In-process Optical Coordinate Measuring Machine (OCMM) offers the potential of diagnosing in a timely manner variation sources that are responsible for product quality defects. Such a sensor system can help manufacturers improve product quality and reduce process downtime. Effective use of sensory data in diagnosing variation sources depends on the optimal design of a sensor system, which is often known as the problem of sensor placements. This thesis addresses coordinate sensor placement in diagnosing dimensional variation sources in assembly processes. Sensitivity indices of detecting process mean and variance components are defined as the design criteria and are derived in terms of process layout and sensor deployment information. Exchange algorithms, originally developed in the research of optimal experiment deign, are employed and revised to maximize the detection sensitivity. A sort-and-cut procedure is used, which remarkably improve the algorithm efficiency of the current exchange routine. The resulting optimal sensor layouts and its implications are illustrated in the specific context of a panel assembly process.
