The symposium concerns the topic of robust design from a practical and industry orientated perspective. During the 2 day symposium we will share our understanding of the need of industry with respect to the control of variance, reliability issues and approaches to robust design. The target audience for the symposium therefore will aim to attract equal numbers of industry and academic delegates with two separate paper submission tracks.
For more information please contact:
Chair: Thomas J. Howard
Co-chair: Tobias Eifler
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8:00 |
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8:30 |
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8:45 |
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9:00 |
Welcome introductionThomas J. Howard
Head of Robust Design Group, DTU
The International Symposium on Robust Design is a dedicated meeting where academics and industry delegates meet to discuss the challenges and advances in robust design and related topics.
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9:10 |
Robust design, Predictable innovationNiels Hansen, Chief Engineer, Novo Nordisk Device R&D
Novo Nordisk is a Danish owned pharmaceutical company having more than 40.000 employees. Novo Nordisk is perhaps best known as the provider of medicines, especially insulin to diabetics but also medicines to treat growth hormone deficiency and haemophilia.
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9:20 |
Denmark: Excellence in Mechanical DesignJanus Juul Rasmussen, CEO Valcon Design
It is a great pleasure to see the creation of a symposium dedicated to the subject of Robust Design. Robust Design is an extremely important and valuable paradigm for production companies. In a globalised market, companies must compete on price, quality and being first on the market with new products. As a consequence, most companies have well-described product development and quality assurance processes to ensure that the products are developed fast have a desired quality level prior to launch.
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9:30 |
Keynote 1 Robust Design Impact in IndustryMartin Ebro, DTU/Valcon Design
Product development from idea to market. Hands-on experience as a design engineer on a wide variety of products including consumer electronics, wind turbines, medical devices and automotive products.
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10:00 |
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10:30 |
Industry Case 1 Prediction of Glass Cartridge Robustness in Assembly line LoadingTorben Hansen, Novo Nordisk
Each year Novo Nordisk produces multimillion injection devices incorporating drug contained glass cartridges. These cartridges will inevitably be subjected to various loadings in both line feeding systems and in the device assembly rigs. It is obviously crucial to preserve the structural cartridge integrity and avoid any form of cracking and fragmentation of the glass for the full life time of the devices. The robustness is quantified by a safety factor against cracking. As shown in figure 1, it implies that both assembly line loadings and the strength of the sub-supplied cartridges are determined along the location of max stress in relation to the rotatory position of the weakest region. These figures can be used to specify the loading for the incoming inspection and prevent future device designs from overloading the cartridges. The cartridge glass is brittle with a low cracking energy and sensitive to impact loading. The glass strength is determined by microscopic manufacturing related imperfections (which have no influence on the performance and integrity of the final device) and is both loading mode and rate dependant. Thus a conventional material property such as the ultimate stress cannot be used to calculate a safety factor. Matters are further complicated by loadings being tolerance dependant and by the fact that each cartridge has a randomised position of the weakest region relative to the maximum loading. This calls for a statistical based calculation of the safety factor. Figure 2 shows an example on a safety margin without distribution overlap. In some cases a limited distribution overlap might be acceptable. |
11:00 |
Scaling Under Dynamic Uncertainty Using Laws of GrowthJulian Lotz, TU Darmstadt
In size range development the designer has to face uncertainty that changes with the scaled parameters of the product. These parameters can be geometric properties, power, loads or cost. Uncertainty occurs in all stages of the product lifecycle. This paper addresses uncertainty that occurs during the usage of the product. Uncertainty in usage processes is often induced by wear, load (fatigue), aging or corrosion. These effects often refer to the product's size. |
11:20 |
A Comparative Study on Tolerance Analysis ApproachesBenjamin Schleich, FAU
