PROCESS OPTIMIZATION USING METACAUSE
By
Dr. Hathibelagal Roshan
Presentation at the SFSA Management Meeting
April 8, 2010
What is Process Optimization
Process optimization is the identification and
control of the input process parameters (Factors)
to achieve the desired output (Response) in any
process.
The most common goals are minimizing cost,
maximizing throughput, and/or efficiency.
This is one of the major quantitative tools in
industrial decision making.
OPTIMIZATION OF CASTING PROCESS
Infoundryterms,aprocessistypicallyasetofequipmentarranged,
controlled,andoperatedinaparticularway,toproduceacasting.
Theproductmustmeetcertainspecifications,suchasacertain
productionrate,productquality,andcost.
Whenoptimizingaprocess,thegoalistomaximizeoneormoreofthe
processspecifications,whilekeepingallotherswithintheirconstraints.
MetalCastingProcessisnotasingleprocess,buthasseveralsub
processessuchasPatternmaking,sandpreparation,molding,melting,
pouring,heattreatment,CleaningandFinishingetc.
ItisessentialtounderstandwhatismeantbyOptimizingeachofthe
subprocesses.
Itisalsousefulforafoundrytoknowthelevelofoptimizationofits
eachofthesubprocesses.
What is required for Casting Process Optimization?
1. Agoodtooltoanalyzethedataanddeterminewhetherthe
processisoptimumornot.(ProcessOptimizerSoftware)
MetaCauseProcessOptimizeristhetool
2. Expertiseintheunderstandingtheprocessandidentifying
thefactorsandresponsesrelevanttotheprocess.
FPR(FactorProcessResponse)Diagramsforeachofsub
processesinthefoundries.
MetaCause Software
MetaCause isadataanalysissoftwaretoolthatgivesyouachecklist
onfactorsettingstoachievedesiredresponses
Processimprovementsoftwarethatuseshistoricaldata
SelflearningsoftwarecutswasteandreducescostsacrossIndustries
Analysesmultivariatedataidentifyingrelationshipsamongvariables
MainEffects
Interactions
InputsdatainaverysimpleExcelformatOutputsachecklistonfactor
settingsasOptimal,AvoidorNoEffect.
MetaCause Software
Responses
Factors
Process Response
Factors
Temp
Quality
Good
Acceptable
Bad
High
Medium
Low
F1
F2
F3
F4
F5
R1
R2
R3
Pressure
Defects
High
Medium
Low
1
2
None
Few
Many
Time
Physical
Properties
High
Medium
Low
4
5
Good
Acceptable
Bad
Operator
Bob
Dave
Sam
Record Data
MetaCause Analysis
Factors
Responses
Observations
Discovers hidden trends
Main Effects & Interactions
Extracts true process behaviour Optimal/Avoid settings
Measures strength of links
Settings with No Effect
Implement Results
Sample Input Data
Sample Input Data
MetaCause Report
Summary Report
LIMITATIONS OF DOE
1. IntheDOE,thenumberofexperimentsneededdependsonthe
[Link]
generallyhigh.
2. IntheDOE,thereisaneedtocarryoutcontrolledexperimentsto
collecttherequireddataanditcouldinterruptregularproduction.
3. IntheDOE,theleveloffactorshavetobewithaconsiderable
differenceinordertohavemeaningfulresults.
4. TheDOEassumesknowndistributionstotheunknownfoundry
processes,assuchtheresultscouldbebiased.
5. TheDOErequirespeoplewithareasonableexpertiseintheuseto
statisticaltechniquestodesignandinterprettheresults.
TECHNOLOGY GAP IN FOUNDRY INDUSTRY
1. Data
2. Information:ProcessedData
3. Knowledge:ActionableInformation
MetaCauseProcessOptimizeranalyzesfoundrydataandprovides
actionableinformation
FPR(FactorProcessResponse)diagramsprovidethenecessary
knowledgerelatingtothevarioussubprocessesinthefoundry
industry
Theintentistogivefoundriestheknowledgetoevaluatetheir
subprocessesanddeterminetheleveloftheiroptimizationand
theirimpactonprofitability.
FPR (Factor-Process-Response) Diagram
Steel Melting Process
Boundary: Melting to Heat Treatment to Testing the Properties of Test Block.
Xs
Factors
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
%C(X1)
%Mn (X2)
%Si (X3)
%S (X4)
%P (X5)
%Ni (X6)
%MoX7)
%Al (X8)
%N(X9)
%Zr (X10)
%Ti (X11)
Mn/S ratio (X12)
Ca/Al ratio (X13)
Tempering Temp (X14)
Tempering Time (X15)
Quench after tempering (X16)
Size of Test Blokc (X17)
Location of test (X18)
BHN of Test Block (X19)
Melter (X20)
Pourer (X21)
Heat Treat Operator (X22)
[Link], Rev. Apr 2, 2010
Ys
Responses
Steel
Melting Process
1.
2.
3.
4.
5.
6.
7.
7.
8.
Tensile Strength, %,Y1
Yield Strength Y2
% Elongation Y3
% Reduction in Area Y4
BHN of Test Block Y5
Charpy value at 40F, Y6
Charpy value at 0F, Y7
Charpy value at 70F, Y8
% of Conchoidal Fracture, Y9
SUMMARY