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Robust Design,

Propagation
p g of Error and Tolerance Analysis
y

c .
In
e,
as
-E
at
St

Webinar presented by: Pat Whitcomb


©

Presentation is posted at www statease com/webinar html


Presentation is posted at www.statease.com/webinar.html

Robust Design 1
Robust Design,
Propagation
p g of Error and Tolerance Analysis
y

c .
In
 Robust Design Concepts
 Propagation of Error (POE)

e,
 RSM Analysis with TA

as
 Lathe Machined Parts
-E
 HDTV signal (as time allows)
at
1. Raymond H. Myers, Douglas C. Montgomery and Christine M. Anderson-Cook (2009), 3rd edition,
St

Response Surface Methodology, John Wiley and Sons, Inc, Sections 2.7-2.8 and 6.6, Chapters 1, 7,
8 and 10.
2. George E.P. Box, William G. Hunter and J. Stuart Hunter (2005), Statistics for Experimenters, 2nd
©

edition
diti JJohn
h Wil
Wiley, Ch
Chapter
t 12
12.

Robust Design 2
Agenda Transition

c .
In
 Robust Design Concepts

e,
 Propagation of Error (POE)

as
 RSM Analysis with TA
-E
 Lathe Machined Parts
 HDTV signal (as time allows)
at
St
©

Robust Design 3
Robust Design

c .
The goal of robust design is to increase profits by consistently

In
satisfying
ti f i customer
t needs.
d

This is accomplished by generating robust designs to

e,
 Minimize
Mi i i d design
i re-workk after
ft d design
i ffreeze

as
 Minimize surprises during design verification
 Accelerate
cce e a e sca
scale
-Ee up a
and
d co
commercialization
e ca a o

Robust designs depends heavily on DOE to translate the Voice-of-


at
Customers (VOCs) and product specifications into process
specifications
St
©

Robust Design 4
Robust Design

c .
Functional Design: Strategy of Experimentation

In
Known Unknown
 Use DOE to model response Phase: Screening Factors Factors

mean as a function of

e,
Screening

controllable factor levels


levels.

as
Phase: Factor effects

 Choose levels of controllable Characterization


and interactions

factors to achieve targeted no


Curvature?
-E
values of the responses. Phase: Optimization
yes
Response
Surface
at
Methods

Ph
Phase: V ifi i
Verification Confirm?
no
Backup
St

Celebrate! yes
©

Robust Design 5
Robust Design

c .
Robust Design: Strategy of Experimentation

In
Known Unknown
 Use DOE to model response Phase: Screening Factors Factors

variability as a function of

e,
Screening

control and uncontrolled

as
factor levels. Phase: Factor effects
and interactions
Characterization
 Choose levels of control no
Curvature?

caused by:
-E
factors to reduce variation Phase: Optimization
yes
Response
Surface
at
Methods

• Lack of control of the


Ph
Phase: V ifi i
Verification Confirm?
no
Backup
control factors.
St

Celebrate! yes

• Variation of the
©

uncontrolled factors
factors.
Robust Design 6
Robust Design Concepts

c .
Concept: Choose levels of the control1 factors in a way that

In
reduces
d output
t t variation.
i ti In
I other
th words,
d make k the
th product,
d t
process or system robust to variation in the inputs; both control

e,
and uncontrolled2 factors. Quality is then improved without
removing
i th
the cause off variation.
i ti

as
1 Control factors (x) are parameters whose nominal values can
be cost
cost-effectively
effectively adjusted by the engineer
-E engineer.
Example: oven temperature.
at
2 Uncontrolled factors (z) are parameters that are difficult,
expensive, or impossible to control.
St

Example: ambient temperature.