Robust product designs are characterized by their insensitivity to disturbances and noise, such as geometric part deviations, which are inevitably observed on every manufactured workpiece. These observed deviations are covered by the axioms of manufacturing imprecision and measurement uncertainty, which convey the concepts of variability and uncertainty as fundamental aspects of robust design. In order to ensure the product function though the presence of these geometric part deviations without building physical artefacts, tolerance simulations are employed in the context of computer-aided tolerancing. Motivated by the shortcomings of existing tools, the concept of Skin Model Shapes has been developed as a novel paradigm for the computer-aided tolerance analysis. This paper presents a comparative study on the standard procedure for the tolerance analysis employing proprietary CAT tools and the tolerance simulation based on Skin Model Shapes, where a focus is set on the methodology and result interpretation. For this purpose, exemplary study cases are highlighted. Based on the comparisons, recommendations for the use of CAT tools in the context of tolerance analysis and robust design are derived. |
11:40 |
Design Guidance for Robust DesignValter Loll, Loll Consult
The short product development cycle and the increased demand of robust, safe and reliable design has made the Test Analysis And Fix (TAAF) method obsolete. Closing the feedback loop on a design from field return (FRACAS) takes years. Closing the feedback loop from testing take months. Therefore a modern design has to build in robustness, safety and reliability during the design process. The paper describes how the Load-Strength theory and other methods can be used to develop design guidance for a robust design. The influence of safety margin and loading roughness is described together with repeated loads. Real examples of design guidance for robustness are shown. |
12:00 |
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13:00 |
Robust Design Workshop: A forensic engineering case
During this workshop the delegates will be placed into teams. They will be given a product and a case file with clues to the product's failure and the major incident that incurred.
Included in the case files will be engineering drawings, specifications, reliability test results, CAD drawings and various other useful bits of information. Working in your groups you will discuss and analyse the design and work out what the problems were, how to solve the problem both in terms of a quick fix and in terms of long term design improvement. Teams will be encouraged to bring their own robust design methods to the table and to discuss their applicability both now and when the design was being developed.
The session will finish with a round of presentations of key findings and improvements followed by pre-prepared expert analysis of the cases and what exactly went wrong. ![]() |
15:00 |
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17:00 |
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20:00 |
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8:00 |
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8:30 |
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8:45 |
Rapid results with robust designTorben Bygvraa Rasmussen, NNE Pharmaplan
Robust design that is insensitive to component variation is of course vital for minimizing product quality issues and ensuring low cost. However obtaining robust design requires the capability to evaluate the design robustness and eventually optimize it – and many producers find it difficult to ”get started” – especially in a way, where results can be demonstrated fast. It is our experience, that a good way to get started is to involve the right people from Marketing, R&D, production and QA/QC, and train dedicated people in the use of ”easy to access” software such as Vartran for finding optimal targets (minimizing the effect of component variation on product functionality), and excel for tolerance analysis. This allows for a fast start where the tolerance analysis may be adapted to the special needs of the producer to ensure the most reliable results. |
09:00 |
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CETOL 6σ tolerance analysis
CETOL 6σ tolerance analysis software provides product development teams with the insight required to confidently release designs to manufacturing. Precise calculation of surface sensitivities exposes the critical-to-quality dimensions in the assembly. Utilizing advanced mathematical solutions, this tolerance analysis solution accelerates optimization to achieve robust designs ready for manufacturing.
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Sigmetrix GD&T Software
A necessary function of the design process, Geometric Dimensioning and Tolerancing (GD&T) is often perceived as a tedious, manual exercise where specifications are drawn by hand and applied to CAD drawings as a separate step.
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OPTIMUS® - Advanced Design Exploration
Input variability is the source of unexpected and often unintended product behavior. Even at world-class manufacturers, it may occur that a design successfully passes deterministic simulation, while some of manufactured items fail production quality control. To avoid this problem in the design stage, the robust design optimization software Optimus takes into account the variability of the design variables, and subsequently applies robustness and reliability concepts and methods to ensure a robust and reliable design. |
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JMP - Statistical Discovery from SAS
Achieving high quality and reliability requires a passion for, and dedication to, continuous learning and improvement. Systematically using data to determine more efficient and effective ways to get things done delivers better products, services and levels of organizational performance, for small or large companies alike.
