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Probabilistic Design for Optimization and Robustness:
* Presents the theory of modeling with variation using physical models and methods for practical applications on designs more insensitive to variation.
* Provides a comprehensive guide to optimization and robustness for probabilistic design.
* Features examples, case studies and exercises throughout.
The methods presented can be applied to a wide range of disciplines such as mechanics, electrics, chemistry, aerospace, industry and engineering. This text is supported by an accompanying website featuring videos, interactive animations to aid the readers understanding.
List of contents
Preface ix
Acknowledgments xi
1 New product development process 1
1.1 Introduction 1
1.2 Phases of new product development 2
1.2.1 Phase I--concept planning 3
1.2.2 Phase II--product planning 4
1.2.3 Phase III--product engineering design and verification 6
1.2.4 Phase IV--process engineering 9
1.2.5 Phase V--manufacturing validation and ramp-up 10
1.3 Patterns of new product development 11
1.4 New product development and Design for Six Sigma 13
1.4.1 DfSS core objectives 13
1.4.2 DfSS methodology 15
1.4.3 Embedded DfSS 16
1.5 Summary 17
Exercises 17
2 Statistical background for engineering design 19
2.1 Expectation 19
2.2 Statistical distributions 24
2.2.1 Normal distribution 24
2.2.2 Lognormal distribution 27
2.2.3 Weibull distribution 30
2.2.4 Exponential distribution 32
2.3 Probability plotting 34
2.3.1 Probability plotting--lognormal distribution 35
2.3.2 Probability plotting--normal distribution 36
2.3.3 Probability plotting--Weibull distribution 37
2.3.4 Probability plotting--exponential distribution 39
2.3.5 Probability plotting with confidence limits 40
2.4 Summary 43
Exercises 44
3 Introduction to variation in engineering design 46
3.1 Variation in engineering design 46
3.2 Propagation of error 47
3.3 Protecting designs against variation 48
3.4 Estimates of means and variances of functions of several variables 51
3.5 Statistical bias 59
3.6 Robustness 59
3.7 Summary 60
Exercises 61
4 Monte Carlo simulation 63
4.1 Determining variation of the inputs 63
4.2 Random number generators 64
4.3 Validation 66
4.4 Stratified sampling 70
4.5 Summary 74
Exercises 75
5 Modeling variation of complex systems 76
5.1 Approximating the mean, bias, and variance 77
5.2 Estimating the parameters of non-normal distributions 81
5.3 Limitations of first-order Taylor series approximation for variance 84
5.4 Effect of non-normal input distributions 91
5.5 Nonconstant input standard deviation 93
5.6 Summary 93
Exercises 95
6 Desirability 98
6.1 Introduction 98
6.2 Requirements and scorecards 99
6.2.1 Types of requirements 100
6.2.2 Design scorecard 101
6.3 Desirability--single requirement 103
6.3.1 Desirability--one-sided limit 104
6.3.2 Desirability--two-sided limit 106
6.3.3 Desirability--nonlinear function 107
6.4 Desirability--multiple requirements 109
6.4.1 Maxi-min total desirability index 114
6.5 Desirability--accounting for variation 115
6.5.1 Determining desirability--using expected yields 115
6.5.2 Determining desirability--using non-mean responses 116
6.6 Summary 118
Exercises 118
7 Optimization and sensitivity 123
7.1 Optimization procedure 123
7.2 Statistical outliers 128
7.3 Process capability 129
7.4 Sensitivity and cost reduction 133
7.4.1 Reservoir flow example 134
7.4.2 Reservoir flow initial solution 135
7.4.3 Reservoir flow initial solution verification 136
7.4.4 Reservoir flow optimized with normal horsepower distribution 138
7.4.5 Reservoir flow optimized with normal horsepower distribution
About the author
BRYAN DODSON,
Executive Engineer, SKF, USA PATRICK C. HAMMETT,
Lead Faculty Six Sigma Program, Integrative Systems & Design, College of Engineering, University of Michigan, Ann Arbor, USA RENÉ KLERX,
Principal Statistician, SKF, The Netherlands
Summary
Probabilistic Design for Optimization and Robustness: * Presents the theory of modeling with variation using physical models and methods for practical applications on designs more insensitive to variation. * Provides a comprehensive guide to optimization and robustness for probabilistic design.
