DOE IMC 1 October 2007

DOE Overview:
Background Information: Participants:
Tool: Pro-Star Hood Top Matt Billman
Date: 10/11/07 Travis Horstman
Press: 217 Scott Dodd
IMC: Omnova Jim Rennick
Rick Mikesell

Summary:
The DOE was conducted in molding on the Pro-Star Hood Top model in Press 217. There were
three factors that were studied for this experiment. Of those three factors IMC Open Height, IMC
Closing Speed, and the interaction of these two factors were found to be significant for the Total
Area of Air Entrapment and the Number of Pits. It showed that an IMC Open Height of 0.04 and
an IMC Closing Speed of 3 produced the best part. A follow-up DOE was also conducted to help
confirm the selected DOE set points. The next step is to ensure that all of the proper controls are
put into place.

DOE Design:
The table below shows the settings that were used for the DOE.

Low Setting Center Points High Setting

IMC Open Height 0.04 0.07 0.10
IMC Shot Size 1.25 1.30 1.35
IMC Closing Speed 3 13 23

See the Appendix for complete details.

DOE Results:
There are two significant factors and one significant two-way interaction over the observed
ranges for air entrapment total and the total number of pits on the part:
IMC Open Height
IMC Closing Speed
IMC Open Height * IMC Closing Speed

The factors and interactions in the table below were found to be statistically significant
with at least a 95% confidence level.
Y-Variable Significant Main Effects Significant Interactions
Air Trap Total IMC Open Height IMC Open Height*IMC Closing Speed
IMC Closing Speed
Number of Pits IMC Open Height IMC Open Height*IMC Closing Speed
IMC Closing Speed
Non Coat None None

The following is a summary of the R-sq and R-sq (adj) for each of the Y-variables in the DOE. An
R-sq value above 50% suggests a strong relationship exists. Therefore, the DOE model explains
56.09% of the variation for Air Trap Total and 66.61% of the variation for the Number of Pits.

Y-Variable DOE R-sq DOE R-sq (adj)

Air Trap Total 56.09% 38.52%
Pits Number Total 66.61% 53.25%
Non Coat 33.25% 6.56%

NOTES: Even though IMC Shot Size does not appear to be significant the selected range for that
variable can impact the significance. Perhaps if a larger range for shot size had been selected the
outcome may have shown it as a significant factor.

Main Effects Plots

Main Effects Plot (data means) for Air Trap Total (in^2)
IMC Open Height IMC Shot Size Point Ty pe
16
Corner
Center
12
Mean of Air Trap Total (in^2)

0
0.04 0.07 0.10 1.25 1.30 1.35
IMC Closing Speed
16
This indicates that to minimize
12
the air entrapment area an IMC
Open Height of 0.04 and an IMC
Closing Speed of 3 should be
8 chosen for the Pro-Star hood top.

0
3 13 23
 Main Effects Plot (data means) for Pits Number
IMC Open Height IMC Shot Size Point Ty pe
Corner
30
Center

20
Mean of Pits Number

10

0
0.04 0.07 0.10 1.25 1.30 1.35
IMC Closing Speed
30 This indicates that to minimize
the number of pits an IMC Open
Height of 0.04 and an IMC Closing
20
Speed of 3 should be chosen for
the Pro-Star hood top.
10

0
3 13 23
Appendix
DOE Design:
This is a 2-Level DOE with 3 factors.

DOE Factors:
1. IMC Open Height
2. IMC Shot Size
3. Closing Speeds - IMC

DOE Design:
Full

Replications:
There are 3 replications used for this DOE.

Center Points:
There are 5 center points used for this DOE. This will provide us with information on the possible
presence of second order affects (curvature) in the model and still allow us to conduct the
screening DOE.

Randomization of Runs:
The run order was randomized per Minitab.

Number of Parts:
There will be a total of 29 parts run for this DOE. (8 combinations * 3 replications = 24 parts + 5
center points).

FIRM (Potential Input Variables):

For each potential input variable it was decided to either Fix the setting, Ignore the setting,
Randomize the setting, or Model the variable.

Interactions:
The interactions will be reviewed for this study. In a full factorial DOE none of the results are
confounded. Therefore, all of the interactions can be studied.

Scoring:
The size of the total air entrapment area was measured (ferning, pits, etc.), the number of pits
was counted, and the total area IMC non-coat was measured.

Required Actions for DOE:

1. New drum of IMC will be set at the start of the trial. The IMC information will be recorded.
2. New rolls of SMC will be brought-up for the trial. Only consecutive rolls will be used.
3. The parts will be sprayed with mold release after every shot.
4. Fix variables for the DOE per the list.
5. The parts will need to be held for scoring after the DOE. The parts will be scored on Friday.
6. Make sure that bolts are tight before running.
Factorial Fit: Air Trap Total versus IMC Open Height, IMC Shot Size, ...

