DOE Manufacturing Industry Application

The bottom line:

In one weekend, engineers used Design of Experiments to figure out why pivotal welds were cracking.  The production line was no longer down, and 60 accelerometers were shipped on time

The project:

Our client  manufactures accelerometers. A pivotal part was cracking, stopping shipment on all accelerometers. The line was down.

Production uses a YAG laser to weld the parts. A Designed Experiment varied the laser power, rpm and revolutions (continuous factors). Two different lens were included in the design (discrete factors).The depth of the weld was measured for each trial run of the experiment.

Experimenters discovered, in seven hours, the optimal settings for the YAG laser to maximize the weld depth. Parts with maximum weld depth did not crack and produced operable accelerometers.