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OptiMal-DOE

Design of experiments with OPTIMAL. 'OptiMal-DOE' is a concept and a software program, which guides you through an optimization of a process or a new design element. 'OptiMal-DOE' is a very important part of all Six -Sigma programmes, where improvement is the most wanted and also the most difficult part. 'OptiMal-DOE' facilitates effective control with the design and analysis of the 'design of experiment' activity.

The OptiMal-DOE program is based upon general "Design of Experiments" and includes the ideas and adaptions, which were developed by Mr. G. Taguchi from Japan.

OptiMal-DOE is the most effective and cost efficient method to optimize complicated and complex relations, where the output (the final result) is dependant of many factors. And it can be achieved in one experiment!

The Method ensures that you can avoid primitive and ineffective runs, typically where you analyze one factor at a time.

There are many good examples on the advantages the method offers.

Some testimonials:

Danfoss has analyzed the production of springs in Tinglev and achieved considerable improvements. In this case you really see how, that a small investment under 1500 $ can lead to improvement in the millin dollar class.

JAI is applying the program to optimize their foundry for shell moulding.
At JAI it happened frequently that cavities and pits were present in the foundry. With support from teh DOE methodology JAI eventually discovered the cause. Since then they could make foundries much better and with a much smaller cycle time. Again a relatively small effort with a big impact.

Casco is applying the method to optimize the glueing process. Todays technology is so advanced that is not a challenge to make a good glue

Casco's effort have been directed to optimize the application process, i.e. what is the best choice for each customer. Again the DOE is the quickest and most effecient way to ensure and optimized process.
A customer achieved a very good result in using Casco's long experience together with OptiMal-DOE in case, where the glue should be applyed on an isolating material..
A preexamination was conducted to find the most probable compression of the isolating material. However applying the DOE it was discovered that the optimized settings were deviating considerable from waht was expected.
Applying DOE, CASCO and its customer achieved a considerable improved process with much greater strength than achieved beforehand.

"Again resources were reduced, higher efficiency achieved, and all in all it renders a much better quality for the end customer", says Uffe Munk from Casco.

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Uddannelse -Træning. Internal as well as external courses are available.

Application - the method in short:
You must instigate a brainstorming, under which you identify the most important factors, you think has an influence on the final result, i.e. teh output, objective or goal we want to achieve.
When the number of factors are identified the program assists you in identifying a likely testplan for the experiment. You achieve the optimization through a carefully designed plan of tke physically conducted runs. OptiMal DOE will do tehn rest for you i.e teh calculations.

OptiMal ask you to input the names of the factors, to be investigated. It also asks you to input the levels to be examined, the levels are also identified during the brainstorming.
In the next step you conduct the physical runs in accordance with the run plan identified from Optimal. OptiMal is used to calculate the results and the best result, i.e. the best combination/setting of all the factors involved.

A graphical display of all the factors relative results/importance is probably the easiest way to read the best combination. This is one of the big advantages by using OptiMal. The program easily displays the most important factors for you, and it also may indicate those factor, which can be neglected in the future. This helps you to "kill" gosts and mythes, which causes concerns and discussions without having any real influence.

Best of all: You will have a result "an estimation" of the best achievable result you may get if you choose to apply the 'best combination' of the factors involved set at the levels calculated (chosen trough calculation) i.e. the levels you have been using to examine the different situations.

In English the experiment is called 'Design of Experiment', in Danish it is called 'Forsøgsplanlægning'. In French it is called 'Plan d'experience'.

Why should I use 6 sigma optimization (and OptiMal-DOE):