Case studies

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Reduce variation in battery performance. Customers and Consumer Reports indicated that the lifetimes of batteries varied noticeably, so the manufacturer wanted to produce batteries with consistent lifetimes.

METHODS:

Proper Statistical Process Control, Regression Models, Reliability Analysis

COST:

$15,000

ESTIMATED SAVINGS:

$700,000 annually

OUTCOME:

50% reduction in variation within 2 Months.


 

Identify the causes of porosity in castings—and remove porosity from critical areas.

METHODS:

Designed Experiment with Predictive Models

COST:

$5,000 and 2 Days of total work

ESTIMATED SAVINGS:

$2,400,000 annually

OUTCOME:

No more problems resulting from porosity – successfully removed from critical areas


 

Identify the causes of shrinkage in injected molded components, achieve target shrinkage, and minimize variation in shrinkage.

METHODS:

Designed Experiment with Predictive Models, Regression Models, Statistical Process Control, Statistical Comparisons, Multi-Response Optimization

COST:

$15,000 and project completed in less than 2 Weeks

ESTIMATED SAVINGS:

$300,000 annually

OUTCOME:

Identified interactions causing variation in shrinkage, achieved target shrinkage, and reduced variation in shrinkage by 80%.


 

Identify the causes of variation in Torque in powertrain components.

METHODS:

Designed Experiment with Predictive Models, Multi-Response Optimization, Statistical Process Control

COST:

$12,000 and project completed within 1 Week

ESTIMATED SAVINGS:

$1,200,000 annually

OUTCOME:

Identified interactions causing variation in torque. Needed to modify specification limits in 2 components in order to resolve issue. Completely eliminated the re-work they had been doing as a result of the variation.


 

Assess and improve automotive engine reliability.

METHODS:

Reliability test planning, reliability analysis and modeling, Designed Experimentation with Predictive Models, Multi-Response Optimization

COST:

$18,000

ESTIMATED SAVINGS:

$3,000,000 annually

OUTCOME:

Identified the minimal amount of testing required to achieve appropriate precision in life and reliability estimates. Estimated the times at which various percentages of the engines would fail (for a specific failure mode). Identified factors and interactions which could be modified to improve engine life.


 

Identify the causes of crankshaft breaks in Prop Planes and testify before a judge and jury as to the causes of the failures.

METHODS:

Reliability Analysis and Models, Regression Methods, Analysis of Variance

COST:

$35,000

ESTIMATED SAVINGS:

Our client was awarded $96,000,000

OUTCOME:

Our client had been wrongly accused of causing crankshaft failures in prop planes. The situation was rectified, and our client was awarded $96,000,000.


 

Identify the causes of variation in roundness of Powdered Metal components. The manufacturer had an 80% scrap rate because it was a new component, and the parts were typically too “out-of-round.”

METHODS:

Designed Experiments with Predictive Models

COST:

$15,000 and project completed in 6 Days.

ESTIMATED SAVINGS:

$1,000,000 annually

OUTCOME:

The first experiment reduced the scrap rate from 80% to 2%. A follow-up DOE eliminated the scrap altogether.


 

Identify the causes of variation in weight of Powdered Metal components. Weight variation was the highest source of waste in the plant.

METHODS:

Designed Experiments with Predictive Models

COST:

$7,500 and project completed within 1 Week.

ESTIMATED SAVINGS:

$500,000 annually

OUTCOME:

The experiment identified the effects and interactions causing the weight variation.


 

Development of new devices, drugs, and formulations can take a very long time. Reducing the development time while minimizing risk is a common objective of our clients.

METHODS:

Designed Experiments with Predictive Models, Reliability Analysis, Hypothesis Testing, Regression, Mixture Experiments with Models, Multi-Response Optimization

COST:

$15,000 is usual.

ESTIMATED SAVINGS:

At least 50% of the development time plus prevention of future liability costs.

OUTCOME:

Traditional methods for product and drug development are slow and don’t always ensure success when transferred to manufacturing. We typically cut development time in half (or better) while accurately assessing and minimizing product liability risk. In addition to product development, we successfully help our clients “scale-up” their formulations and products to high-volume manufacturing as well.


 

Clearly communicate information to jurors and judges in product liability cases and other cases involving product risk (Expert Testimony). Produce high-quality statistical analyses and models that cannot be undermined by opposing experts.

METHODS:

Data Analysis/Statistical Methods, Graphical Methods

COST:

$295/hour + expenses

ESTIMATED SAVINGS:

Varies greatly from one lawsuit to another.

OUTCOME:

Satisfied clients.


 

Compare medical device designs to minimize the risk of complications in human tissue.

METHODS:

Binary and Ordinal Logistic Regression, Analysis of Variance, General Linear Modeling, Chi-Squared Tests

COST:

$15,000

ESTIMATED SAVINGS:

Potential product liability costs.

OUTCOME:

Intelligent design selections of medical device manufacturers.


 

Educate Product Development, Manufacturing, R&D, Quality, and Business personnel in the proper use of statistical methods while generating excitement and enthusiasm for the application of the methods.

METHODS:

  • Passionate instruction from highly educated and experienced consultants
  • Applications to client products and processes
  • Superior communication skills
  • Excellent course materials that are useful for ongoing reference
  • Ongoing email & phone support at no charge

COST:

$200-$400 per person per day (depending on class format and sizes)

ESTIMATED SAVINGS:

Potential product liability costs.

OUTCOME:

Highly motivated employees who are:

  • Anxious to apply knowledge
  • Capable of solving complex problems and preventing problems
  • Able to reduce variation
  • Able to improve reliability