Design for Six Sigma with MATLAB

Kevin Cohan The MathWorks, Inc.

2007 The MathWorks, Inc.

Design for Six Sigma

Classic Six Sigma focuses here Relative Cost to Make a Design Change
1000

DFSS focuses here

100

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Research

Design

Development

Production

Product Stage
http://www.dtic.mil/ndia/2003test/kiemele.pdf

DMAIC Methodology D M A I C
Define the problem / defects Measure the current performance level

DMAIC

Analyze to determine the root causes of the problem / defects Improve by identifying and implementing solutions

that eliminate the root causes

Control by monitoring the performance of the improved process

http://www.dtic.mil/ndia/2003test/kiemele.pdf

Example

Optimization of an Engine Cooling Fan Design

Image courtesy of Novak Conversions

2007 The MathWorks, Inc.

Define:
Define the Problem
Existing engine isnt cooled sufficiently under difficult driving conditions

DMAIC

New design requirement

Airflow > 875 cubic feet per minute

Approach
Optimize design factors

for maximum airflow Use the MATLAB product family to implement the DMAIC methodology

Image courtesy of Novak Conversions

Measure:
Measure Cooling Fan Performance
Import historical data from Excel Establish baseline for comparison
Mean

DMAIC

= 842 ft3 / min Std Dev = + 2 ft3 / min

Analyze:
Clearance

DMAIC
Distance

Analyze Factors that Affect Performance

Three design factors we can modify
Pitch

Factors Distance from radiator Blade pitch angle Blade tip clearance

(d) (p) (c)

Range Min Max 1.0 1.5 15 35 1.0 2.0

Units inches degrees inches

7

Analyze:

DMAIC

Analyze Factors that Affect Performance

Gather additional data from existing system
Modify our design factors and measure performance
(d) (p) (c) ? Performance Blade tip clearance

Fit a model to the performance data Evaluate the model to understand the

Distance from radiator ?

effect of each design factor

What tests do we run?

and how many?
Test Run 1 2 3 n

Blade pitch angle ?

Analyze:

DMAIC

Analyze Factors that Affect Performance

Use a designed experiment to gather performance data Choose the Box-Behnken function to determine points in the design space

Analyze:

DMAIC

Analyze Factors that Affect Performance

Fit a quadratic model to the data (regstats function)

AF = B0 + B1X1 + B2X2 + B3X3 + B4X1X2 + B5X1X3 + B6X2X3 + B7X12 + B8X22 + B9X32 AF X1 X2 X3 = = = = Airflow (ft3/min) Distance from radiator (inches) Fan pitch angle (degrees) Tip clearance between fan blades and shroud (inches)
10

Analyze:
factors (distance, pitch, clearance) simultaneously

DMAIC

Analyze Factors that Affect Performance

Use rstool to visually inspect interaction between all three design

11

Improve:
Improve the Cooling Fan Performance
Use optimization to automate the task of finding the maximum airflow
fmincon function

DMAIC

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Improve:
Improve the Cooling Fan Performance

DMAIC

Use uncertainty analysis to ensure a robust design Two main contributors

Model uncertainty Manufacturing variability

Factors Model noise Distance from radiator Blade pitch angle Blade tip clearance

Nominal Value and Tolerance 3 0.00 +/- 0.96 ft /min (d) (p) (c) 1.00 +/- 0.005 inch 27.3 +/- 0.5 degrees 1.00 +/- 0.005 inch

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Improve:
Improve the Cooling Fan Performance
Use Monte Carlo simulation to determine impact of these variations
Mean

DMAIC

= 882 ft3 / min Std Dev = + 2 ft3 / min

14

Control:
Use Statistical Process Control (SPC) techniques to monitor and control manufacturing and installation of the fan

DMAIC

Control the Manufacturing and Installation

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Summary
Continued emphasis on quality initiatives Data analysis increasingly becoming an integral part of the engineering design process MATLAB product family can support these initiatives

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Questions?

2007 The MathWorks, Inc.

2007 The MathWorks, Inc.