In the world of manufacturing, the assembly of parts is a critical process that can significantly impact product quality. However, determining the best process and parameters for assembling parts is not always straightforward. Sometimes, it takes more than just running a few parts to fine-tune the assembly process. This is where Design of Experiments (DOE) becomes invaluable.
What is a DOE?
A Design of Experiments is a structured, systematic method used in manufacturing and various other fields to optimize processes, enhance product quality, and gain a better understanding of the factors influencing a specific outcome. This involves systematically varying and controlling factors that may influence the assembly process. In the context of assembling parts, these factors can include part geometry, material, forming force, forming distance, forming speed, chosen assembly process, and tooling geometry.
Factors to Test During a DOE for Assembly
Part Geometry: Considerations such as shape, diameter, and length.
Part Material: Different materials can react differently when being formed.
Forming Force: The amount of force applied during assembly.
Forming Distance: The distance the parts move during assembly.
Forming Speed: The speed at which the assembly process occurs.
Chosen Assembly Process: Different methods may yield different results.
Tooling Geometry: The shape and design of the tools used in assembly.
Why run a Design of Experiments?
Running a DOE for part assembly is valuable for several reasons:
Identifying Influential Factors: Helps determine which factors significantly affect the outcome to better understand the assembly process.
Optimizing Parameters: Aims to identify the optimal combination of parameters that lead to the desired outcome, improving product quality.
Robustness: Design of Experiments aids in developing robust processes that are less sensitive to variations in factors, making the manufacturing process more reliable and consistent.
Cost Reduction: By minimizing variability, a DOE leads to cost savings through improved efficiency, reduced waste, and enhanced product quality.
Risk Mitigation: Identifies and addresses potential risks early, enabling proactive risk management.
In summary, a Design of Experiments is a powerful tool in the context of assembling parts, helping manufacturers systematically explore and understand the factors influencing the assembly process. It leads to more efficient, optimized, and robust manufacturing processes, ultimately contributing to improved product quality and reduced costs.
Case Study
Consider a fuse manufacturer who approached us with a 50% failure rate with their current press and crimp process. The end cap of the fuse cartridge was spinning when it wasn't supposed to. We suggested replacing the crimp process with our Roller Forming Process and conducted a DOE on a small scale in our Solutions Lab to test different parameters including varying levels of forming and tooling geometry.
Mini DOE for Roller Forming
Under-Forming and Over-Forming: Testing different levels of forming to understand the optimal range and how variations during production would affect the outcome.
Tooling Geometry: Experimenting with various tool designs to find the most effective one.
Results
The roller forming process outperformed the crimp process in terms of consistency and reliability. All parts passed testing, showcasing the secure form provided by roller forming. This case study emphasizes the importance of conducting a DOE, especially when facing a high part failure rate or implementing a new process.
Conclusion
In conclusion, the Design of Experiments is an invaluable tool for optimizing part assembly processes. Manufacturers can utilize a DOE when faced with challenges like high part failure rates or when implementing new assembly methods. Through systematic testing and parameter optimization, a DOE contributes to more efficient and reliable manufacturing processes, leading to enhanced product quality and cost savings.
If you're grappling with high failure rates or introducing a new part, leverage our expertise in performing a Design of Experiments. Reach out to our team for tailored support in optimizing your assembly process, identifying the right parameters, and achieving the results you desire. Your success begins with strategic experimentation – contact us today.