©

Robust Design 7
Control vs Uncontrolled Factors

c .
Determining whether a factor is an uncontrolled or a controlled one

In
often
ft depends
d d on the
th team’s
t ’ objective
bj ti or the
th scope off the
th project.
j t
A factor considered controlled in some cases might be considered

e,
uncontrolled in others.

as
For example material durometer (hardness):
 iss controllable
co o ab e to
-E o a design
des g engineer,
e g ee , who
o ge
gets
s to
o cchose
ose the
e
material.
at
 but may be uncontrolled to a process engineer who only
sees the
th variation
i ti within
ithi th
the chosen
h material.
t i l
St
©

Robust Design 8
Agenda Transition

c .
In
 Robust Design Concepts

e,
 Propagation of Error (POE)

as
 RSM Analysis with TA
-E
 Lathe Machined Parts
 HDTV signal (as time allows)
at
St
©

Robust Design 9
Propagation of Error (POE)
Transmitted Variation

c .
Objective: Reduce the variation transmitted to the

In
response from variation in control factors
factors.

e,
as
-E
at
St
©

Robust Design 10
Propagation of Error
How it works

c .
Once a relationship has been established between a factor and a

In
response, the
th variation
i ti in
i the
th output
t t can be:
b

1. Dependent on the level of the control factor

e,
2. Independent of the level of the control factor

as
-E
See pictures on next two pages 
at
St
©

Robust Design 11
Propagation of error
Dependent
p

c .
The transmitted variation is

In
Effect of Input
dependent
d d t on the
th level
l l off on Response

the control factor.

e,
Therefore, set the level of the
control factor to reduce

as
variation transmitted to the
response from variation
-E
(lack-of-control) of the
control factor.
at
St

A B
©

Control Factor

Robust Design 12
Propagation of error
Independent
p

c .
The transmitted variation is

In
independent
i d d t off the
th level
l l
of the control factor.

e,
Therefore, set the level of the
control factor to center the

as Response
Effect of Input
process mean on target. on Response

-E
R
at
St

A B
©

Control Factor

Robust Design 13
Power Circuit Design Example

c .
Consider two control factors:

In
1. Transistor Gain – nonlinear relationship to output voltage
2. Resistance – linear relationship to output voltage

e,
The variation in gain and resistance about their nominal values is

as
known. Both variances are constant over the range of nominal
values being considered.
-E
at
St
©

Robust Design 14
Power Circuit Design Example
((reduce variation))

c .
In
e,
as
-E
at
St

Variation is reduced by using a nominal gain of 350.


©

That shifts the output off-target


off target to 125 volts
volts.
Robust Design 15
Power Circuit Design Example
((return to target)
g )

c .
In
e,
as
-E
at
St

Decrease the nominal resistance from 500 to 250.


©

Thi corrects
This t the
th output
t t to
t the
th ttargeted
t d 115 volts.
lt
Robust Design 16
Power Circuit Design Example
on target
g with reduced variation

. c
To illustrate the theory, the control

In
factors
f were usedd in
i two steps:
first to decrease variation and

e,
second to move back on target. g

as
In practice, numerical optimization
can be used to simultaneously
-E
obtain all the goals.
at
St
©

Robust Design 17
Propagation of error
Just a little mathematical explanation
p

c .
Find regions where variation in the control factors transmits the least

In
variation to the response.
response

e,
Ŷ  0  1x1  11x12
Y

as
Ŷ  15  25x1  0.7x12
-E
at
St

The goal is to minimize the slope, which is


©

th 1st derivative
the d i ti off ththe prediction
di ti equation.
ti
Robust Design 18
Propagation of error
Just a brief mathematical explanation
p

c .
Assume σx = 1 and σresid = 0

In
Yˆ  0  1x1  11x12

e,
Yˆ  15  25 x1  0.7 x12

as
2
 Y  2
 Ŷ2   
 x   2

 x 
resid
-E
 25  1.4 x1   x2   resid
2
 Yˆ 
at
2
St

As the slope of the relationship between X and Y


©

decreases the variation transmitted to Y decreases


decreases, decreases.
Robust Design 19
Propagation of error
Goal: Minimize p
propagated
p g error ((POE))

c .
What is POE?

In
2 2
 f  2  f  2
 2Yˆ     xi      z j   resid
2
POE   2Yˆ
i  x i  j  z j

e,

The amount of variation transmitted to the response

as
(using the transfer function):
 from the lack of control of the control factors and variability
-E
from uncontrolled factors
(you enter these standard deviations),
at
 plus
l th
the normall process variation
i ti
St

(obtained from the ANOVA).


