1. D e s i g n y o u r s u c c e s s ! GIesserei Umwelt Technik GmbH ASSISTANT Systematical optimization without „Trial & Error“ Systematical optimization without „Trial & Error“ Process optimization – ASSISTANT Software

2. D e s i g n y o u r s u c c e s s ! GIesserei Umwelt Technik GmbH Product properties Parameter b Parameter a Process optimization ASSISTANT-Software Design of experiments Optimization algorithms Process optimization GUT „3P-System ® “ holistic approach for optimization Product optimization Simulation (filling, solidification and stress) Process sequence optimization Process sequence optimization MyLOGI ® Process modeling

3. D e s i g n y o u r s u c c e s s ! GIesserei Umwelt Technik GmbH Design of experiments and process optimization Why are experiments necessary? Why is statistics necessary? Why should a design of experiments being carried out? What results are expectable? Example of die casting Example of injection moulding

4. D e s i g n y o u r s u c c e s s ! GIesserei Umwelt Technik GmbH Experiments are necessary because … Standing the companies ground on the market Constant improvement of products and processes by : increasing the functionalities of products cost reduction (increase of productivity, minimizing the scrap) reduction of the development time for new products reduction of the throughput time in the production line Constant improvement of products and processes by : increasing the functionalities of products cost reduction (increase of productivity, minimizing the scrap) reduction of the development time for new products reduction of the throughput time in the production line Improvements are not possible only by analyzing data of the production line In order to determine dependencies between parameter and properties, systematic experiments are necessary

5. D e s i g n y o u r s u c c e s s ! GIesserei Umwelt Technik GmbH Statistics is necessary because … Random differences at measurements, materials and process conditions lead to a disturbance of the results Statistical procedures are based on a safeguard against wrong decisions caused by random scattering and on a compensation of random varieties by averaging Distinctions of variants of processes and products that are less than the fivefold of the standard deviation of the disturbances should be recognized Differences should be determined qualitatively

6. D e s i g n y o u r s u c c e s s ! GIesserei Umwelt Technik GmbH Design of experiments is necessary because …. Experiments are time consuming and cost intensive so that the amount of single experiments must be reduced. A dedicated planning of the trials allows an estimation of the necessary number of trials, of the costs and allows an analysis of the possibilities trial and error is avoided and knowledge is more transparent A systematical analysis of the results lead to better understanding which steps should be taken for a further improvement „The TQM, SixSigma, KVP, Kaizen,…. - we are aware of the necessity of a continous improvement. Design of experiments is a collection of ideas and procedures which helps us to proceed systematically and to learn a lot with a little expenditure. (Prof. Dr. Wilhelm Kleppmann, Taschenbuch Versuchsplanung, 2003, Hanser Verlag)

7. D e s i g n y o u r s u c c e s s ! GIesserei Umwelt Technik GmbH Results of DOE? The results leads to an empirical model. This model shows quantitatively the dependencies between the parameters and the properties The report and further analysis allows to – calculate the right combinations of Parameters that are optimal for a product – see the right direction that leads to improvements – to evaluate if there are contrary demands The report and further analysis allows to – calculate the right combinations of Parameters that are optimal for a product – see the right direction that leads to improvements – to evaluate if there are contrary demands The calculated dependencies are valid – in the defined area – with respect to the statistical noise – with respect to the used mathematical model The calculated dependencies are valid – in the defined area – with respect to the statistical noise – with respect to the used mathematical model

8. D e s i g n y o u r s u c c e s s ! GIesserei Umwelt Technik GmbH Finding the right setup - 1 How do specialists find the right setup ? The right setup is found by professionals on base of their experiences Based on their experiences that they got during the long work with the processes they know intuitively how to setup the process in order to get all quality criteria in the given tolerances with respect to the maximum throughput.

9. D e s i g n y o u r s u c c e s s ! GIesserei Umwelt Technik GmbH Finding the right setup - 2 X Process parameter 2 o X o X Process parameter 1 Specialist 1 Specialist 2 Optimal point How do specialists find the right setup?

