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| Problem Definition & Objective Setting (STEP) | | |
| Describe the Manufacturing Problem (TEXT) | | |
| What are the initial observations and symptoms of the problem? (TEXT) | | |
| What is the current process capability (e.g., Cp, Cpk)? (NUMBER) | | |
| What is the primary objective of the DOE? (Choose One) (SELECTION options: Reduce Variation, Improve Mean, Reduce Cost, Improve Quality, Other (Specify)) | | |
| Define specific, measurable, achievable, relevant, and time-bound (SMART) objectives for the DOE. (TEXT) | | |
| Target improvement percentage (e.g., reduce defect rate by 10%) (NUMBER) | | |
| What are the key constraints limiting the improvement? (SELECTION options: Cost, Time, Equipment, Material, Other (Specify)) | | |
| Describe the current process control measures (if any). (TEXT) | | |
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| Factor & Response Selection (STEP) | | |
| Describe the manufacturing process being studied. (TEXT) | | |
| What is the desired output metric (e.g., throughput, yield, defect rate)? (NUMBER) | | |
| Select the units of measurement for the response variable (e.g., pieces/hour, %, parts per million). (SELECTION options: Pieces/Hour, Percentage (%), Parts Per Million (PPM), Millimeters (mm), Seconds, Other (Specify in LONG_TEXT)) | | |
| List potential factors that could influence the response. (TEXT) | | |
| For each potential factor, briefly describe how it impacts the response (positive or negative). (TEXT) | | |
| Estimate the current average value of the response variable. (NUMBER) | | |
| Which factors are considered the most critical to investigate (based on prior knowledge or experience)? (SELECTION) | | |
| Describe any constraints on the factor ranges (e.g., equipment limitations, safety regulations). (TEXT) | | |
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| Experimental Design Selection (STEP) | | |
| Primary Design Type (SELECTION options: Full Factorial, Fractional Factorial, Response Surface Methodology (RSM), Mixture Design, Taguchi Design) | | |
| Number of Factors to be Studied (NUMBER) | | |
| Number of Levels per Factor (NUMBER) | | |
| Central Composite Design (If using RSM) (SELECTION options: Face-Centered, Circle, Incomplete Block) | | |
| Justification for Chosen Design (TEXT) | | |
| Randomization Method (SELECTION options: Latin Square, Random Order, Cyclical) | | |
| Number of Replicates (NUMBER) | | |
| Considerations for Interactions (if applicable) (TEXT) | | |
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| Experimental Setup & Validation (STEP) | | |
| Equipment Calibration Date (NUMBER) | | |
| Standard Operating Procedure (SOP) Verified? (SELECTION options: Yes, No) | | |
| Describe Equipment Setup and Configuration (TEXT) | | |
| Measurement System Analysis (MSA) Score (e.g., % agreement) (NUMBER) | | |
| Environmental Conditions Controlled? (SELECTION options: Yes, No) | | |
| Document any deviations from planned setup (TEXT) | | |
| Attach Photos/Videos of Setup (Optional) (UPLOAD) | | |
| Date of Setup Verification (DATE) | | |
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| Data Collection & Analysis (STEP) | | |
| Number of Replicates per Run (NUMBER) | | |
| Measurement Resolution (e.g., decimal places) (NUMBER) | | |
| Calibration and Measurement System Analysis (MSA) Documentation Review (TEXT) | | |
| Statistical Software Used (e.g., Minitab, R, JMP) (SELECTION options: Minitab, R, JMP, Other) | | |
| Sample Size for Each Factor Level (NUMBER) | | |
| Description of Data Validation Procedures (TEXT) | | |
| Analysis Method Used (e.g., ANOVA, Regression) (SELECTION options: ANOVA, Regression, Other) | | |
| Raw Data File (CSV, Excel) (UPLOAD) | | |
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| Results Interpretation & Conclusion (STEP) | | |
| Summarize the key findings of the DOE. (TEXT) | | |
| What is the R-squared value for the model? (Indicates model fit) (NUMBER) | | |
| Which factors were found to be statistically significant (p < 0.05)? (SELECTION options: Factor A, Factor B, Factor C, No significant factors found) | | |
| Describe the interaction effects observed (if any). (TEXT) | | |
| What is the predicted optimal setting for the factors? (NUMBER) | | |
| Does the model adequately explain the variability in the response? (Based on R-squared & Residual Analysis) (SELECTION options: Yes, the model is a good fit., The model needs improvement., The model is not appropriate.) | | |
| What conclusions can be drawn from the DOE results regarding the original manufacturing problem? (TEXT) | | |
| Which of the following recommendations are made based on the DOE? (SELECTION options: Adjust factor settings, Modify process parameters, Investigate further, No action required) | | |
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| Implementation & Verification (STEP) | | |
| Describe the proposed changes to the manufacturing process based on DOE findings. (TEXT) | | |
| Target improvement percentage for the response variable (e.g., yield, defect rate). (NUMBER) | | |
| Planned start date for implementing the changes. (DATE) | | |
| Planned completion date for implementation. (DATE) | | |
| Number of production runs to monitor after implementation. (NUMBER) | | |
| Method for initial verification (e.g., pilot run, gradual rollout). (SELECTION options: Pilot Run, Gradual Rollout, Full Production Implementation) | | |
| Describe the verification plan, including data collection methods and acceptance criteria. (TEXT) | | |
| Which key performance indicators (KPIs) will be monitored during verification? (SELECTION options: Yield, Defect Rate, Cycle Time, Material Waste, Cost per Unit) | | |
| Verification Result: Pass/Fail (SELECTION options: Pass, Fail, Needs Further Investigation) | | |
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| Documentation & Reporting (STEP) | | |
| Project Objective Summary (TEXT) | | |
| Detailed Experimental Procedure (TEXT) | | |
| Raw Data Files (CSV, Excel) (UPLOAD) | | |
| Statistical Analysis Output (e.g., Minitab, JMP) (UPLOAD) | | |
| Number of Replicates Run (NUMBER) | | |
| List of Assumptions Made During Analysis (TEXT) | | |
| Potential Limitations of the Study (TEXT) | | |
| Report Distribution List (SELECTION options: Engineering Team, Quality Control, Management, Other) | | |
| Report Completion Date (DATE) | | |
| Engineer Signature (SIGNATURE) | | |