It is expressed as a standard deviation.
©

Robust Design 20
Propagation of error
Simple
p One-Factor Illustration (p
(page
g 1 of 2))

c .
1. Build a One Factor

In
RSM design.
d i
2. Factor A: low level = 0

e,
and high level = 15

as
3. Design for a cubic
model.
-E
4. Sort by Factor A and
enter this data:
at
St
©

(continued on next page)

Robust Design 21
Propagation of error
Simple
p One-Factor Illustration (p
(page
g 2 of 2))

c .
5. Compute effects and select appropriate model.

In
Fitted equation (in terms of actual factor values) is:
  14.95  25.05 A  0.71A 2

e,
Y

6. Enter the standard deviation for each factor:

as
From the Design Layout Screen - View, Column Info Sheet –
enter
t 1.00
1 00 for
f F -E
Factor
t A.A

The response standard deviation is filled in automatically


at
from the ANOVA after the analysis is completed
completed.
St
©

Robust Design 22
Propagation of error
Simple
p One-Factor Illustration

c .
Analyze the response (R1) and look at the one factor plot

In
and the propagation of error plot (from the View menu
menu.))
One Factor One Factor

e,
233.081 2
3
2 25.0693 3

as
178.289 19.804

POE(R1)
R1

123.497 14.5387 2

68.7051
-E 9.27348
at
13.9131 2
3
2 4.00821 3

0.00 3.75 7.50 11.25 15.00 0.00 3.75 7.50 11.25 15.00
St

A: A A: A

ŷ  14.95  25 x1  0.7 x12


 25  1.4 x1 
2
 yˆ   x2   resid
2
©

assume  x  1 and  resid  0.95


Robust Design 23
Propagation of error
((linear relation between factor and response)
p )

c .
If the response is a linear function of the independent factors,

In
the transmitted variation is a constant.
constant

e,
as
ŷ   0  1x1

ŷ  15  25 x1
-E
at
St
©

Robust Design 24
Propagation of error
Linear relationship
p (p
(page
g 1 of 2))

c .
assume  x  1 and resid  3.17

In
yˆ   0  1 x1

e,
yˆ  15  25 x1

as
2
 Y  2
 
2
yˆ 
 x   2

 x 
resid

 yˆ   25 
2
-E
 x2   resid
2
 Constant
at
St

Since the slope of the relationship between X and Y is constant,


the variation transmitted to the response also remains constant.
©

Robust Design 25
Propagation of error
Linear relationship
p (p
(page
g 2 of 2))

c.
Point Prediction node:

In
e,
as
-E
 25 
2
 yˆ   x2   resid
2
at
 25  1   3.17324 
2 2 2

St

 25.206
©

Robust Design 26
Agenda Transition

c .
 Robust Design Concepts

In
 Propagation of Error (POE)

e,
 RSM Analysis with TA

as
 Lathe Machined Parts
 DOE (Design-Expert)
-E (Design Expert)
 Tolerance analysis (VarTran)
at
 HDTV signal (as time allows)
St
©

Robust Design 27
Robust RSM Simulation
Precise Machined Parts

c .
Acme precision machine company has been having trouble holding

In
nominal values on their new highly
highly-automated
automated lathe.
lathe Your job is to
study the process and reduce deviations from nominal. Previous work

e,
has determined that three factors are the key influencers on the
process:

as
Factor Units Range

Feed Rate
-E
Cutting Speed fpm
ipr
330 - 700
0.01 – 0.022
at
Depth of cut inches 0 05 – 0.10
0.05 0 10
St

The factor levels given are the extreme values, do not exceed them.
©

Robust Design 28
Robust RSM Simulation
Precise Machined Parts

c .
Which design is an appropriate Screening Known Unknown

In
Factors Factors
choice
h i for
f the
th Lathe
L th DOE?
Trivial
Screening many

e,
What model should we design Vital few
Characterization
f ?
for?

as
Factor effects
and interactions

no
-E Optimization
Curvature?

yes
Response
at
Surface
methods
St

Verification no
Confirm? Backup

Celebrate!
©

yes

Robust Design 29
Robust RSM Simulation
Precise Machined Parts

c .
The experimenters chose to run a Box-Behnken design.