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10:15 |
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10:30 |
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Methodology to identify an ideal point of time for performing a FMEA during the product development processJan Würtenberger, TU Darmstadt
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Sensitivity Analysis of Tolerances which Restrict Multiple Similar Geometry ElementsPhilipp Ziegler, FAU
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11:30 |
Industry Case 2 Validation of Customer Requirements by System Simulation Taking Tolerances and System Variations into AccountMatthias Ehlert, BMW
The aim of the following contribution is to introduce an integrated process which allows the implementation of factors that have a significant impact on the limiting positions. These limiting positions and their effects on geometric deviations and displacements need to be investigated in order to ensure that functional aspects of an assembly are fulfilled for large quantities. |
12:00 |
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13:00 |
Keynote 2 LEGO's production challenge: maintaining process capability and product quality while increasing production volume and bringing new products to the market.Rikke Andersen, Six Sigma Engineer / LEGO System A/S
LEGO is one of the leading brands of the toy industry. One of core values is the play promise: a positive playing experience for every child each time it plays with LEGO. |
13:30 |
Robust Design Principles to Evaluate Additive Manufacturing CapabilitiesIñigo Flores, Aalto University
Additive manufacturing (AM) is generating a paradigm shift by expanding the manufacturing capabilities. However, quality of AM produced parts is dependent on a number of machine, geometry and process parameters.
The impact of inputs, such as the machine technology, the part orientation, the part location and the quality of the digital data, affects the AM outcomes drastically. A user of such type of equipment faces the problem of selecting optimal sets of input variables and therefore, it is necessary to support this selection process that is based typically in tacit knowledge of the machine operator or service suppliers. |
13:50 |
Robust Design of active Systems - an approach to consider disturbances within the selection of sensorsTillmann Freund, TU Darmstadt
Uncertainty occurs in every phase of the product lifecycle, while the properties of the product and thus its corresponding behavior regarding influence parameters are mostly determined during the development phase. One goal of product development is therefore the atic support of the development of robust products. To achieve this goal, uncertainty must be methodically identified, analyzed and finally controlled by purposeful operations. One way to control emerging uncertainty is the application of active systems, for example the application of a feed-forward controller within a machine to compensate for reduced stiffness compared to a regular machine. On the other side, the use of active-control-systems generally increases a system's complexity and creates additional uncertainty.
In order to handle these conflicting factors a methodical approach is presented within this paper that contains apropriate models, criteria and procedures to asses the inherent uncertainty of active/adaptive systems.
The information obtained can then be used to develop robust active-/adaptive-systems. |
14:10 |
Robust Design Process for the Dimensional and Geometrical Features on Cold Formed ComponentsJulian D. Booker, Bristol
Plain spherical bearings are precision assemblies with a low frictional moment finding wide application in industry where they operate in harsh environments. They are manufactured using a cold forming process known as 'nosing'. An experiential approach is currently used by a manufacturer to develop new bearing products and determine associated process settings for the nosing process. Typically, inefficiencies can be observed for the bearing assembly post-nosing where any one of nine different failure modes may occur leading to rework or scrap costs due to a number of component and process inconsistencies. The initial focus is the outer bearing shell component and the geometrical relationships of the end chamfer features. Process capability measures are developed for a bearing model, with parts individually tracked through the nosing process to examine the influence out-of- tolerance variation on process integrity, measured forming loads and frictional moment. A validated Finite Element (FE) model is used to predict the complex elastic-plastic material behaviour at high strain-rates in the nosing process to support the simulation of in-process failure modes. These models take into account the geometrical and dimensional variations of the chamfers, material property variation and coefficient of friction. Predictions are made for feature process capabilities which produce lower failure rates in production. The robust design process outlined concludes with improved component and process design, and to aid the development of future bearing products using nosing. |
14:30 |
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15:00 |
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16:00 |
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20:00 |
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Chair: Thomas J. HowardAssociate ProfessorDTU MECHANICAL ENGINEERING
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Co. Chair: Tobias EiflerPostdocDTU MECHANICAL ENGINEERING
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Martin EbroReliability Specialist
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Simon Moritz GöhlerPhD StudentDTU MECHANICAL ENGINEERING
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Søren Nygaard PedersenPhD StudentDTU MECHANICAL ENGINEERING
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Aryan ChristiansenResearch AssistantDTU MECHANICAL ENGINEERING
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Andreas RafnResearch AssistantDTU MECHANICAL ENGINEERING
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