10. D e s i g n y o u r s u c c e s s ! GIesserei Umwelt Technik GmbH Finding the right setup - 3 In order to find the optimal setup a systematical procedure is absolutely necessary In order to find the optimal setup a systematical procedure is absolutely necessary How do we find the right setup?

11. D e s i g n y o u r s u c c e s s ! GIesserei Umwelt Technik GmbH Simple processes …are often easy to understand. The dependencies between process parameters and product features can be determined with only a few experiments. …are often easy to understand. The dependencies between process parameters and product features can be determined with only a few experiments. Simple processes

12. D e s i g n y o u r s u c c e s s ! GIesserei Umwelt Technik GmbH Real processes Real processes...... are much more complex! The complexity increases with the amount of parameters an properties. With conventional methods the dependencies are hardly determined. Thus an optimization is much more difficult.... are much more complex! The complexity increases with the amount of parameters an properties. With conventional methods the dependencies are hardly determined. Thus an optimization is much more difficult.

13. D e s i g n y o u r s u c c e s s ! GIesserei Umwelt Technik GmbH Optimization with ASSISTANT - Definition Optimization with ASSISTANT The dependencies are evaluated by Optimization with ASSISTANT The dependencies are evaluated by the definition of parameters and properties 0

14. D e s i g n y o u r s u c c e s s ! GIesserei Umwelt Technik GmbH Optimization with ASSISTANT – design of experiments Optimization with ASSISTANT The dependencies are evaluated by Optimization with ASSISTANT The dependencies are evaluated by A clever design of experiments

15. D e s i g n y o u r s u c c e s s ! GIesserei Umwelt Technik GmbH Optimization with ASSISTANT – Model generator Optimization with ASSISTANT The dependencies are evaluated by Optimization with ASSISTANT The dependencies are evaluated by Flexible model building

16. D e s i g n y o u r s u c c e s s ! GIesserei Umwelt Technik GmbH Optimization with ASSISTANT – parameter optimization Optimization with ASSISTANT The dependencies are evaluated by Optimization with ASSISTANT The dependencies are evaluated by Efficient optimization of parameters

17. D e s i g n y o u r s u c c e s s ! GIesserei Umwelt Technik GmbH Optimization with ASSISTANT - Visualization Optimization with ASSISTANT The dependencies are evaluated by Optimization with ASSISTANT The dependencies are evaluated by Visualizing of the dependencies

18. D e s i g n y o u r s u c c e s s ! GIesserei Umwelt Technik GmbH Optimization with ASSISTANT – simulation and analysis Optimization with ASSISTANT The dependencies are evaluated by Optimization with ASSISTANT The dependencies are evaluated by Analysis and simulation of new settings

19. D e s i g n y o u r s u c c e s s ! GIesserei Umwelt Technik GmbH Example: production of a piston with die casting improvement of the surface quality Decreasing porosities at the rings Decreasing porosity at the bottom Decreasing porosities at the shaft Targets of the optimization: avoiding of defects

20. D e s i g n y o u r s u c c e s s ! GIesserei Umwelt Technik GmbH Results Number of experiments: 60 Optimization time: 6 hours An optimized parameter setup could be determined. With that setup piston with a very good quality could be produced. ASSISTANT minimized the number of necessary trials in order to find the best settings. Results

21. D e s i g n y o u r s u c c e s s ! GIesserei Umwelt Technik GmbH Example: injection moulding

22. D e s i g n y o u r s u c c e s s ! GIesserei Umwelt Technik GmbH Targets of the optimization Complete filling Avoiding of filling lines Avoiding of flashes Targets of the optimization: improving the quality

23. D e s i g n y o u r s u c c e s s ! GIesserei Umwelt Technik GmbH Results Number of experiments: 150 Optimization time: 4 hours Increase of yield: 3% A new machine setting was found. That setting was far away from the specialists experiences. The specialists did no expect a good result with that setting and therefore no experiments were carried out in that area before. Results

24. D e s i g n y o u r s u c c e s s ! GIesserei Umwelt Technik GmbH Optimization with ASSISTANT – Design your success! The optimization with ASSISTANT is carried out by systematical procedure with and clever design of experiments flexible modeling of the dependencies efficient parameter optimization analysis of the dependencies Optimal productivity and quality Optimal productivity and quality