In
 The significant factors are already known, and optimization is
the focus.

e,
 The region of interest and the region of operability are very
similar (can’t exceed the stated factor levels.)

as
 They would like to fit a quadratic model.
-E
The key response is delta, i.e. the deviation of the finished part’s
dimension from its nominal value. Delta is measured in mils,
at
1 mil = 0.001 inches.
St
©

Robust Design 30
Robust RSM Simulation
Precise Machined Parts

c .
1. Build a three factor Box-Behnken response surface design.

In
(The
(Th extreme
t values
l define
d fi a Box-Behnken
B B h k design.)
d i ) Save
S the
th
design as “Lathe.dxp”.

e,
2. Right click on the response column header and run the
simulation: Lathe.sim

as
3. Fit an appropriate model (reduce as needed) to the response:
d lt
delta. -E
4. Examine the response surface to find factor levels where delta
at
is zero.
St
©

Robust Design 31
Robust RSM Simulation
Precise Machined Parts

c .
delta
0.022

In
0.2
0.3
Note the variety of
0.1 speed and feed
combinations that can

e,
-0.2
0.019 0.0

-0.1
produce a delta of 00.

as
You could also
B: Feed

0.016 5
explore the other
-E -0.2
02
graph combinations
of speed vs. depth
at
0.013

-0.1
01
and feed vs. depth.
-0.3
St

0.010

330 423 515 608 700


©

A: Speed

Robust Design 32
Robust RSM Simulation
Precise Machined Parts – Add POE

c .
1. Enter information on the expected variation of the controllable

In
factors
f t about
b t their
th i sett points.
i t From
F the
th Design
D i node, d go tot
“Column Info Sheet” and enter:

e,
Variable Standard Deviation

as
A – Speed 5 fpm
B – Feed 0.00175 ipr
-E
C – Depth 0.0125 inches

2. Use the POE model graphs to explore the transmitted error as a


at
function of the independent factors
factors.
St

3. Re-save (“Lathe.dxp”)
©

4 Save as a VarTran file: “Lathe


4. Lathe.vta
vta”
Robust Design 33
Robust RSM Simulation
Precise Machined Parts – Add POE

c .
POE(delta) POE(delta)
0.022

In
0.100
0.13

0.14
0.26
0.019 0.088 0.24

e,
0.12 0.22
0.2
0.18

C: Deptth
B: Feed
d

0 16
0.16
0.18 0.16 0.14 0.12
0.14 5

as
0.016 0.19 0.17 0.15 5 0.075

0.013

-E 0.063
0.14
0.16 0.18
0.2 0.22
0.240.26
at
0.010 0.050
330 423 515 608 700 330 423 515 608 700

A: Speed A: Speed
St

These are two of the three views of the propagated error


- - where is POE minimized?
©

Robust Design 34
Robust RSM Simulation
Precise Machined Parts – Optimization
p

c .
1. Use numerical optimization to find factor levels near zero delta

In
that
th t are also
l robust:
b t
Response Goal Low High

e,
Delta Target = 0 -0
0.4
4 04
0.4

as
POE(Delta) Minimize 0.0 0.3

-E
2 Choose settings to operate the lathe:
2.
Speed fpm
at
Feed ipr
St

Depth inches
Delta mils
©

POE(Delta) mils
Robust Design 35
Robust RSM Simulation
Precise Machined Parts – Point Prediction

c .
In
e,
as
-E
 The tolerance interval using the POE standard deviation is from
at
-0.4462 to +0.4462.
 Since the specifications are -0.4400 to 0.4400 VarTran should
St

find the process marginally capable at best.


©

Robust Design 36
Agenda Transition

c .
 Robust Design Concepts

In
 Propagation of Error (POE)

e,
 RSM Analysis with TA

as
 Lathe Machined Parts
 DOE (Design-Expert)
-E (Design Expert)
 Tolerance analysis (VarTran)
at
 HDTV signal (as time allows)
St
©

Robust Design 37
How Do We Model Tolerances
for Complex
p Systems?
y

c .
VarTran® is a software package developed by Dr. Wayne Taylor.

