David O. Kazmer, P.E., Ph.D.
Specializing in plastic product design and polymer process development.

Plastics Manufacturing Management Research

Quality Modeling

A quality modeling system has been developed between 1995 and 2005 support manufacturing process development and quality control. The system relies on multiple transfer functions that relate the process variables to the quality attributes. The Extensive Simplex Method is a proprietary algorithm used to derive the set of all feasible process settings based upon the specification limits for the quality attributes. Three different types of feasibility are analytically derived including 1) the global feasible set that establishes the extreme limits of feasibility by allowing all the process variables to vary simultaneously within their allowable range, 2) the local feasibility, which shows the immediate feasibility for each process setting holding other process variables at their current setting, and 3) the controllability that is indicative of the range that may be obtained for each quality attribute while holding other quality attributes at their current value.

The system explicitly considers both modeling uncertainty and uncontrolled variation; the specification limits may be automatically tightened by the magnitude of the confidence intervals and variation intervals to ensure feasibility to a desired level of confidence and robustness.  The interface includes 1) the transfer function matrix, 2) tracking of the process settings which may be used in a manner similar to statistical process control charts, 3) tracking of the quality attributes which may be used in a manner similar to statistical quality control charts, 4) the joint feasibility of all pairs of process variables, and 5) the joint feasibility of all pairs of quality attributes (similar to Pareto Optimal graphs). An example is provided for an injection molding process with four process variables and three quality attributes.

Lean Design and Manufacturing

Globalization is the process by which a business or company becomes international or starts operating at an international level. For corporations and their owners, globalization may provide access to lower cost resources (such as labor or materials) and/or new markets for the sale of finished goods. These increased profits must be substantial enough to offset the real or perceived transaction costs associated with obtaining the good or service from a foreign market. With respect to a global enterprise, the most significant transaction costs may include transportation costs, information costs, and enforcement costs.

Research has shown that all transaction costs are decreasing. As a result, international competition has and will continue to most efficiently produce products anywhere in the world. To remain competitive, manufacturers must maximally utilize all material and labor resources. Ongoing research is evaluating these market conditions and evaluating the potential outcome of industries and technologies. The two figures below compare the utilization of resources using 1960s technology (left) and modern technology (right). Sustained advances may eventually reduce the labor content associated with manufacturing in industrialized nations below 3%, a magnitude similar for agriculture. Manufacturers must continually advance or become obsolete.

Fifty Years Ago

Modern Technology

 

Other Research

We've conducted much other research on engineering design and optimization, engineering education, and other topics. Please see the publications below, review other portions of this site, and contact us with questions.

Related Publications

  1. Kazmer, D.O. and C. Roser, “Evaluation of Product and Process Design Robustness,” Research in Engineering Design, 1999. 11 (1), p. 21-30.

  2. Kazmer, D.O., “Best Practices for Injection Molding,” Journal of Injection Molding Technology, 1997. 1(1): p. 10-17.

  3. Kazmer, D., L. Zhu, and D. Hatch, “Process Window Derivation With an Application to Optical Media Manufacturing,” ASME Journal of Manufacturing Science, v. 123, p. 303-314, 2001.

  4. Xu, H. and D. O. Kazmer, “A Stiffness-Based Criterion for Ejection of Injection Molded Parts,” International Journal of Polymer Processing, 1999. 14 (1), p. 52-60.

  5. S. Dong, C. E, B. Fan, K Danai, and D. O. Kazmer, “Process-Driven Input Profiling for Plastics Processing,” Submitted to the ASME Journal of Manufacturing Science.

  6. B. Fan and D. O. Kazmer, “Warpage Prediction of Optical Media,” Journal of Polymer Science: Part B Polymer Physics, v. 41, p. 859-872, 2003.

  7. Ivester, R., Danai, K. and D. O. Kazmer, “Virtual Search Method for Injection Molding,” Journal of Injection Molding Technology, 1998, 2 (3), p. 165-172.

  8. Y. Cui, R. X. Gao, and D. O. Kazmer, “A Bond Graph Approach to Energy Efficiency Analysis of a Self-Powered Wireless Pressure Sensor,” Submitted to Journal of Smart Structures and Systems.

  9. R. Karania and D. Kazmer, “Low Volume Plastics Manufacturing Strategies,” Submitted to ASME Journal of Mechanical Design.

  10. L. Zhu and D. O. Kazmer, “An Extended Simplex Method for Global Feasibility Evaluation,” Journal of Engineering Optimization, v. 35, n. 2, p. 165-176, 2003.

  11. D. Kazmer, D. Kapoor, C. Roser, L. Zhu, and D. Hatch, “Definition and Application of A Process Flexibility Index,” ASME Journal of Manufacturing Science, v. 125, p. 164-172, 2003.

  12. C. Roser, D. Kazmer, and J. Rinderle, “An Economic Design Change Method,” ASME Journal of Mechanical Design, v. 125, n. 2, p. 233-239, 2003.

