.
• Count the values below the line and the values above the line. Add them. This is the total
count.
17
• We obtain a total count of 16. Since this value is greater than 6, this cause is a source of the
problem.
Table 6.3.1 Data on drill deflection

drill deflection due to

position clamp pressure
G 0.0115 0.021603326
G 0.0125 0.023481876
G 0.0085 0.015967676
G 0.007 0.013149851
G 0.0145 0.027238975
G 0.01 0.018785501
G 0.0165 0.030996074
G 0.0145 0.027238975
B 0.0285 0.053538664
B 0.031 0.058235035
B 0.044 0.082656149
B 0.0475 0.08923106
B 0.0285 0.053538664
B 0.0285 0.053538664
B 0.026 0.048842292
B 0.026 0.048842292

Table 6.3.1(II) Arranging data in ascending order and calculating the total count

drill deflection due to clamp

pressure
G 0.013
G 0.015
G 0.018
G 0.021
G 0.023
G 0.027
G 0.027
G 0.03
B 0.053
B 0.053
B 0.053
B 0.053
B 0.058
B 0.082
B 0.089
18
B 0.089
Identifying whether the cause is actionable or not :

 Total variation from the 16 data in this data it is 0.076 microns

 Find out

total variation 0.076

∗100 = ∗100 = 165.21%
tolerence 0.046

if the percentage is <= 75% then the cause is a root cause or else it is not a root cause

Table 6.3.1(III) conclusion of paired comparison

drill deflection due to clamp

pressure
G 0.013
G 0.015
G 0.018
G 0.021
G 0.023
G 0.027
G 0.027
G 0.03
B 0.053
B 0.053
B 0.053
B 0.053
B 0.058
B 0.082
B 0.089
B 0.089
Total count 16
Existing specification 0 – 0.046
New specification 0.04 – 0.05
Root cause (yes/no) no

19
 6.3.2 Variable Search

 This tool is used for both Problem solving and Process optimization.
 This technique is used only for studying design causes.
 Data collection is done by conducting trials.

There are two phases in variable search, the planning phase and the Data collection and
analysis phase:

Planning Phase

 Identification of Design parameters for doing the trial

 Identification of – condition and + condition.
 Identification of responses (Quality parameter)

Data collection and analysis Phase

 Conducting initial trials till the difference comes in Quality parameter.
 Finding out which parameters are significant and which aren’t, and whether
insignificant parameters have zero contribution or not.
 Conducting factorial analysis for significant parameters to quantify the impact on
quality.
 Making math equation and finding out the optimal setting.

First, we list the parameters which have a direct impact on the problem by identifying them
with the following three rules:
 Parameters which can change easily in the process without incurring much cost.
 Parameters which are not hardware condition related and
 Parameters whose optimal conditions can be implemented in regular process.

Table 6.3.2 Variable search trial-1 settings

No Parameter Unit of
‘-’ setting ‘+’
measure setting
(UOM)
1 Top clamp psi 80 85
pressure (A)

2 Side clamp psi 65 70

pressure (B)

20
  Existing condition is always the ‘-‘ setting. ‘+’ condition is the condition which is
likely to reduce the rejection (Based on experience and knowledge of the operator),
‘+’ doesn’t mean a higher or lower value.
 For our experiment the SSV’s are Top and Side clamp pressure (unit in psi) with the
‘-‘ and ‘+’ condition listed in the above table.

Next,
 Produce 1 batch with all the parameters set to ‘–‘ condition.
 Then, produce 1 batch with all the parameters et to ‘+’ condition.

 We do this alternatively and make 3 batches in ‘–‘ condition and batches in ‘+’ condition

 If the application is Process optimization, produce a batch of 10 numbers. Check all the
quality parameters (responses) in all the10 parts

 If the response is Variable, calculate the average of 10 values and this will be taken as the
response.

The theme of this project is problem solving with the problem having specific response so the batch
size is calculated accordingly.

¿ 100
batch
rejection %

Since rejection percentage is 30% the batch size is approximately 3.

