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Taguchi
Applications of Taguchi approach approach to
to statistical design of statistical design
experiments in Czech Republican
447
industries
Received December 2003
Jiju Antony, V. Somasundarum and Craig Fergusson Revised May 2004
Division of Management, Caledonian Business School, Accepted May 2004
Glasgow Caledonian University, Glasgow, UK, and
Pavel Blecharz
VSB-TU The Faculty of Economics, University of Ostrava,
Sokolska, Czech Republic
Introduction
Statistical design of experiments (SDOE) plays a powerful role in many organisations
today in terms of improving process efficiency, product quality and process capability;
and reducing process variability, costs of poor quality such as scrap, rework and other
failure costs. This powerful technique has proven to be one of the most effective and
reliable weapons in the twenty-first century arsenal of globally competitive
organisations. It was initially developed by R.A. Fisher at Rothamsted Agricultural
Station, London, England (Fisher, 1935). However, the person who is seen to have most
influenced the development of SDOEs (SDOE) in the industrial world is Dr Genichi
Taguchi. Dr Taguchi has been very successful in integrating statistical methods into
the powerful engineering processes for achieving greater process stability, capability
and yield. Taguchi emphasised the importance of designing quality into products and
processes right from the design stage through to the entire product development cycle
(Taguchi, 1987). A number of successful applications of the Taguchi approach to
SDOEs have been reported by many American and European manufacturers (Phadke, International Journal of Productivity
1989; Quinlan, 1985; Taguchi and Yokohama, 1993; Rowlands et al., 2000; Antony et al., and Performance Management
Vol. 53 No. 5, 2004
1999). The SDOE methodology developed and promoted by Taguchi has accentuated pp. 447-457
the importance of making products’ functional performance or process performance q Emerald Group Publishing Limited
1741-0401
insensitive to various sources of noise conditions (e.g. ambient temperature changes, DOI 10.1108/17410400410545914
IJPPM relative humidity fluctuations, equipment or machine performance degradation, tool
53,5 wear, product-to-product variation, etc.). This is also known as robust parameter
design (RPD). RPD is essentially a part of Taguchi’s SDOE.
Despite the successful applications of the Taguchi approach to SDOE, a wider use of
the approach and its associated techniques is only possible by gaining a better
understanding of the method (i.e. where, when and how to use) and its analysis. The
448 successes and failings of the Taguchi approach to SDOE have been widely discussed
(Nair, 1992; Pignatiello and Ramberg, 1991; Bendell et al., 1989; Box et al., 1988; Kumar
et al., 2000). Taguchi’s main successes have been to demonstrate the importance of
designing quality into products and processes at early stages of the product
development process, making processes robust against undesirable nuisance factors
without actually eliminating them completely from the process, simplifying the use of
SDOE as a powerful tool for industrial engineers, and so on. On the other hand,
Taguchi’s main weaknesses have been the use of linear graphs for assigning factors
and interactions to various columns of the orthogonal array (OA), the use of
signal-to-noise ratio (SNR) as a performance indicator of robustness, lack of use of
sequential and adaptive approach to experimentation, lack of importance on
interactions among the process or design parameters, and so on.
thereby minimise the effect of random noise factors which have significant impact on
the process performance. SNR for nominal-the-best quality characteristic (here it is
burn time) is calculated using the following equations (Roy, 2001):
SNR ¼ 10 log MSD ð1Þ
where:
X
n
ðyi mÞ2
i
MSD ¼ : ð2Þ
n
Here, MSD (mean squared deviation) is a measure of deviation of a product’s
performance characteristic (y) from its desired target value (m). Based on the above
equations, SNR is calculated corresponding to each design point. Table III presents the Taguchi
SNR values for all 16 trial conditions. approach to
Having obtained the SNR values, the next step was to obtain the mean SNR at low
and high levels of each design parameter. The main effects plot for the SNR is shown in statistical design
Figure 1. The main effect plot clearly indicates that design parameters A, B, C, D and E
have the biggest influence on the SNR. In order to determine the statistical significance
of the effects, it was decided to perform ANOVA (analysis of variance) for the SNR. 451
Pooling strategy was employed (Roy, 2001) to create adequate degrees of freedom for
1 3.433
2 6.599
3 25.025
4 26.021
5 10.261
6 9.233
7 8.167
8 9.447
9 10.591
10 8.695
11 25.071
12 29.586
13 22.163
14 24.629
15 8.313 Table III.