In
VarTran can be used to establish and assess targets and
tolerances for product and process inputs (x’s)

e,
The targets and tolerances selected are those which:

as
 minimize the variation in the output (y)
 center
t the -E
th output
t t (y)
( ) on its
it ttargett value
l
at
St
©

RDTA section 1 38
Requirements for VarTran

c .
Vartran requires that a y = f(x) model has been established

In
The y = f(x) model can come from the following sources:

e,
 Pre-existing mathematical relationship

as
 Design of experiments (factorial or response surface)
 A combination of the above
-E
at
St
©

RDTA section 1 39
Requirements for VarTran

c .
In order to fullyy optimize
p p
a product p
or process, the

In
following elements are required for input to VarTran:

e,
1. Inputs (target and range)
2. Capabilities of inputs

as
(variation about their set points)
3 Outputs (responses)
3. -E
4. Model (y = f(x))
at
5 Specifications for outputs
5.
St
©

RDTA section 1 40
Precise Machined Parts
Tolerance Analysis
y

c.
Open VarTran file “Lathe.vta”:

In
Lathe.dxp

e,
A : Speed R1 : delta

as
B : Feed I/O

C : Depth SYSTEM

-E
s_R1 : delta residual std dev
at
St
©

Robust Design 41
Tolerance Analysis
PCA Requires
q Five Items

.
c
1) Inputs 3) Outputs

In
e,
2)) Capabilities
p
of Inputs

as
4) Model: Y=f(x)

-E
at
St
©

Robust Design
5) Specs for Outputs 42
Precise Machined Parts
Tolerance Analysis
y

c .
Need to enter specifications to conduct tolerance analysis:

In
e,
as
-E
at
St
©

Robust Design 43
Precise Machined Parts
Tolerance Analysis
y

.
c
In
e,
as
Use Interval
-E optimization.
at
St
©

Robust Design 44
Precise Machined Parts
Tolerance Analysis
y

.
c
In
e,
as
-E
Cpk of 1.11 < 1.3
at
Marginal at best.
best
St
©

Robust Design 45
Tolerance Analysis
Improving
p g Cpk – It’s a Business Decision

c .
 Change Specifications

In
(engineering
( i i requirements
i t andd VOC)
 Improve the Controls

e,
(more cost)
 Improve Measurement System

as
(more cost and/or R&D)
-E
 Change the Design
(more R&D)
at
 Refuse the Business
(cost of lost opportunity)
St

 Accept 2-3% Failure Rates


((depends
p on criticalityy – back to VOC))
©

Robust Design 46
Precise Machined Parts
Improving
p g Cpk

c.
In
e,
as
Better control of
-E factor C (depth)
does the most to
improve capability.
at
St
©

Robust Design 47
Precise Machined Parts
Improving
p g Cpk

. c
In
e,
as
-E
at
Reduce std dev by ½:
St

0.0125 → 0.00625
©

Robust Design 48
Precise Machined Parts
Tolerance Analysis
y

.
c
In
Re-optimize,

e,
then find new
process

as
capability.
-E
Cpk of 1.53
at
is good
improvement!
St
©

Robust Design 49
How Does VarTran Work?

c .
VarTran relies on having a good y=f(x) model.

In
The variability in outputs (y’s) depends on the variability of

e,
the inputs (x’s).

as
We input the expected variation in the x’s and VarTran uses
statistical tolerancing techniques to calculate the
resultant distribution of y(s)
-E y(s).

VarTran takes advantage of non-linear effects and


at
interactions to find the values of x which minimize the
variation in y and center y on the target value.
St
©

RDTA section 1 50
Empirical Tolerancing

c .
Use DOE and Empirical Tolerancing:

In
1. When we cannot write the transfer function due to:

e,
 Predictive equation not being known from first principles.
 Existing
E i ti results
lt differing
diff i from
f our models!
d l !

as
2. When the Y(‘s) are too risky to be left untested and
tolerance modeling is insufficient to guarantee results
-E results.
at
St
©

RDTA section 1 51
Agenda Transition

c .
 Robust Design Concepts

In
 Propagation of Error (POE)

e,
 RSM Analysis with TA

as
 Lathe Machined Parts
 HDTV signal (as time allows)
-E
Incorporates uncontrolled (noise)
at
 DOE (Design-Expert)
 Tolerance analysis (VarTran)
St
©