Estimated Effects and Coefficients for Air Trap Total (in^2) (coded units)

Term Effect Coef SE Coef T P

Constant 7.910 2.145 3.69 0.001
IMC Open Height 13.161 6.580 2.145 3.07 0.006
IMC Shot Size -4.527 -2.264 2.145 -1.06 0.304
IMC Closing Speed 11.293 5.646 2.145 2.63 0.016
IMC Open Height*IMC Shot Size -5.206 -2.603 2.145 -1.21 0.239
IMC Open Height*IMC Closing Speed 10.344 5.172 2.145 2.41 0.026
IMC Shot Size*IMC Closing Speed -1.551 -0.775 2.145 -0.36 0.721
IMC Open Height*IMC Shot Size* IMC -1.979 -0.990 2.145 -0.46 0.649
Closing Speed
Ct Pt -3.460 5.165 -0.67 0.511

S = 10.5062 R-Sq = 56.09% R-Sq (adj) = 38.52%

Analysis of Variance for Air Trap Total (in^2) (coded units)

Source DF Seq SS Adj SS Adj MS F P

Main Effects 3 1927.36 1927.36 642.45 5.82 0.005
2-Way Interactions 3 819.05 819.05 273.02 2.47 0.091
3-Way Interactions 1 23.50 23.50 23.50 0.21 0.649
Curvature 1 49.53 49.53 49.53 0.45 0.511
Residual Error 20 2207.61 2207.61 110.38
Pure Error 20 2207.61 2207.61 110.38
Total 28 5027.04

Factorial Fit: Number of Pits versus IMC Open Height, IMC Shot Size, ...

Estimated Effects and Coefficients for Pits Number (coded units)

Term Effect Coef SE Coef T P

Constant 17.58 3.551 4.95 0.000
IMC Open Height 29.17 14.58 3.551 4.11 0.001
IMC Shot Size -8.33 -4.17 3.551 -1.17 0.254
IMC Closing Speed 22.00 11.00 3.551 3.10 0.006
IMC Open Height*IMC Shot Size -10.33 -5.17 3.551 -1.45 0.161
IMC Open Height*IMC Closing Speed 20.33 10.17 3.551 2.86 0.010
IMC Shot Size*IMC Closing Speed -1.17 -0.58 3.551 -0.16 0.871
IMC Open Height*IMC Shot Size* IMC -3.50 -1.75 3.551 -0.49 0.628
Closing Speed
Ct Pt -10.38 8.552 -1.21 0.239

S = 17.3966 R-Sq = 66.61% R-Sq (adj) = 53.25%

Analysis of Variance for Number of Pits coded units)

Source DF Seq SS Adj SS Adj MS F P

Main Effects 3 8424.8 8424.83 2808.28 9.28 0.000
2-Way Interactions 3 3129.5 3129.50 1043.17 3.45 0.036
3-Way Interactions 1 73.5 73.50 73.50 0.24 0.628
Curvature 1 446.1 446.13 446.13 1.47 0.239
Residual Error 20 6052.8 6052.80 302.64
Pure Error 20 6052.8 6052.80 302.64
Total 28 18126.8

Factorial Fit: Non-Coat versus IMC Open Height, IMC Shot Size, IMC Closing

Estimated Effects and Coefficients for Non-Coat (coded units)

Term Effect Coef SE Coef T P

Constant 0.2500 0.08975 2.79 0.011
IMC Open Height 0.3333 0.1667 0.08975 1.86 0.078
IMC Shot Size -0.1667 -0.0833 0.08975 -0.93 0.364
IMC Closing Speed -0.1667 -0.0833 0.08975 -0.93 0.364
IMC Open Height*IMC Shot Size 0.0000 0.0000 0.08975 0.00 1.000
IMC Open Height*IMC Closing Speed -0.0000 -0.0000 0.08975 -0.00 1.000
IMC Shot Size*IMC Closing Speed -0.1667 -0.0833 0.08975 -0.93 0.364
IMC Open Height*IMC Shot Size* IMC -0.3333 -0.1667 0.08975 -1.86 0.078
Closing Speed
Ct Pt 0.1500 0.21615 0.69 0.496

S = 0.439697 R-Sq = 33.25% R-Sq (adj) = 6.56%

Analysis of Variance for Non-Coat (coded units)

Source DF Seq SS Adj SS Adj MS F P

Main Effects 3 1.00000 1.00000 0.33333 1.72 0.194
2-Way Interactions 3 0.16667 0.16667 0.05556 0.29 0.834
3-Way Interactions 1 0.66667 0.66667 0.66667 3.45 0.078
Curvature 1 0.09310 0.09310 0.09310 0.48 0.496
Residual Error 20 3.86667 3.86667 0.19333
Pure Error 20 3.86667 3.86667 0.19333
Total 28 5.79310