Case Studies

DoE - Design of Experiments - Taguchi Method

Type of Industry:

Automotive Supplier



Duration (total / actual consulting days):

7 Months / 40 Days

Company Targets:

Assurance of product quality; stabilization and optimization of welding processes


Quality requirements to welding products are met reliably; welding processes are stable and even exceed the requirements given; NIO parts and rework are reduced to almost none

Status quo (outlined):

  • Product: Quality requirements to welding products are met reliably
  • Welding processes are not stable, quality relevant parameters are fluctuating and are not reproducible.
  • Internal test series (carried out over a period of several months) haven’t led to a significant improvement in quality.

Actions planned by the company:

Further test series to find the optimum welding parameters based on the one-factor-at-a-time method.

Master plan by SYNCRO EXPERTS:

Systematic optimization of the welding parameters based on the DoE method (Design of Experiments). This method helps to determine the optimum control parameters, taking into account the effect of parameter combinations. Test series are conducted systematically using statistical methods, thus reducing the complexity and number of experiments significantly.


  • Mapping of the exact process sequence within the welding machine.
  • Determination of the relevant parameters (control parameters and disturbances).
  • Involvement of machine operators and the machine manufacturer.
  • Checking of control parameters in respects to their actual effect (comparison of set value to actually measured value; stability of measured values over time and in respect to other influences).
  • Determination of relevant control parameters and an orthogonal array for the test series.
  • Conduction of the experiments according to the DoE experimental plan (significantly reduced complexity and number of experiments).
  • Determination of the response- and the interaction table, to identify influences, interdependencies and interferences between different parameters.
  • Determination of the optimum set of parameters, referred to as the “paper champion”.
  • Testing of the paper champion in live operation (confirmation experiment).


Quality requirements to welding products are met (and even exceed) reliably.

Process stability has improved significantly.

Your Contact:

Michael Hoff



+ 49 441-361 85 222