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ISRU

ISRU. Industrial Statistics Research Unit. I NDUSTRIAL S TATISTICS R ESEARCH U NIT. We are part of Newcastle University, Department of Mechanical, Material and Manufacturing Engineering based in the in the Stephenson Building. WHAT DO ISRU DO?. Mission Statement:

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ISRU

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  1. ISRU Industrial Statistics Research Unit

  2. INDUSTRIAL STATISTICS RESEARCH UNIT We are part of Newcastle University, Department of Mechanical, Material and Manufacturing Engineering based in the in the Stephenson Building.

  3. WHAT DO ISRU DO? Mission Statement: "To promote the effective and widespread use of statistical methods throughout European industry and to use the ideas and experience so gained for the benefit of students and the wider academic community."

  4. THE WORK ISRU DOES CAN BE BROKEN DOWN INTO 3 MAIN CATEGORIES: • Consultancy • Training • Major Research Projects All with the common goal of promoting quality improvement by implementing statistical techniques

  5. Typical UK or Regional projects • Assessment of environmental risks in chemical and process industries • Introduction of statistical process control (SPC) in micro-electronics company • Help to develop a new catheter for open-heart surgery via designed experiments (DoE)

  6. Typical UK Food Projects • Waffle Manufacturer • Bakery - Biscuits • Bakery - Shortbread • Butter Manufacture • Soft-Drinks Bottling Plant • Crisp Manufacturer • Tea Blender • Cheese Maker

  7. Typical UK Food Projects • Involved in development of Quorn • One other large company - • Helped reduce waste on a production line • The company changed it’s name • Used to be called Rowntrees

  8. Some past successes • Manufacturing Down-time cut by 40% • Production Waste reduced by 50% • Lead times reduced from 6 to 3 weeks • Stock holding levels halved • Material use optimised saving £150k pa • Expensive equipment shown to be unnecessary in a new process

  9. Other Benefits • Better monitoring of processes • Better involvement of people • Staff morale is raised • Waste is reduced • Throughput is increased • Profits go up

  10. Tools of the trade • Measurement • Logical problem solving • Data analysis • Process capability • SPC, TQM, DoE • Empowered team formation • etc

  11. “Voice of the Customer” Concept of assessing customer wishes and giving them what they want Links suppliers and customers in “supply chain” Becomes easier to make better products and protects market

  12. EXPERIMENTAL DESIGN‘Taguchi’ • What can it do for companies? Minimise cost Maximise output More information than otherwise

  13. Teaching Company Schemes Key UK Government sponsored Technology Transfer Mechanism • Government sponsored up to 70% • for graduate on substantial project • over 2 years working at the Company • with academic supervision from partner University • We employ the graduate

  14. ISRU have had TCS with • Amersham International • Boots • Wavin Industrial Products • ICI *Quality Award • Food for Thought • Villa Soft Drinks • RR Donnelley • Glaxo *Best Practice Award

  15. European Research Projects

  16. Fatigue Crack Growth Rate in Steel Rails 6 Labs mostly major European Steel producers Two stages - Fractional design - material constraints New way of determining ‘stages’ of crack growth based upon plots of moving average of MSE through a derived curve New European Standard First time that a balanced Factorial array has been embedded in EC research contract?!

  17. Transient Pressures Safety of water and sewage systems Pressure Hammer - Dangerous 6 partners - great interest throughout World Large rigs in Italy and Holland - The ‘Watterloop’ - filling in the Zieder - Zee Petrochemical Industry applications Safety (risks) Model Experimental Design - Uncertainty in ‘constants’ largely unknown!

  18. Firemen’s Boots Safety Standards for footwear Many Partners - mostly in Scandinavia Questionnaire for Firemen Several experiments now designed Eventually - Trial of new standards Side issue - advice on stats aspects other standards - Huge scatter - simple ANOVA can solve - standards need urgent repair USA standards also have flaws

  19. CIS II Find the hidden patterns in survey data 75000 responses from round EC ISRU approach - Screen then Model Data Mining - The usual suspects - FA / PCA - Regression - C-Correlations - GAs Much interest in Europe about Innovation WE may be leading the field in this?

  20. Sensory Analysis of Butter First ever international intercomparison on sensory analysis in the Dairy industry 9 Labs throughout Europe e.g. Lurpak - French Food Safety Agency - 11 partners 4 stages - 4 experimental designs Sampling Protocol -Fractional Factorial Used DoE - Compared to ANOVA - this is best way see - Avery and Masters 1999

  21. Recent Projects EC 5th Framework - ‘Competitive Growth’ - Water Quality - CRM - Public health office - Microbes - Industrial Experimental Design EC- Standards Measurement and testing- Sensory Analysis for Food Packaging Materials and Taste taints EC Standards - Cyclic Oxidisation Testing

  22. Recent Projects Thematic Network on Industrial Statistics 30 Partners across Europe To push forward use of statistics in Business and Industry Pro-Enbis Thematic Net on Water Surges 20 partners to investigate the effects of Waterhammer

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