Laboratory Experiments In Process Design And Optimization

This paper describes an approach used to teach various aspects of manufacturing process design, optimization and improvement via hands-on experiences in laboratory experimentation. The experiments were conducted using a very low cost apparatus for launching projectiles. They utilized several basic physical principles such as elasticity, gravity, sliding friction, and fluid friction. Various geometric characteristics of the apparatus and the process were used as variables. Optimization of the process for a set of goals and proof runs finished the experiments. Individual and team approaches were used for goal setting, brainstorming of expected results, possible sources of process errors and measurement errors, control of the process, preliminary test runs and what-if scenarios. These activities were included at the beginning of the experiments to teach the importance of organizational aspects of engineering experimentation and initial problem analysis. Observations from classroom are compared to observations from an industrial setting where this experiment was used as a tool to teach concepts of Design of Experiments. The observations from both environments include some aspects of group dynamics as well as evaluation of accomplishment of objectives and setting of goals for possible further improvements. Some of the biggest advantages of this experiment are very low cost, portability, ease of reproducing in various environments and flexibility in devising objectives appropriate to analytical skill level of the students.