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
numberoffactors.Thenumberoffactorsincastingprocessare
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)

Dr.Roshan, 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