{ "disclosure": "SYNTHETIC DEMONSTRATION — fictional study; no real employer/customer engagement, implementation or approval", "basis": { "version": "improvement-1.0", "record": "SYN-DOE-M01 Rev A", "factoryId": "SYN-OPS-01", "component": "SYN-VS25", "machine": "SYN-MC-01", "station": "SYN-ST-M01", "seed": 41973, "replications": 4, "runs": 32, "targetMm": 25, "lslMm": 24.9, "uslMm": 25.1, "t975df24": 2.063898562, "baselineSetting": "S1", "controls": [ "Same fictional material grade, blank geometry, fixture, tool type and calibrated measurement method.", "One independent blank and a reset/stabilized setup per run; four replications of all eight settings.", "Completely randomized run order; no tool-wear trend, carryover, blocks or nuisance drift in this generator.", "Cycle response is cut-only elapsed seconds; energy is machine-plus-coolant Wh during that cut." ], "sources": [ { "title": "NIST: Two-level full factorial designs", "url": "https://www.itl.nist.gov/div898/handbook/pri/section3/pri3331.htm" }, { "title": "NIST: Effect uncertainty from replication", "url": "https://www.itl.nist.gov/div898/handbook/pri/section5/pri5971.htm" }, { "title": "NIST: Randomized run sequences", "url": "https://www.itl.nist.gov/div898/handbook/pri/section3/pri331.htm" } ], "limitations": [ "Synthetic equations encode the mechanism. Experimental effects describe this generator, not validated real machining physics.", "Only eight tested corners are compared; no interpolation, global optimum, production capability or machine recommendation.", "Pointwise 95% intervals assume independent normal errors and equal variance within each response. They are not simultaneous selection guarantees.", "No real implementation, confirmation trials, cost savings, customer results or approval evidence exists.", "Cut seconds cannot replace the factory's six-minute machining-and-inspection work assumption or establish capacity." ] }, "settings": [ { "id": "S1", "a": -1, "b": -1, "c": -1, "feedMmRev": 0.12, "speedMMin": 120, "coolantLMin": 6 }, { "id": "S2", "a": 1, "b": -1, "c": -1, "feedMmRev": 0.2, "speedMMin": 120, "coolantLMin": 6 }, { "id": "S3", "a": -1, "b": 1, "c": -1, "feedMmRev": 0.12, "speedMMin": 180, "coolantLMin": 6 }, { "id": "S4", "a": 1, "b": 1, "c": -1, "feedMmRev": 0.2, "speedMMin": 180, "coolantLMin": 6 }, { "id": "S5", "a": -1, "b": -1, "c": 1, "feedMmRev": 0.12, "speedMMin": 120, "coolantLMin": 10 }, { "id": "S6", "a": 1, "b": -1, "c": 1, "feedMmRev": 0.2, "speedMMin": 120, "coolantLMin": 10 }, { "id": "S7", "a": -1, "b": 1, "c": 1, "feedMmRev": 0.12, "speedMMin": 180, "coolantLMin": 10 }, { "id": "S8", "a": 1, "b": 1, "c": 1, "feedMmRev": 0.2, "speedMMin": 180, "coolantLMin": 10 } ], "lossWindow": { "id": "SYN-CI-OBS-01", "skids": 8, "description": "Fixed eight-skid teaching window; independent of editable weekly demand." }, "losses": [ { "id": "travel", "title": "Loaded travel", "minutes": 3.5, "basis": "Modeled walking time", "evidence": "CI-E01", "events": [ "210 loaded metres from the baseline layout at eight skids; 30 trips.", "Assumed 1 m/s loaded walking speed: 210 / 60 = 3.50 person-minutes. Empty return, pickup and congestion excluded." ], "question": "Can a feasible layout reduce loaded travel?", "next": "Compare equal-demand layouts in the material-flow workspace. Route distance is a modeled exposure, not a timed observation.", "href": "/engineering-lab/layout" }, { "id": "setup", "title": "Setup / changeover", "minutes": 62, "basis": "Synthetic event log", "evidence": "CI-E02", "events": [ "SYN-SET-01: 34 attended person-minutes; tool/fixture preparation.", "SYN-SET-02: 28 attended person-minutes; setup verification. Two changeovers in the fixed window." ], "question": "Which preparation can occur before the machine stops?", "next": "Observe and separate internal/external tasks, trial staged tooling, then verify first-off quality. The machining experiment does not estimate setup savings.", "href": null }, { "id": "waiting", "title": "Attended waiting", "minutes": 48, "basis": "Synthetic event log", "evidence": "CI-E03", "events": [ "SYN-WAIT-01–04: 12, 9, 16 and 11 person-minutes, each for one idle operator.", "Fictional fixture, kit and review readiness delays; exclusive logged segments. These are not the NCR chronology or elapsed lead time." ], "question": "Does a readiness check remove avoidable waiting?", "next": "Trace missing readiness information, test a pre-start checklist and measure idle time. Existing material holds still require independent NCR disposition.", "href": "/engineering-lab/ncr" }, { "id": "rework", "title": "Rework", "minutes": 45, "basis": "Synthetic event log", "evidence": "CI-E04", "events": [ "SYN-RWK-01–03: 18, 12 and 15 attended person-minutes for three fictional repair events.", "Inspection notes raise dimensional consistency as a hypothesis. No causal attribution, scrap count or link to existing SPC lots is established." ], "question": "Can process settings improve dimensional margin without excessive cycle time or energy?", "next": "Use the randomized machining experiment to test the setting mechanism. Confirm on new parts before claiming any reduction in historical rework.", "href": null } ], "verificationPlan": [ { "id": "measurement", "title": "Measurement and setup", "criterion": "Verify gauge resolution/bias, fixture, tool condition, material and stabilized coolant. Record actual setup and calibration evidence." }, { "id": "confirmation", "title": "Independent confirmation", "criterion": "Run 12 new blanks at the proposed setting, across three fresh setups. Check every diameter against 24.90–25.10 mm; compare mean error, cut time and cut energy against the saved study limits. Investigate any failure; no automatic approval." }, { "id": "monitoring", "title": "Sustain and control", "criterion": "Collect at least 100 subsequent individual measurements across representative tool life and shifts. Assess stability before estimating capability or revising control limits; define a hold/investigate response to signals." }, { "id": "work", "title": "Standard work and review", "criterion": "Propose SYN-SW-M01 Rev B and SYN-CP-M01 Rev B with settings, setup checks, first-off inspection, reaction plan and traceable change approval. Keep current work and quality holds until reviewed." } ], "defaultStudyLimits": { "guardUm": 40, "cycleSec": 80, "energyWh": 36 }, "analyses": [ { "response": "errorUm", "n": 32, "df": 24, "mse": 35.657172185080505, "sse": 855.7721324419321, "grandMean": 10.848773945831752, "effects": [ { "term": "A", "effect": 42.44994180902714, "low": 38.092648411458825, "high": 46.80723520659545 }, { "term": "B", "effect": 29.0095128901205, "low": 24.65221949255219, "high": 33.36680628768881 }, { "term": "C", "effect": -31.61831027639393, "low": -35.97560367396224, "high": -27.26101687882562 }, { "term": "AB", "effect": 27.520500883152376, "low": 23.163207485584067, "high": 31.877794280720686 }, { "term": "AC", "effect": -30.935868674311845, "low": -35.293162071880154, "high": -26.578575276743535 }, { "term": "BC", "effect": -18.946141304091203, "low": -23.303434701659512, "high": -14.588847906522894 }, { "term": "ABC", "effect": 6.326276424455921, "low": 1.9689830268876118, "high": 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