Algoryx Correlation Master Training Program

Day 1 - Class Day

The first objective of Day 1 is for trainees to fully understand the foundational algorithms underlying the Algoryx technology. This is accomplished through a hands-on case study, trainer presentation and class discussion.

The second objective of Day 1 is for trainees to learn the pre-analysis procedures that are followed to select press parameters, to define the processing window, to create induced variation parts, to use the most appropriate measurement techniques and to learn how to create the Excel data input workbook. This is accomplished through class discussion and review of multiple procedural handouts.

Main agenda items include training on:

  1. A hands-on case study to illustrate fundamental correlation relationships;
  2. Analysis algorithms including:
    1. Inducing variation versus press settings lockdown;
    2. Selecting the Predictor Dimension (PD);
    3. Creating correlation charts, regression lines and boundary conditions;
    4. Identifying defect conditions;
    5. Understanding optimum PD position and range;
    6. Understanding optimum tooling changes;
    7. Understanding optimum tolerance relaxations;
    8. Transferring excess process capability from one molded part to another;
    9. Three methods for optimizing press settings;
  3. Simulation algorithms;
  4. Cycle time reduction and cosmetic improvement algorithms;
  5. New Product Development (NPD) procedures using the Correlation Master™ software;
  6. Structuring the DOE ; and,
  7. Generating the data input workbook.
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Day 2 - Laboratory Day

The objective of Day 2 laboratory training is for trainees to be knowledgeable and comfortable:

  1. Running the Correlation Master software in the analysis mode;
  2. Interpreting the graphical and tabular output of the software including the:
    1. Rankings Table for PD selection;
    2. Constraint Table for optimum positioning of the PD;
    3. Offset Table for optimum tooling adjustments;
    4. Tolerance Relaxation Tables for optimum tolerance relaxations; and,
    5. Correlation Charts for conformance and non-conformance;
  3. Evaluating the "as is" Operating Capability (Opk) against requirements;
  4. Determining the design, tooling, process and measurement system changes necessary to meet Opk/Cpk requirements; and,
  5. Running the Correlation Master software in the simulation mode to confirm that the recommended design, tooling, process and measurement system changes will result in parts that meet Opk/Cpk requirements.

This is accomplished by trainees running the Correlation Master™ software using actual production and design engineering data. The class is divided into three teams. Each team does a case study. The three case studies are based on a simple mold with few cavities, a medium complexity mold with a medium number of cavities and a complex mold with high cavitation. Each team then presents its study results to the class for detailed discussion and critique.

A detailed Day 2 case study procedure is attached.

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Day 3: Part 1 - Cost Reduction and Schedule Acceleration

First Day 3 Objective

The first objective of Day 3 is for three teams to determine the cost reduction and schedule acceleration resulting from using the Algoryx technology on three different parts.

The first Day 3 objective is accomplished by trainees modifying a financial spreadsheet template to the actual Qualification, Certification and Validation procedures of your company. This is done by each of the three teams. The teams evaluate a simple, a typical and a complex part and estimate:

  1. The cost savings resulting from a 5% average reduction in press cycle time.
  2. The number of tooling changes they eliminate and the cost savings;
  3. The number of design tolerance relaxations they eliminate and the cost savings (and the indirect benefit of preserving design integrity);
  4. The number of press tuning cycles they eliminate and the cost savings;
  5. The reduced number of cost of gauges for Qualification and Certification;
  6. The reduced number and cost of in-process gauges for production;
  7. The reduced amount of inspection for Qualification, Certification, Validation and the cost savings;
  8. The reduced amount of SPC and Cpk analysis for Qualification, Certification, Validation and the cost savings;
  9. The cost reduction from having fewer NPD team meetings (for both external and internal suppliers) and reduced travel costs;
  10. The advantage of using the correlation approach when dealing with offshore tooling suppliers;
  11. The number of months quicker to get to market;
  12. The direct value of getting to market quicker–more sales, more profits; and,
  13. The indirect value of getting to market quicker–improved competitive position.

The financial estimates are incorporated into a financial spreadsheet template following your current Quality Assurance (QAP) procedures. We will need three copies of your current Qualification/Certification/Validation procedures.

Each team incorporates their estimate of schedule acceleration into a schedule spreadsheet template.

Each team also creates one or more slides that list the hard-to-quantize intangible benefits from using the Algoryx technology.

Each team summarizes its cost savings, schedule acceleration and quality improvements results into a short (20 minute) presentation.

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Day 3: Part 2 - Implementation Criteria

Second Day 3 Objective

The second objective of Day 3 is to determine the criteria for when using the Algoryx technology should be mandatory for both new and refurbished tools.

The second Day 3 objective is accomplished by having trainees select from the following list of candidate criteria or establish their own criteria:

  1. The number of critical/box dimensions times the number of cavities is ≤ 10 and the annual production volume is ≤ 10,000; or,
  2. The annual production volume is greater than 50,000 parts; or,
  3. The NPD team has had a difficult time qualifying/validating a similar tool in the past; or,
  4. The process engineer anticipates a narrow process window: or,
  5. Measurement is difficult, time-consuming or expensive; or,
  6. Destructive measurement is required; or,
  7. Functional testing is required; or,
  8. In-process gauges cost ≤ $TBD; or,
  9. The tool costs ≤ $TBD; or,
  10. Tooling changes cost ≤ $TBD; or,
  11. More than one production tool will be made; or,
  12. A pre-production tool will be scaled up to a production tool with a greater number of cavities; or,
  13. An internal or external supplier has trouble meeting Cpk requirements; or,
  14. An internal or external customer mandates the use of the Algoryx technology; or,
  15. The NPD/refurbishment team anticipates validation problems for whatever reason and decides that it wants to use the Algoryx technology.
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Day 3: Part 3 - Management Presentation

Third Day 3 Objective

The third objective of Day 3 is to present the team results to management.

The third Day 3 objective is accomplished by inviting Management to attend the three team cost and schedule savings presentations. The three presentations take one hour.

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