Enhancing Manufacturing Processing Stability and Efficiency with Linear-Regression Analysis: Modeling on a Flow-Drill Screw (FDS) Joining Process

The instability (in processing time) in the flow-drill screwing process is undesired but inescapable due to variations in material property, gauge, and process parameters. A substantial number of materials and lab labor need to be used to test and control the variability of the real manufacturing joining process. To enhance the stability and efficiency of the screwing process, this study seeks multi-disciplinary collaboration by applying linear-regression modeling. Six hundred and forty-eight data points were collected and split into an 80% training set for model building and a 20% test set for model validation. A multiple linear-regression model was built. The results indicated that, compared to variable base level (6000 rpm rotational speed and 1100 N downforce), higher rotational speed (8000 rpm, 7000 rpm), greater downforce (1200 N, 1300 N), and their interaction were significantly associated with passage (processing) time, while the switch point did not significantly affect passage time. The interaction plot and effect size were adopted to provide measurements of the effect magnitude on processing time. The coefficient of determination indicated that 86% of the variability in the passage time can be explained by this model. Statistical analysis, such as data visualization, statistical modeling, and other data-driven analysis methods, can be used to detect underlying relationships between variables, investigate variations, and make predictions in the manufacturing process. The outcomes from the data-driven analysis can benefit from improving the economical manufacturing system, refining the processing setting, and reducing test material costs, labor, and lead time.