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Material Variation FAQs

Algoryx is a powerful anlaytical tool that:
  1. Identifies when changes in material have a significant impact on the Operating Range; and,
  2. Provides alternative solutions and procedures for dealing with the new (and possibly suspect) material.

Material variation can be divided into 4 categories:

  1. Variation within a lot;
  2. Variation between lots from the same supplier;
  3. Variation between different suppliers; and,
  4. Variation caused by large changes in environmental conditions such as ambient temperature or humidity, which may affect the wetness/dryness of the pellets.

The generalized experience of Algoryx’s customers is as follows.

  1. Material variation within a lot is usually small enough that it does not have any noticeable impact on the Algoryx Operating Range (OR).
  2. Material variation between lots from the same supplier is usually small enough that it does not have any noticeable impact on the Algoryx OR. However, lot-to-lot variation for a material supplier with poor quality control can cause noticeable changes in the Algoryx OR.
  3. Material variation between different suppliers is more likely to cause a change in the Algoryx OR.
  4. Material variation caused by large changes in environmental conditions can cause changes in the Algoryx OR.

Major changes in material composition can have a significant impact on dimensional output. Algoryx does not magically make material variation disappear. Material variation is a fact of life and has to be dealt with one way or another.

Q1: Is the OR calculated by Algoryx material specific?
A1: Yes. The OR calculated by Algoryx is material specific.

Q2: How, then, does the molder determine whether or not the change to the new material is significant enough to require a new Operating Range?
A2: Repeat the Induced Variation Study (IVS) and analyze the new versus the old OR and Operating Limits. Under most circumstances, it is sufficient to do a 3-setup IVS instead of a 5- or 9-setup IVS.

Q3: How, specifically, does one analyze the new versus the old Operating Range?
A3: Review the Algoryx Constraint Table to see if the OR (the distance between the Operating Limits) has changed.

  1. If the new OR is greater than the old OR, then Opk has increased.
  2. If the new OR is the same as the old OR, then Opk is unchanged.
  3. If the new OR is less than the old OR, then Opk has decreased. In this instance, compare the decreased Opk against customer requirements.
    1. If the new Opk equals or exceeds customer Cpk requirements, then you are OK.
    2. If not, then you will need to increase the size of the OR. See the standard seven Algoryx methods for increasing the size of the OR.

Q4: How do I learn more about Algoryx’s methods for handling material variation?
A4: Agoryx provides procedures and much more information on how to evaluate the effects of material variation during Algoryx’s on-site training classes and when doing individual mold analyses for customers.

Take the Algoryx Challenge – See how Algoryx can help you manage material variation!