Methods and apparatus for automated predictive design space estimation

An apparatus for estimating a design space of a plurality of input factors and output responses for a physical process, comprising a processor configured to:

• (a) calculate, for each input factor of the plurality of input factors for a physical process, a calculated range of input values within a corresponding experimented range of input values, wherein calculating is performed in parallel for the plurality of input factors and calculating comprises:
• predicting values of one or more output responses for the physical process based on the first range of input values for each input factor of the plurality of input factors to determine a first performance metric for each of the one or more output responses;
• and
• creating the calculated range of input values for each input factor of the plurality of input factors by adjusting the first range of input values based on a comparison of the first performance metric and a predetermined performance metric;
• (b) calculate a modified range of input values for each of the plurality of input factors, wherein calculating is performed for the plurality of input factors one at a time and calculating comprises, for each input factor of the plurality of input factors:
• selecting a second range of input values for the input factor based on the calculated range of input values;
• predicting values of the one or more output responses based on the second range of input values to determine a second performance metric for each of the one or more output responses;
• and
• creating the modified range of input values for the input factor by adjusting the second range of input values based on a comparison of the second performance metric and the predetermined performance metric;
• and
• (c) predict a design space estimate based at least on the modified ranges of input values, wherein the modified ranges of input values each comprise a largest region of variability where criteria are fulfilled for one or more of the input factors.

A computer program product, tangibly embodied in a non-transitory machine-readable storage device, the computer program product including instructions being operable to cause a data processing apparatus to:

• (a) calculate, for each input factor of a plurality of input factors for a physical process, a calculated range of input values within a corresponding experimented range of input values, wherein calculating is performed in parallel for the plurality of input factors and calculating comprises:
• predicting values of one or more output responses for the physical process based on the first range of input values for each input factor of the plurality of input factors to determine a first performance metric for each of the one or more output responses;
• and
• creating the calculated range of input values for each input factor of the plurality of input factors by adjusting the first range of input values based on a comparison of the first performance metric and a predetermined performance metric;
• (b) calculate a modified range of input values for each of the plurality of input factors, wherein calculating is performed for the plurality of input factors one at a time and calculating comprises, for each input factor of the plurality of input factors:
• selecting a second range of input values for the input factor based on the calculated range of input values;
• predicting values of the one or more output responses based on the second range of input values to determine a second performance metric for each of the one or more output responses;
• and
• creating the modified range of input values for the input factor by adjusting the second range of input values based on a comparison of the second performance metric and the predetermined performance metric;
• and
• (c) predict a design space estimate based at least on the modified ranges of input values, wherein the modified ranges of input values each comprise a largest region of variability where criteria are fulfilled for one or more of the input factors.

A system for estimating a design space of a plurality of input factors and output responses for a physical process, the system comprising:

• (a) means for calculating, for each input factor of the plurality of input factors for a physical process, a calculated range of input values within a corresponding experimented range of input values, wherein calculating is performed in parallel for the plurality of input factors and calculating comprises:
• predicting values of one or more output responses for the physical process based on the first range of input values for each input factor of the plurality of input factors to determine a first performance metric for each of the one or more output responses;
• and
• creating the calculated range of input values for each input factor of the plurality of input factors by adjusting the first range of input values based on a comparison of the first performance metric and a predetermined performance metric;
• (b) means for calculating a modified range of input values for each of the plurality of input factors, wherein calculating is performed for the plurality of input factors one at a time and calculating comprises, for each input factor of the plurality of input factors:
• selecting a second range of input values for the input factor based on the calculated range of input values;
• predicting values of the one or more output responses based on the second range of input values to determine a second performance metric for each of the one or more output responses;
• and
• creating the modified range of input values for the input factor by adjusting the second range of input values based on a comparison of the second performance metric and the predetermined performance metric;
• and
• (c) means for predicting a design space estimate based at least on the modified ranges of input values, wherein the modified ranges of input values each comprise a largest region of variability where criteria are fulfilled for one or more of the input factors.

A computerized method for estimating a design space of input factors and output responses for a physical process, comprising:

• (a) calculating, using a processor, for each input factor of one or more input factors for a physical process, a calculated range of input values within a corresponding experimented range of input values, wherein calculating comprises:
• predicting values of one or more output responses for the physical process using a Monte Carlo simulation based on a first range of input values for the input factor to determine a first performance metric for each of the one or more output responses;
• and
• creating the calculated range of input values for the input factor by adjusting the first range of input values based on a comparison of the first performance metric and a predetermined performance metric;
• (b) calculating, using the processor, a modified range of input values for each of the one or more input factors, wherein calculating comprises, for each input factor of the one or more input factors:
• selecting a second range of input values based on the calculated range of input values;
• predicting values of the one or more output responses using a Monte Carlo simulation based on the second range of input values to determine a second performance metric for each of the one or more output responses;
• and
• creating the modified range of input values for the input factor by adjusting the second range of input values based on a comparison of the second performance metric and the predetermined performance metric, wherein the first performance metric, the second performance metric, and the predetermined performance metric are a measure of the number of values of the one or more output responses within predetermined limit values;
• and
• (c) predicting, using the processor, a design space estimate based at least on the modified ranges of input values, wherein the modified ranges of input values each comprise a largest region of variability where criteria are fulfilled for one or more of the input factors.