Transcript Final_Presentation.ppt

Coating Cans Wear Analysis
Kevin Jacob
DSES_6070
Background
• Coating process uses fixtures (cans) to mask
part leaving the area to be coated exposed to
the coating material.
• Coating thickness is assessed by having a
positive correlation to the weight of the part
before and after coat (weight gain).
• Along with process variation, measurement and,
tooling variation are significant.
• Process is reaching its maturity and tool wear is
affecting the quality of parts.
Current Coating Trends
Interaction Plot for Gain
Data Means
0.52
Ca n ID
Nu m b e r 1
060
061
062
063
064
065
066
067
0.50
068
069
070
071
072
073
074
075
076
Mean
0.48
077
078
079
080
081
083
084
085
086
087
088
0.46
089
091
092
093
094
095
096
097
0.44
098
099
100
101
102
103
104
105
106
107
108
0.42
109
110
111
112
113
114
115
116
117
0.40
118
119
120
CatArc 3
CatArc 7
CatArc 8
Coater
CatArc10
Coating Gain Analysis
Probability Plot of Gain
Normal
99.99
Mean
StDev
N
AD
P-Value
99
95
0.4594
0.02494
962
0.690
0.071
Percent
80
50
20
5
1
0.01
0.35
0.40
0.45
Gain
0.50
0.55
• Norma Distribution
was determined as
the best distribution to
study the Weight Gain
variation.
Probability Plot for Service_Times
LSXY Estimates-Complete Data
C orrelation C oefficient
Weibull
0.927
Weibull
99.9
95
80
Percent
50
20
5
2
1
1500
2000
3000
4000
Service_Times
5000
6000
7000
• A Weibull Distribution
is used to study the
Can Wear.
Data Analysis
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Service_Times
2880
3840
3360
3840
3840
3120
6000
3600
2880
3840
4080
3360
3840
4800
3600
4560
2640
3120
3600
2640
2640
Failure_Times
6720
2640
6720
2640
6720
• Shows a snapshot of
service time
accumulated on
Cans.
• 53 masks still in
service while 5 failed.
Weibull Analysis
Distribution Overview Plot for Service_Times
LSXY Estimates-Complete Data
P robability Density F unction
Table of Statistics
Shape
4.73668
Scale
4066.56
M ean
3722.10
StDev
895.688
M edian
3763.77
IQ R
1230.84
F ailure
53
C ensor
0
A D*
4.592
C orrelation
0.927
Weibull
99.9
0.00045
90
P DF
P er cent
0.00030
0.00015
0.00000
2000
50
10
1
3000 4000
5000
Ser vice_T imes
2000
Surv iv al F unction
Hazard F unction
0.004
Rate
100
P er cent
5000
Ser vice_T imes
50
0
0.002
0.000
2000
3000 4000
5000
Ser vice_T imes
2000
3000
4000
5000
Ser vice_T imes
Shape: 4.7668
Scale: 4066.56
MTTF: 3722
Maple Analysis
Reliability Function, PDF vs Time
Failure rate function, Hazard function vs Time
Conclusion
• The mean Time to Failure is 3722.
• Optimize coating times to reduce wear on
cans.
• Investigate other materials to manufacture
masks.