Six Sigma Methodologies in Ignition Coil Manufacturing Using Experimental Design - Improve Step 2002-01-0899

Quality issues in magnet wire stripping and soldering have led to continuous improvement efforts in ignition coil manufacturing using Six Sigma methodologies. This effort has resulted in the investigation of an alternative product and process design, microjoining. This paper describes the continuation of development occurring during the improvement phase of a Six Sigma project. The confirmation of the results is accomplished through the use of experimental design, response surface methodologies, mathematical modeling and optimization of the process. Nonlinear design of experiments have been used to confirm a breakthrough microjoining process developed that is an alternative to soldering. The statistical methods used to develop the process build on the current documented research efforts. These results significantly extend the level of knowledge of designed experiment application in the welding field and summarize a typical analysis performed in the improvement phase of a Six Sigma project.