Just to clarify, JMP does not suggest a maximum number of runs. JMP provides a default number of runs based on some simple heuristics. Feel free to choose another number based on the evaluation information, such as the power analysis.
Let me re-state your answer about experts choosing the levels to produce passing and failing viscosity. The change in the viscosity over the factor range will be 3-4 times larger than the standard deviation of the viscosity. Is that true?
Yes, I meant using the categorical factor type instead of the discrete numeric factor type for all the factors. You can estimate the interactions but the number of runs is much larger and likely not practical for you.
The correlations are unavoidable due to the specifications for this design. On the other hand, the worst correlation is about 1/3, so you still have the ability to estimate these parameters and if the effect is much larger than the standard deviation, with reasonably high power.
This design seems like a good choice, based on the information provided here so far.
Just a reminder: glad you came to the JMP Community for help! We will do our best. But I want to set realistic expectations. This area is not meant to provide consulting or training. It is meant to help with specific problems or issues. We can point to other resources if you need more extensive help with the design of experiments.