Contech analyser for_robust_design_v1.6_en

Digital revolution for robust products and
intelligent processes

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Contents
Introduction: Analyser for Robust Design
The intelligent tool to analyse products and processes………….……………………............. 3
Modular structure and features........…………………………………………………….............. 4
Data analysis in the current Industry 4.0 environment..…………………………...….............. 5
Curve Analysis Module (KA)
Specifications and features: Curve Analysis Module............................................................. 6
Operating principle: Curve Analysis Module……………………………………....................... 7
User interface and teach in process………………………………………………………………. 8
Application possibilities: Curve Analysis Module..……..............…....................................... 10
Transfer Function Module (TF)
Specifications and features: Transfer Function Module………………………............…….... 11
Operating principle: Transfer Function Module..………………………………..............…..... 12
Application possibilities: Transfer Function Module…......……………………...........….........13
SPC Module (SPC)
Specifications and features: SPC Module.…..……………..................………............……....14
Operating principle: SPC Module.................…..………………………………..............…..... 15
Analyser for Robust Design
Your benefits using the Analyser for Robust Design............................................................ 16
Contact us……...........................................................….…………….................................. 17

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for Robust Design
The intelligent tool to analyse products and processes
Although for many companies it is still a ‘Vision for Industry 4.0’, we already have a standard
product available:
The Analyser for Robust Design,
the fully automated online tool for zero-defect and robust products and processes.
» Distinguishes OK and NOK cases based on curve characteristics and / or continuous
values (measurements) from sensor data
» Provides the connections between failure types and their root causes and offers
troubleshooting actions and solutions for each failure type
» Provides cause-effect interactions between requirements Yi (outputs) and cause
variables / influencing factors Xi (inputs)
» Predicts the achievement of requirements Yi
» Helps optimizing the process parameters and influencing factors for each requirement
» Real-time processing of small series of measurements and big data collections
» Supports clearing developments, accelerates industrialisation of products and
processes and provides features to ensure proper series production processes and
production process analysis
» Decreases failure rates consistently, reduces rework and the risk of warranty claims
» Provides a significant contribution to a zero-defect strategy and process optimisation
with a digital integration of the production in terms of Industry 4.0

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for Robust Design
Modular structure and features
The Analyser for Robust Design has an application specific, modular structure with
standardised modules:

for Robust Design
Data analysis in the current Industry 4.0 environment
In the Industry 4.0 environment, there are currently a few data analysis approaches for
product- / process data and measurable requirements.
Data analysis in the current Industry 4.0 environment and pioneering role of the Analyser for Robust Design
With the pioneering role and the modular structure, the Analyser for Robust Design
provides several application possibilities for prescriptive statistics (‘What should be
done?’). In this block, only very little and often no human interaction and statistical
knowledge is necessary to analyse data and decide on troubleshooting actions.
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Curve Analysis Module
Specifications and features
Curve Analysis Module (KA):
» Knowledge based, intelligent expert system in production and assembly
» Distinguishes OK and NOK cases based on curve characteristics and / or continuous
values (measurements) from sensor data
» Identifies typical failure types from NOK product validation and process curve
characteristics or NOK measurements and displays them with their percentage
» Connects the failure types to their cause(s), provides troubleshooting actions and
solutions and generates a knowledge database in your company
Statistical curve and failure type analysis with the Analyser for Robust Design
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Operating principle with teach in process using expert knowledge
Production and assembly processes
Digital monitoring and storage of process parameters and their
(curve) characteristics.
Data interface, user interface
Flexible data interface to import (curve) data (online or via
database). Graphical user interface to display individual
parameters / curve characteristics.
Teach in process
One-time storage of curve specific expert knowledge
for different failure types or other irregularities.
Book of Knowledge
Stored failure causes, recommended troubleshooting actions and
solution proposals to fix the failures (optional).
Failure cause analysis
Automated analysis of all process output data and identification of
the occurred failure types. Graphic presentation of the results with
failure type percentages and prioritised causes and troubleshooting
actions / solutions (optional via Book of Knowledge).

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User interface and teach in process
The process curves that were selected for analysis with the Analyser for Robust Design
are displayed in the user interface with their respective parameters, process limits and further
information. In a one-time teach in process, an expert can evaluate a representative part of
the curves and store the respective failure types in the system.
User interface with exemplary process curve (here: NOK curve) in teach in mode
With the stored knowledgebase, the Analyser for Robust Design with Curve Analysis
Module can provide the most probable root causes for the failure types identified from the
curve characteristics and prioritise them. The root causes are in turn linked to the respective
troubleshooting actions and solutions.

The Curve Analysis Module of the Analyser for Robust Design is able to provide
systematic analysis of failure types and causes and return the respective troubleshooting
actions and solutions based on the so called ‚Book of Knowledge‘, a technology database
with expert knowledge.
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Failure types (with percentages) and link to prioritized failure causes and troubleshooting actions /
solutions in the ‘Book of Knowledge’

