Correlation Master Software

Algoryx’s Correlation Master software program is the high-powered computer application that implements Algoryx’s patented Mold Characterization algorithms.

Correlation Master is offered in two versions: Standard and Professional. Correlation Master Standard has the capacity to process up to 250 part dimensions and works using Microsoft Office Excel® 2003 data input workbooks. Correlation Master Professional has the capacity to process up to 16,000 part dimensions and works with both Microsoft Office Excel® 2003 and Microsoft Office Excel® 2007 data input workbooks.

Correlation Master uses high-powered statistical and computational methods to determine which one part dimension in one cavity is the statistically-best Predictor Dimension of all other dimensions in all other cavities. Determining the Predictor Dimension typically requires tens (or hundreds) of thousand of calculations. Determining the Predictor Dimension for large data sets would not be practical without today’s high-speed computers.

Once Correlation Master determines which part dimension is the statistically-best Predictor Dimension, it then determines the relationship between the Predication Dimension and all other part dimensions. These relationships are displayed as correlation charts. There is one correlation chart for each predicted dimension.

Correlation Master superimposes design targets and design tolerances on each correlation chart. When all dimensions in a cavities are evaluated, the result is an Operating Range. The Operating Range is equivalent to a producibility window. The Operating Target is the center of the Operating Range and is the operating point that gives the highest quality, lowest scrap and lowest rework.

FDA Software Validation

Correlation Master has been validated to FDA Software Validation Requirements.

Mold Characterization Studies

Algoryx integrates all elements of the molding process—including design tolerances, design GD & T, the mold, the press, the measurement system and material—a  into a single, unified system through a Mold Characterization Study.

Algoryx has discovered that a single predictor dimension (PD) is the statistically best predictor for all other dimensions. This means that one dimension in one cavity can serve as a predictor for all other dimensions and cavities in a mold.

As part of the Mold Characterization Study the use of Correlation Master identifies this predictor dimension and more:

  • Calculates an Operating Range for the predictor dimension (PD). When process settings are adjusted to keep the PD within the Operating Range, ALL dimensions on the part will be produced in specification.
  • Calculates an Operating Target for the PD. The Operating Target is a value inside of the Operating Range. The Operating Target gives you the highest quality, lowest scrap and lowest rework. Process engineers and press operators simply “dial in” the PD to the Operating Target and the Cpk is optimized for the entire system of dimensions
  • Calculates a Tolerance Relaxation Table that preserves design integrity by specifying the order in which tolerances should be relaxed. This data is particularly important in problem situations where a part has historically been very difficult (or impossible) to produce.
  • Calculates an Offset Table that enables single-step mold tuning that is optimum over your entire processing window.
  • Generates Correlation Charts that present a visual picture of the regression line for the predicted dimension relative to specification limits.

Algoryx  is available as an annual software License per site (unlimited molds per site), or on a mold by mold consulting basis.

“Correlation Master is a web-based, Software as a Service (SaaS) software application
that is automatically updated by Algoryx any time there is a software change.
This means our corporate IT department doesn’t need to be involved in most Algoryx software updates.”
Director of Information Services, Diversified International OEM

“The Correlation Master software has a shallow learning curve.”
Molding Technician, Molding Company

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