Process optimization via robust parameter design when categorical noise factors are present

When categorical noise variables are present in the Robust Parameter Design (RPD) context, it is possible to reduce process variance by not only manipulating the levels of the control factors but also by adjusting the proportions associated with the levels of the categorical noise factor(s). When no adjustment factors exist or when the adjustment factors are unable to bring the process mean close to target, a popular approach for determining optimal operating conditions is to find the levels of the control factors that minimize the estimated mean squared error of the response. Although this approach is effective, engineers may have a difficult time translating mean squared error into quality. We propose the use of a parts per million defective objective function. Furthermore, we point out that in many situations the levels of the control factors are not equally desirable due to cost and/or time issues. We have termed these types factors non-uniform control factors. We propose the use of desirability functions to determine optimal operating conditions when non-uniform control factors are present and illustrate this methodology with an example front industry. Copyright (C) 2006 John Wiley & Sons, Ltd.