Robust Design 52
Uncontrolled Factors in RSM
High
g Definition TV

c .
The goal for a robust product design is to achieve high signal with

In
low
l variance.
i
There are four control factors and three uncontrolled factors.

e,
 Control
C t l factors:
f t x1, x2, x3 and
d x 4.

as
 Uncontrolled factors: z1, z2 and z3.
-E
We are interested in a quadratic model, but the experiments are
expensive and time is short. Let’s try to minimize the runs in the
at
DOE.
St
©

Robust Design 53
Uncontrolled Factors in RSM
Building
g a Design
g (p
(page
g 1 of 2))

c .
1. Start with a 7 factor “Min Run Res V” (MR5) CCD.

In
e,
as
-E
at
St
©

Robust Design 54
Uncontrolled Factors in RSM
Building
g a Design
g (p
(page
g 2 of 2))

. c
2. Enter factor names and levels:

In
e,
as
-E
at
St

3. There is one response: “signal”.


4. Save your design as “HDTV.dxp”.
©

Robust Design 55
Uncontrolled Factors in RSM
Simulate and Analyze
y Response
p

c .
1. Run the simulation by:

In
 right-clicking on the response column heading

e,
 choosing “Simulate Response”

as
 choosing the “HDTV.sim” file and clicking OK.
2 Analyze the response (signal)
2. -E (signal).
at
St
©

Robust Design 56
Uncontrolled Factors in RSM
Add POE and Optimize
p (page
(p g 1 of 2))

c.
1. Click on the “Design” node and choose “Column Info Sheet”

In
andd enter
t the
th standard
t d d deviation
d i ti for
f each
h factor:
f t

e,
as
-E
at
St
©

Robust Design 57
Uncontrolled Factors in RSM
Add POE and Optimize
p (page
(p g 2 of 2))

c .
2. Find levels of the controllable factors to:

In
 maximize signal (LL = 70, UL = 100)
 minimizing variation (LL = 4, UL = 20)

e,
3 Re-save
3. R “HDTV d ” and
“HDTV.dxp” dSSave as “HDTV
“HDTV.vta”
t ”

as
Note: We can
can’tt select (optimize) levels for the uncontrolled
-E
factors. Therefore set them to their midpoint using the
goal of “equal to →”.
at
St
©

Robust Design 58
Uncontrolled Factors in RSM
Point Prediction (Tolerance Interval)

c .
 The tolerance interval using the POE standard deviation starts at 75.16.

In
 Since
Si the
h lower
l specification
ifi i lilimit
i iis 70 V
VarTran
T should
h ld fifind
d the
h process
capable.

e,
as
-E
at
St
©

Robust Design 59
Agenda Transition

c .
 Robust Design Concepts

In
 Propagation of Error (POE)

e,
 RSM Analysis with TA

as
 Lathe Machined Parts
 HDTV signal (as time allows)
-E
Incorporates uncontrolled (noise)
at
 DOE (Design-Expert)
 Tolerance analysis (VarTran)
St
©

Robust Design 60
HDTV with Uncontrolled Factors
Tolerance Analysis
y

.
c
Open VarTran file “HDTV.vta”:

In
HDTV dxp
HDTV.dxp
A : x1 band width R1 : signal

e,
B : x2 freq

as
C : x3 power
I/O
D : x4 color

E : z1 voltage
-E SYSTEM
at
F : z2 compression
St

G : z3 bits
©

s_R1 : signal
g residual std dev

Robust Design 61
Uncontrolled Factors
Tolerance Analysis
y

c .
Handling uncontrolled factors during tolerance analysis:

In
 Long-term this factor will fluctuate within some range.
 The best guess for the current setting of this factor is it’s

e,
midpoint.
midpoint

as
 Set uncontrolled factors to their nominal values.

