A solution framework for response surface-based multiple quality characteristics optimization

Abstract

A common problem generally encountered during manufacturing process improvement involves simultaneous optimization of multiple ‘quality characteristics’ or so-called ‘responses’ and determining the best process operating conditions. Such a problem is also referred to as ‘multiple response optimization (MRO) problem’. The presence of interaction between the responses calls for trade-off solution. The term ‘trade-off’ is an explicit compromised solution considering the bias and variability of the responses around the specified targets. The global exact solution in such types of nonlinear optimization problems is usually unknown, and various trade-off solution approaches (based on process response surface (RS) models or without using process RS models) had been proposed by researchers over the years. Considering the prevalent and preferred solution approaches, the scope of this paper is limited to RS-based solution approaches and similar closely related solution framework for MRO problems. This paper contributes by providing a detailed step-by-step RS-based MRO solution framework. The applicability and steps of the solution framework are also illustrated using a real life in-house pin-on-disc design of experiment study. A critical review on solution approaches with details on inherent characteristic features, assumptions, limitations, application potential in manufacturing and selection norms (indicative of the application potential) of suggested techniques/methods to be adopted for implementation of framework is also provided. To instigate research in this field, scopes for future work are also highlighted at the end.