Table 6.3.2(II) variable search trial-1

Trials - +
st
1 run 0.057 0.05
nd
2 run 0.04 0.04
rd
3 run 0.053 0.042
Median 0.053 0.042
Range 0.017 0.01
D 0.011
d 0.0135
D/d 0.81481481

21
  If the D/d ratio is >= 3, conclusion is there is a difference in Quality
between the – and + setting.
 If the D/d ratio is < 3, then check whether D/d ratio is >= 1.25 and there is
no overlap in the responses of ‘–‘ setting and ‘+’ setting, then also the there
is a difference in Quality between the’ –‘ and ‘+’ setting.
 If D/d ratio is > 1.25 and < 3, but there is a overlap in the responses of the
‘-‘ and ‘+’ setting, then there is no difference in Quality between the
‘-‘and ‘+’ setting.
 If the D/d ratio is <1.25, then there is no difference in Quality between
the – and + setting.

 Since the D/d ratio is < 1.25, there is no difference in quality for the first trial.
 If there is no difference in quality, we take the ‘+’ setting as ‘-‘ setting and then we
identify new ‘+’ setting and then we do the same data calculation and D/d ratio
calculation until we get a difference in quality.

Table 6.3.2(III) variable search trial-2 settings

No Parameter Unit of ‘-’ setting ‘+’

measure setting
(UOM)
1 Top clamp psi 85 90
pressure

2 Side clamp psi 70 75

pressure

Table 6.3.2(IV) Variable search trial-2

Trials - +
1st run 0.05 0.045
2nd run 0.04 0.048
3rd run 0.042 0.036
median 0.042 0.045
range 0.008 0.012
D 0.003
d 0.01
D/d 0.3

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  Since the D/d ratio is < 1.25 there is no difference in quality and we repeat the
process again.

Table 6.3.2(V) Variable search trial-3 settings

No Parameter Unit of ‘-’ setting ‘+’

measure setting
(UOM)
1 Top clamp psi 90 95
pressure
2 Side clamp psi 75 80
pressure

Table 6.3.2(VI) Variable search trial-3

Trials - +
1st run 0.045 0.013
2nd run 0.048 0.026
3rd run 0.036 0.014
median 0.045 0.014
range 0.012 0.013
D 0.031
d 0.0125
D/d 2.48

 Since the D/d ratio is > 1.25 and < 3 and there is no overlap in responses, there is
difference in quality between the ‘-‘ and ‘+’ setting.

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 Fig 6.3.2(I) Main effects plot for response

Now, we proceed to find out which parameter has contributed to the difference in
quality by interpreting a graph which we draw by following the below steps :
 Make a graph with the responses on the Y axis and indicating the ‘1st run’, ‘2nd
run’ and ‘3rd run’ on the X-axis.
 Then we find out the average of the medians from the table 6.3.2.6.
 Then we draw a horizontal line at the average value of the medians.
 We then mark the ‘-‘ and ‘+’ setting responses

 We then calculate the UDL and LDL for the ‘+’ and ‘-’ setting as per the formula
shown below :

UDL ¿

LDL ¿

UDL ¿

LDL ¿

24
 Draw the UDL and LDL after calculating :

Table 6.3.2(VII) Variable search decision limits

Limits values
1.45*0.009 0.01305

UDL(-) 0.05805
LDL (-) 0.03195

UDL (+) 0.02705

LDL (+) 0.00095

median line 0.0295

Table 6.3.2(VIII) Variable Search significant parameters test

A-R+ 0.026 A+R- 0.015

B-R+ 0.022 B+R- 0.02
A-B-R+ 0.025 A+B+R- 0.038

A-R+ represents that the top clamp pressure is fixed at ‘-’ setting (ref table 6.3.2.5) and ‘R+’
represents later parameter B is in’+’ setting vice versa for A+R- .
B-R+ represents that the side clamp pressure is fixed at ‘-’ setting (ref table 6.3.2.5) and
‘R+’ represents later parameter A is in ’+’ setting vice versa for A+R- .

