Process Optimization with DoE (Design of Experiments)

11M2234

Master

German

5.0

only summer term

1 semester

The production of industrial products requires comprehensive knowledge of material and production-oriented product and process optimization. This requires knowledge of systematic-empirical methods for process analysis and optimization, as the product quality resulting from industrial processes often depends on numerous process parameters and cannot be described or optimized with sufficient accuracy using theoretical approaches alone. The aim of this module is to know, evaluate and apply these scientific-empirical methods and to implement them in a specific case study by means of a project task.

Theoretical part: general principles of empirical-scientific process analysis and optimization. Product and process optimization using statistical experimental methodology DoE (Design of Experiments), basic principles of DoE, screening experimental designs, factorial and fractional factorial experimental designs, Taguchi, Shainin, response surface designs (such as CCD). Evaluation of experimental designs, ANOVA, regression methodology, graphical and numerical optimization of several responses (target variables).

Practical part: Selection of a demo process (e.g. plastic injection molding process, metal welding process). Definition of target variables to be optimized (product characteristics e.g. dimensions, weight, strength). Analysis and optimization of the process parameters using DoE. Evaluation of the test results using scientific methods and DoE Software. Preparation of a project report with presentation of suitable test plans, parameter and process settings, proof of measuring equipment capability, effect analysis and evaluation, presentation of optimization results, conclusions for product quality and manufacturing process.

The total workload for the module is 150 hours (see also "ECTS credit points and grading").

• Written examination

• Field work / Experimental work

Exam (K1): see valid study regulations

Experimental work: written report (group work), approx. 40 pages

Fundamentals of mathematics, statistics, quality management, materials technology, metallurgy, plastics technology

Students have knowledge of and experience with modern DoE optimization techniques for product and process optimization. These methods and their potential for process analysis and optimization are comprehensively presented in the theoretical part of the module and implemented in a case study in the practical part.

Students will be able to optimize industrial processes using the latest knowledge in terms of product quality and economic efficiency, applying scientifically based DoE methods and mathematical and statistical evaluation procedures.

Students will be able to optimize industrial processes systematically and empirically with regard to product quality and economic efficiency using the latest scientific DoE methods and mathematical and statistical evaluation procedures.

Students master a range of advanced subject-related methods based on DoE in order to analyze, evaluate and optimize the influences of processing parameters on product quality in industrial manufacturing processes. Relationships between influencing variables and response variables, including the interactions of the parameters, would not have been recognized without the application of DoE due to the complexity of processes. As a result, students see DoE as a powerful tool for gaining knowledge and optimizing processes and quality parameters.

Increasing demands on the quality of industrial products require knowledge of the relationships between process parameters and product quality as well as the evaluation of optimization potential. Students have the competence to apply the necessary science-based DoE methods and associated skills to any industrial process.

Graduates are able to initiate, carry out and evaluate the necessary investigations, process analyses and optimizations in the development of new products in industry and research.

Students reflect on, integrate and expand their knowledge, methods and skills in a subject-related context. This content is implemented in a team to work on a case study and the results are discussed in a professional exchange under supervision and then summarized, interpreted and evaluated in writing. 

• Schröder, Cathrin

• Schröder, Cathrin

R. Schwegmann, A. Giertler