-E
at
St
©

Robust Design 62
Uncontrolled Factor z1
Tolerance Analysis
y

.
c
In
e,
as
-E
at
Min = Nominal
Max = Nominal
St

do Not include
in optimization
©

Robust Design 63
Uncontrolled Factor z2
Tolerance Analysis
y

.
c
In
e,
as
-E
at
Min = Nominal
Max = Nominal
St

do Not include
in optimization
©

Robust Design 64
Uncontrolled Factor z3
Tolerance Analysis
y

.
c
In
e,
as
-E
at
Min = Nominal
Max = Nominal
St

do Not include
in optimization
©

Robust Design 65
HDTV with Uncontrolled Factors
Tolerance Analysis
y

c .
Need to enter specifications to conduct tolerance analysis:

In
e,
as
-E
at
St
©

Robust Design 66
HDTV with Uncontrolled Factors
Tolerance Analysis
y

c .
In
Statistical Tolerance
Before optimizing let’s check LSL

e,
the Cpk you get by simply ran
th nominal
the i l settings
tti on the
th

as
input factors. 67.378 terrestrial 109.07

Characteristic Value
-E Average:
Standard Deviation:
88.224
6.9486
Cp: ----
at
Cc: ----
Cpk: 0.87
St

Def. Rate (normal): 0.436 %


Z-Score (short-term): 2.62
Sigma Level: 2.62
©

Interval for Values = (67.378, 109.07) +/-3SD


Robust Design 67
HDTV with Uncontrolled Factors
Tolerance Analysis
y ((before optimization)
p )

c .
In
e,
as
-E
at
St
©

Robust Design 68
HDTV with Uncontrolled Factors
Tolerance Analysis
y

c .
In
e,
as
Use Simplex
Optimization -E
at
St
©

Robust Design 69
HDTV with Uncontrolled Factors
Tolerance Analysis
y

c .
In
Statistical Tolerance
LSL

e,
as
70 terrestrial 105.3

Characteristic Value
-EA
Average:
Standard Deviation:
89 999
89.999
5.1002
Cp: ----
at
Cc: ---- Cpk of 1.31
C k
Cpk: 1 31
1.31
is acceptable!
St

Def. Rate (normal): 44 dpm


Z-Score (short-term): 3.92
Sigma Level: 3.92
©

Interval for Values = (74.699, 105.3) +/-3SD


Robust Design 70
HDTV with Uncontrolled Factors
Tolerance Analysis
y ((after optimization)
p )

c .
In
e,
as
-E
at
St
©

Robust Design 71
HDTV with Uncontrolled Factors
Tolerance Analysis
y

c .
In
Targets and Tolerances of Inputs
Input Type Tolerance / Category LSL USL Average and Variation Requirements

e,
A Statistical 127.24 + ---- - ---- ---- ---- Average = 127.24, Std. Dev. <= 5
B Statistical 9.6518 + ---- - ---- ---- ---- Average = 9.6518, Std. Dev. <= 1

as
C Statistical 53525 + ---- - ---- ---- ---- Average = 53525, Std. Dev. <= 2500
D Statistical 588.88 + ---- - ---- ---- ---- Average = 588.88, Std. Dev. <= 60
E
F
Statistical
Statistical
-E
150 + ---- - ----
6 + ---- - ----
----
----
----
----
Average = 150, Std. Dev. <= 35
Average = 6, Std. Dev. <= 2
at
G Statistical 7.5 + ---- - ---- ---- ---- Average = 7.5, Std. Dev. <= 3
s_R1 Statistical 0 + ---- - ---- ---- ---- Average = 0, Std. Dev. <= 1.9194
St

Tolerance / Value Targets and Tolerances of Outputs


Output Type At Target LSL USL Average and Variation Requirements
©

R1 Statistical ---- + ----- - ------ 70 Ave = 89.999, Std. Dev. <= 5.1002

Robust Design 72
How to get help

c .
 Search publications posted at www.statease.com

In
 In Stat-Ease software press for Screen Tips, view
reports in annotated mode, look for context-sensitive

e,
help (right-click) or search the main help system
system.

as
 Explore Experiment Design Forum http://forum.statease.com
and
a d post
pos your
you ques
question
o ((if not
-E o ppreviously
e ous y aanswered).
s e ed)

 E-mail stathelp@statease.com for answers from


at
Stat-Ease’s staff of statistical consultants
St

 Call 612.378.9449 and ask for “statistical help”


©

Thank YOU for attending!


Robust Design 73

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