Response surface-based robust parameter design optimization with both qualitative and quantitative variables

The response surface-based robust parameter design, with its extensive use of optimization techniques and statistical tools, is known as an effective engineering design methodology for improving production processes, when input variables are quantitative on a continuous scale. In many engineering settings, however, there are situations where both qualitative and quantitative variables are considered. In such situations, traditional response surface designs may not be effective. To rectify this problem, this article lays out a foundation by embedding those input variables into a factorial design with pseudo-centre points. A 0–1 mixed-integer nonlinear programming model is then developed and the solutions found using three optimization tools, namely the outer approximation method, the branch-and-bound technique and the hybrid branch-and-cut algorithm, are compared with traditional counterparts. The numerical example shows that the proposed models result in better robust parameter design solutions than the traditional models.