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Optimizing Part Assembly: The Power of Design of Experiments

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

Why run a Design of Experiments?

Running a DOE for part assembly is valuable for several reasons:

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


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.


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.


Articulating Roller FormingSolutions LabProcess IdentificationPrototypingElectronics