  13. Zhu, L. and D. Kazmer, “A Performance-Based Representation for Engineering Design,” ASME Journal of Mechanical Design, v. 123, n. 4, p. 486-493, 2001. 

  14. Kazmer, D.O. and D.S. Roe, “Exploiting Melt Compressibility to Achieve Improves Weld Line Strenths,” International Journal of Plastics, Rubber and Composites Processing, 1998. 27 (6), p. 272-278.

  15. D. Hatch and D. Kazmer “Process Transfer Function Development For Optical Media Manufacturing,” International Journal of Advanced Manufacturing Technology, v. 18, n. 4, 2001.

  16. Taylor, C.A., H.G. DeLorenzi, and D.O. Kazmer, “Experimental and Numerical Investigations of the Thermoforming Process,” Polymer Engineering and Science, 1992. 32(16): p. 1163-1173.

  17. D. Kazmer and L. Zhu, “A Quality Modeling System,” Submitted to the Journal of Quality Technology.

  18. Kazmer, D.O., “Precision Process Control,” Precision Injection Molding, Hanser Publishers, R.W. Friedl, J. Greener, Ed., 2005.

  19. Kazmer, D. O., "Dynamic Feed Control for Injection Molding," Ph.D. Dissertation, Mechanical Engineering Design Division, Stanford University, 1995.

  20. Roser, C. and D. O. Kazmer, “Defect Cost Analysis,” Plastics Failure Analysis and Prevention", J. Moalli Ed. , 2001.

  21. Karania, R., Kazmer, D., and C. Roser, "Plastic Product and Process Design Strategies," ASME DETC 9th Design for Manufacturing Conference, 2004.

  22. D. Kazmer, “The Development of Robust & Confident Decision Spaces,” Proceedings of the 4th National Science Foundation Design & Manufacturing Conference, 2002. San Juan, Puerto Rico. 

  23. Kazmer, D. O.,  Hatch, D., and L. Zhu“An Investigation of Variation and Uncertainty in Six Sigma,” ASME DETC 7th Design for Manufacturing Conference, v 3, p 21-29, 2002. 

  24. David O. Kazmer, Vijay Kudchadkar, and Ranjan Nageri, "Performance of a Self-Regulating Melt Pressure Valve," Proceedings of the 2005 Society of Plastics Engineers Annual Technical Conference, 2005.

  25. David O. Kazmer and Hitesh Mundhra, "Derivation of Process Windows," Proceedings of the 2005 Society of Plastics Engineers Annual Technical Conference, 2005.

  26. R. Abbott, R. Combs, D. Kazmer, G. Magnant, S. Winebaum, “Elimination of Process Constraints in Plastics Injection Molding”, Molding 2003 Executive Technology Conference, New Orleans, LA, 2003.

  27. Balasubrahmanyan, G. and D. Kazmer (2003). “Thermal Control of Melt Flow in Cylindrical Geometries,” Society of Plastics Engineers Annual Technical Conference: Injection Molding Division, Nashville, TN.

  28. Wang. F., Dong, S., Danai, K. D., and D. O. Kazmer, “Input Profiling for Injection Molding by Reinforcement Learning,” Society of Mechanical Engineers, Dynamic Systems and Control Division, v 70, 2002, p 701-708. 

  29. Hatch, D., D. O. Kazmer, and B. Fan, “Dynamic Cooling Design for Injection Molding,” Society of Plastics Engineers Annual Technical Conference, May 2001. Dallas, TX. 

  30. David O. Kazmer, "Wall Thickness Optimization In Molded Product Design," Proceedings of the 2005 Society of Plastics Engineers Annual Technical Conference, 2005.

  31. D. Kazmer and L. Zhu, "An Integrated Performance Modeling System," Design for Manufacturing Symposium at the 2004 International Mechanical Engineering Congress, Anaheim, CA, 2004.

  32. Zhu, L., and D. O. Kazmer, “A Method for Multi-Criteria Decision Making,” Proceedings of the 4th National Science Foundation Design & Manufacturing Conference, 2002. San Juan, Puerto Rico

  33. L. Zhu and D. O. Kazmer, “An Extended Simplex Method for Global Feasibility Evaluation,” ASME Design Automation Conference, 2002.

  34. Zhu, L., and D. O. Kazmer, "An extensive simplex method mapping the global feasibility," Proceedings of the 28th Design Automation Conference, ASME Design Engineering Technical Conferences, v 2, 2002, p 765-771 Sep 29-Oct 2 2002, Montreal, Que., Canada. 

  35. Kazmer, D. O., Zhu, L., Roser, C., “Some Advances in Design Representation and Feasibility Analysis,” Proceedings of the 3rd National Science Foundation Design & Manufacturing Conference, 2001. 

  36. Roser, C. and D. O. Kazmer, “Defect Cost Analysis.” in Proceeding of the Society of Plastics Engineers Annual Technical Conference, 1999. New York, NY. 

  37. Kazmer, D. O., Roe, D. S., “Increasing Knit-Line Strength through Dynamic Control of Volumetric Shrinkage,” in Proceeding of the Society of Plastics Engineers Annual Technical Conference, 1994.