16 10.168 SNR values
Figure 1.
Main effects plot for the
SNR
IJPPM the error term so that sound conclusions about the significance of effects of design
53,5 parameters can be drawn. ANOVA was performed with the idea of sub-dividing the
total variation of data into useful and meaningful components of variation due to main
effects (i.e. effects of design parameters). The pooled ANOVA table is shown in
Table IV. The table shows that the most influential design parameters are E, C and A,
which account for more than 80 per cent of total variation in data.
452 Table IV indicates that design parameters C and E are statistically significant at
both 5 per cent and 1 per cent significance levels, whereas design parameters A, B and
D are statistically significant at only 5 per cent significance level. This, in essence,
shows that design parameters A, B, C, D and E have significant effect on “burn time”.
SNRpredicted ¼ T þ ðA2 TÞ
þ ðB1 TÞ
þ ðC 2 TÞ
þ ðD2 TÞ
þ ðE 2 TÞ
ð3Þ
454
Figure 2.
Noise of alternator (before
experiment)
The experiment was carried out using the L12 OA. The results of the experiment along
with SNR are illustrated in Table VI. As the objective of the experiment was to
minimise the noise, SNR for smaller-the-better quality characteristic was selected. Each
trial condition was replicated three times to capture variability due to uncontrollable
Run A B C D E F G H I J K Y1 Y2 Y3 SNR
Figure 3.
Main effects plot for the
SNR
IJPPM Design Degrees of Sum of Mean Pure sum of Percentage
53,5 parameter freedom squares square F-ratio squares contribution (r)
SNRpredicted ¼ T þ ðA1 TÞ
þ ðD2 TÞ
þ ðF 2 TÞ
þ ðI 2 TÞ
¼ 245:66 þ ð241:704 þ 45:66Þ þ ð244:245 þ 45:66Þ
ð7Þ
þ ð243:905 þ 45:66Þ þ ð243:459 þ 45:66Þ
¼ 236:33
From the predicted SNR value, the noise (i.e. response or quality characteristic) was
generated. The predicted noise at the optimal condition was 65.53. In other words, at the
optimal condition, the total sum of squares of plus (positive) deviations from curve of
customer requirement is 65.53 in the speed range of 1,600-10,000 RPM. The noise before
experiment was estimated to be 205.84. A significant reduction in noise was observed
after the experiment (refer to Figure 4). The next phase of this study is to further analyse
the effect of factors such as angle of chamfer (different angles), tail of the star (cut or no
cut), type of chamfer (single or double) etc. on the performance of star.
Conclusion
The Taguchi approach to SDOE has intensive applications in the engineering design
and development environment. Although many companies in Europe and the USA
Figure 4.
Noise of alternator (after
experiment)
have used the Taguchi approach to SDOE with success, very few applications of this Taguchi
method are realised or reported in the Czech Republic. This paper presents two
applications of the Taguchi approach to SDOE in the Czech Republican industries.
approach to
Both case studies were primarily focused on the use of scientific experiments in the statistical design
new product development process. Both experiments were successful in terms of
meeting the objectives set out by the team from both organisations. The results of the
study have made an increased awareness of the application of SDOE to the engineering 457
fraternity in both organisations. For wider application of such powerful techniques, the
first step is to promote the Taguchi approach of experimental design through local
industry networking, seminars and workshops. The initial events should be primarily
targeted for executive leaders, senior managers and directors of various business units
from various organisations. This should be followed by more detailed training on such
methods from well experienced Taguchi practitioners or consultants who have a lot of
hands-on experience.
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