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Application possibilities
» Fundamental idea: use of curve characteristics for failure analysis
» Universal operating principle with a great variety of individual, cross-sector
application possibilities
» All digitally monitored product and process parameters represented by their curve
characteristics and / or continuous values can be analysed, controlled and optimised with
the Curve Analysis Module
» Preventive failure avoidance or reactive product and process optimisation
Possibleapplicationareas (examples)
1. Digitally monitored fastenings (and similar assembly processes)
> Torque level [Nm] by torsion angle [°]
> Different tightening strategies, several stages / phases
2. Hysteresis loops
> Materials engineering: stress-strain diagrams
> Valves: Force [N] by travel [mm] at certain waypoints and Fmax.
> Control engineering
3. Acoustics and vibration issues
> Vibrations, NVH issues (sound pressure level [dB] by number of rotations [rpm])
> Acoustics and noise optimisation
4. Injection molding (e.g. of plastics)
> Pressure [Pa, bar, psi] by time [s] or travel [mm]
> Temperature [°C, °F] by time [s] or travel [mm]
> Optimisation of the open / closed loop control technology
and many more…

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Transfer Function Module
Transfer Function Module (TF):
» Filters the relevant cause variables influencing the quality of a product, process or
process step
» Identifies and describes the dependencies and cause-effect interactions between
product / process requirements (Yi) and the respective process parameters and cause
variables (Xi) with statistical models represented as transfer functions:
The Xi depicts 1 to n measurable, monitored cause variables or parameters that influence the resulting
quality requirements (Yi) of the product or process. f depicts the transfer function.
» Predicts the conformance to requirements (Yi) for the used process parameters and
cause variables Xi
» Optimises the process parameters and cause variables based on the cause-effect
interactions.
Filtering of statistically significant cause variables Xi

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Operating principle for product / process optimisation
Digital monitoring and storage of measurable product or
process parameters.
Teach in – cause variables
Compilation and prioritisation of the statistically significant and
measurable cause variables (Vital View).
Teach-In - Transfer function
Identification of the transfer function(s) and cause-effect
interactions for products or (sub)processes using statistical data
analysis methods. Storage in the technology database
‘Book of Knowledge for Transfer Functions’.
Qualitymanagement and product / process optimisation
Optimised parametrisation and tolerance management of products
and processes by continuous and predictive calculations based on
the transfer function(s).

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Application possibilities
» Fundamental idea: use of statistical models based on measurable cause variables for
product and process optimisation
» Universal operating principle for a great variety of individual, cross-sector application
possibilities
» All monitored product and process parameters can be predicted, controlled and
optimised using the Transfer Function Module
» Preventive and reactive product and process optimisation
Possibleapplicationareas (examples)
1. Monitored adhesive bonding processes (and similar assembly processes)
> Adhesion, cohesion and peel strength = f (viscosity, temperature, adhesive bead size, etc.)
2. Hysteresis loops
> Breaking systems: response time = f (Xi)
> Valves: recuperating force = f (Xi)
3. Acoustics and vibration issues
> Vibrations, NVH issues: sound pressure level [dB] by number of rotations [rpm] = f (Xi)
> Acoustics and noise optimisation
4. Injection molding (e.g. of plastics)
> Shrinkage, corrugation, dimensions = f(pressure [Pa, bar, psi], holding pressure time [s],
tool temperature [°C, °F], etc.)
5. Extrusion of plastics / rubber
> Profile geometry, hardness, stress-strain coefficient = f (Xi)
and many more…

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SPC Module
SPC Module (SPC):
» Processes product and process parameters that are monitored online and are available as
curve characteristics and / or continuous values
» Monitors defined and selected SPC parameters continuously and fully automated
including an early warning system for deviations
» Provides stored reaction plans with tasks per parameter and requirement violation,
including responsibilities, troubleshooting actions and solutions
Graphical definition of a SPC parameter in a series of curves

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SPC Module
Operating principle for product / process monitoring
Digital online monitoring and storage of measurable
product or process parameters.
Teach in – SPC parameters
Graphical or analogue definition of statistically significant and
measurable SPC parameters.
Monitoring of product / process parameters
Continuous and fully automated monitoring of the defined
SPC parameters including an early warning system for
deviations and slide control to set constant product and
process parameters.
Qualitymanagement and reaction plans
Reaction plans with tasks per parameter and requirement violation
including responsibilities, troubleshooting actions and solutions.

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for Robust Design
Your benefits using the Analyser for Robust Design
 Replaces existing manual or automated methods for failure analysis, product &
process monitoring and optimisation
 Increases the efficiency and effectivity of data analysis
 Identifies failure types and root causes fast and provides troubleshooting actions
and solutions
 Creates robust products and processes
 Decreases failure rates consistently, reduces rework and the risk of warranty
claims
 Identifies cause-effect interactions between requirements and cause variables and
predicts the conformance to requirements
 Monitors defined and selected SPC parameters continuously and fully automated
including an early warning system and reaction plans for deviations
 Stores retrievable expert knowledge and / or transfer functions for products and
processes in the technology database ‘Book of Knowledge (for Transfer
Functions)’
 Provides a universal operating principle for a great variety of individual,
cross-sector application possibilities
 Includes a standardised interface to import sensor data
 Only system requirement: Windows 7 or newer

Do you have any questions or do you need any further information?
We are looking forward to support you concerning your issues and projects.
Please do not hesitate to contact us or visit our homepages:
Consulting and engineering services: www.mts-contech.de
Analyser for Robust Design: www.contech-analyser.de
Postal address:
Wernher-von-Braun-Straße 8
D-82256 Fürstenfeldbruck
Office:
Oskar-von-Miller-Straße 4d
D-82256 Fürstenfeldbruck
Telephone +49.8141.888 403-0
Fax +49.3222.376 25 38
E-mail info@mts-contech.com
www.mts-contech.de
www.contech-analyser.de

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