  38. Kazmer, D. O., “Advanced Design Methodologies for the Blow Molding Process,” 20th Annual Structured Products Conference, Society of the Plastics Industry, 1991.

  39. Hatch, D., D. O. Kazmer, and M. Niemeyer, “Transfer Function Development for Injection Molding of Optical Media.” in Proceeding of the Society of Plastics Engineers Annual Technical Conference, 1999. New York, NY. 

  40. D. Kazmer, “Domain-Centric Design Education,” ASME IDETC 10th Design for Manufacturing Conference, 2005.

  41. Kazmer, D., "Declaring an Engineering Major: By Choice or By Chance?," American Society of Engineering Education New England Section 2004 Annual Conference, April 2-3, 2004. 

  42. Doshi, N. and D. Kazmer (2003), “Layout Design of a Platenless Molding Machine,” Society of Plastics Engineers Annual Technical Conference: Injection Molding Division, Nashville, TN.

  43. Fan, B. and D. Kazmer (2003), “Effect of Low Temperature Shift Factor Modeling on Predicted Part Quality,” Society of Plastics Engineers Annual Technical Conference: Applied Rheology Special Interest Group, Nashville, TN.

  44. Kazmer, D., S. Orroth, N. Schott (2003), “Future Directions for Plastics Engineering Education”, Society of Plastics Engineers Annual Technical Conference: Injection Molding Division, Nashville, TN. 

  45. Zhu, L., Zhao, Y., and D. O. Kazmer, “Feasibility Mapping of Non-Linear Systems,” Proceedings of the Institute for Operations Research and the Management Sciences, Decision Analysis Section, November 2000. Austin, TX. 

  46. Kazmer, D. O., “On the Divergence of Case Studies and Hardware Prototypes in Active Learning,” 1998 American Society of Engineering Education Northeast Regional Meeting. 

  47. Kazmer, D., “The Economics of Lights Out Manufacturing,” Society of Plastics Engineers Topical Conference on Injection Molding Systems, Cleveland, OH, October, 2004. 

  48. D. Kazmer, “What’s the big deal about something very small? The Business of Nano”, Rotary Club Meeting, Dracut, MA, May 17, 2005.

  49. Kazmer, D., “Advances in Molding Technology,” Delphi Central Research, Detroit, MI, August, 2004. 

  50. Kazmer, D., “Competitive Molding Technologies,” Society of Manufacturing Engineers EASTEC Lean Manufacturing Conference, Springfield, MA, May, 2004. 

  51. Kazmer, D., “Modern Injection Molding,” Northeast Utilities Energy Conservation Seminar, Berlin, CT, March, 2004. 

  52. Kazmer, D., “Competing in the 21st Century,” Plastics Institute of America Quarterly Meeting, Lowell, MA, February, 2004. 

  53. D. Kazmer, "Interactive Learning: Simulating The Design Process," Symposium on Manufacturing Education, Stanford University, 2000. 

  54. D. Kazmer, “Trends in the Plastics Industry: Product Development Paradigms and Impact on Human Resources,” Society of Manufacturing Engineers Plastics Molding & Manufacturing Annual Trends Report, 2000. 

  55. D. Kazmer, “Quality Control Capability Assessment,” Society of Manufacturing Engineers Plastics Molding & Manufacturing Annual Trends Report, 2000. 

  56. Kazmer, D. O., “Commanding the Technical Frontier: Engineering Education for the 21st Century,” 50th Anniversary Celebration of the University of Massachusetts Amherst College of Engineering, 1998. 

  57. Kazmer, D. O., “University Research and Teaching Capabilities for Husky,” Commonwealth of Massachusetts Economic Development Office, 1997.

  58. Kazmer, D. O., “University Research Activities,” AlliedSignal Plastics, 1997.

  59. D. Kazmer, “Lean Development,” Flow Front Magazine, Moldflow Inc., April, 2005.

  60. D. Kazmer, Invention Disclosure, Method for Dynamic Cost Estimation of Injection Molded Article, 2002.

  61. Zhu, L., and D. O. Kazmer, "An Extensive Simplex Method for Mapping Global Feasibility," 2001. 

  62. D. Kazmer, Invention Disclosure, Manufacturing Translation between Production Machines and Suppliers, 2003.

  63. Kazmer, D. O., “Reflection on Teaching and Learning,” speech to University of Massachusetts’ Celebration of Teaching and Learning, March 25, 1999. 

  64. Kazmer, D. O., "1998 Informant: Activities of the Design and Processing Quality Lab," 1998. 

  65. D. Kazmer, Invention Disclosure, Laser Grid Array Stereolithography, 1997.

  66. D. Kazmer, Invention Disclosure, Screw Design for Efficient Recycling of Polymeric Materials, 1997.

  67. Poslinski, A. J., Aslam, S., Kazmer, D. O., “Effects of Viscosity Variation on Injection Molding,” GE Research & Development Technical Information Series Number 92CRD146, 1992.