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Fig 6.3.2(II) Finding out which parameters are significant

We then make conclusions based on the following conditions:

 If the + line and the – line both cross the middle line, then that parameter is the
only significant parameter.
 If only one line crosses the middle line or is very close to it, then that parameter
is one of the significant parameters.
 If both the lines do not cross the middle line, then that parameter is not
significant. But whether or not it has zero contribution depends upon other
criteria.
 But, for our case we get one line crossed for A and B so we can conclude that A
and B are important parameters. (Further confirmed by the fact that both lines
cross for both A&B).

6.3.3 Factorial Analysis

For this next step, this type of analysis is done only for the important parameter,
which in our case are A and B.

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 Table 6.3.3(I) Factorial analysis

A B responses average

(-)90 (-)75 0.045,0.048,0.036,0.025 0.0385

(+)95 (-)75 0.015,0.022 0.0185

(-)90 (+)80 0.026,0.02 0.023

(+)95 (+)80 0.013,0.026,0.014,0.038 0.02275

Regression equation :

5.964−0.06325 × A−O. O 7420× B+ 0.000790×( A × B)

The interaction plot explains that when the side clamp pressure is 75 psi and top clamp
pressure is changed from 90psi to 95psi there is change in the mean of response this
shows that the top clamp and side clamp pressure has interaction between them.

Interaction Plot for response

Fitted Means
top clamp pr * side clamp p side
0.040 clamp p
75.0
80.0

0.035
Mean of response

0.030

0.025

0.020

90.0 95.0
top clamp pr

Fig 6.3.3 Interaction plot for responses

 Using this equation and by taking range of top clamp and side clamp pressure
values with the help of data tables function in ‘what if analysis’ excel function
there are different combinations of top clamp pressure and side clamp pressure
settings (ref table )
 To find the optimal response , the value of optimal response is calculated
27
 accordingly
 response is Lower is better - USL−2.3 ×d
 response is Higher is better - LSL+2.3 ×d
 response is nominal is better - Middle 50% of tolerance
 in this project the response is nominal is better that is the tolerance of shift
should be in the range of 0 – 0.025 mm.

Table 6.3.3(II) Combinations from regression equation

A/B 60 65 70 75 80 85 90 95 100 105 110 115

40 1.10 0.94 0.78 0.62 0.46 0.31 0.15 -0.01 -0.17 -0.33 -0.49 -0.64
45 0.96 0.82 0.69 0.55 0.41 0.27 0.13 -0.01 -0.15 -0.28 -0.42 -0.56
50 0.83 0.71 0.59 0.47 0.35 0.24 0.12 0.00 -0.12 -0.24 -0.36 -0.48
55 0.70 0.60 0.50 0.40 0.30 0.20 0.10 0.00 -0.10 -0.20 -0.30 -0.39
60 0.56 0.48 0.40 0.32 0.24 0.16 0.09 0.01 -0.07 -0.15 -0.23 -0.31
65 0.43 0.37 0.31 0.25 0.19 0.13 0.07 0.01 -0.05 -0.11 -0.17 -0.23
70 0.29 0.25 0.21 0.17 0.13 0.09 0.05 0.01 -0.02 -0.06 -0.10 -0.14
75 0.16 0.14 0.12 0.10 0.08 0.06 0.04 0.02 0.00 -0.02 -0.04 -0.06
80 0.03 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02
85 -0.11 -0.09 -0.07 -0.05 -0.03 -0.01 0.01 0.03 0.05 0.07 0.09 0.11
90 -0.24 -0.20 -0.16 -0.13 -0.09 -0.05 -0.01 0.03 0.07 0.11 0.15 0.19
95 -0.38 -0.32 -0.26 -0.20 -0.14 -0.08 -0.02 0.04 0.09 0.15 0.21 0.27

From the table 6.3.3(II) it is clear that for 3 combinations of the top clamp and side clamp
pressure the misalignment is zero they are (95psi,50psi),(95psi,55psi) and (100psi,75psi).

References
28
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