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TAGUCHI TECHNIQUES
• Taguchi method
• Loss function
• Orthogonal array
• Robust design
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OBJECTIVE OF TAGUCHI METHODOLOGY
By setting the factors at their optimal level and changes in environmental factors,
stable and high quality products can be obtained.
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QUALITY: TRADITIONAL VS TAGUCHI’S VIEW
o Traditionally, “Quality” is when the o As per Taguchi, “Quality” is when the process
process output is within Customer output is at the Target.
Specifications. o Every time, Process mean deviates from Target
and there is process variance, there are bound to
o Hence, NO QUALITY LOSS is there, be quality losses.
if product is within the specifications. o Larger the deviation of mean from the target, larger
is the loss.
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TRADITIONAL VIEW WITHOUT NOISE FACTORS
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TRADITIONAL VIEW WITH NOISE FACTORS
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TAGUCHI’S VIEW WITH NOISE FACTORS
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TAGUCHI’S METHOD
Taguchi says that every time a process moves away from the
Target, there is loss to customer.
(even if the process is within SPECs)
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WHEN TO USE TAGUCHI METHODOLOGY ?
• In cases, where the number of CONTROL FACTORS > NUMBER OF NOISE FACTORS
[Better chance of finding a factor that helps reduce the noise]
• The product/ process under design is extremely critical. In no condition shall the
process deviate from the target.
• When the design objective is not just to attain the nominal best for the Response
but is to attain best relationship between the output response and an input Signal
factor.
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TAGUCHI’S LOSS FUNCTION
o According to Taguchi (Japanese Engineer), every time the process deviates from the target, even
if it stays within the SPECs, there is loss to the society (Producer and Customer)
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Loss (y) = 𝑘 𝑦 − 𝑚 Ex: CARs being called back due
10 to minor errors
TAGUCHI’S LOSS FUNCTION
2
Loss (y) = 𝑘 𝑦 − 𝑚
2
Loss (y) = 𝑘 𝑦 − 𝑚
Where, k = A / 𝑑2
And
This function drives the OBJECTIVE of the Taguchi’s design, which is to design a process that
not just complies to the Customer specifications BUT also is aligned to the TARGET.
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SIGNAL TO NOISE RATIO
• Control factors (Signals) are those design and process parameters that can be
controlled.
• Noise factors cannot be controlled during production of product; controlled during expt.
• To get the desired result (Higher S / N Ratio):
• Identify optimal control factors that not only increase the QUALITY but also reduce NOISE.
: Standard deviation or
natural variance
: Mean / Average
Ex. Radiation
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leakage in Microwave Oven; pollution; leakage current.
VARIATION OF THE QUADRATIC LOSS FUNCTION
2
Loss (y) = 𝑘 𝑦 − 𝑚
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CASE STUDY: Tool Wear in a Process
2
$4.00 = k 𝐿𝑆𝐿 – 𝑚
The lower specification limit (LSL) is substituted into equation, which is where the $4.00
loss is incurred. The upper specification limit also could be used for this calculation.
Solving for k,
$4.00
𝑘 = 2
𝐿𝑆𝐿 – 𝑚
$4.00
𝑘 = 2
−0.010 – 0.0
2
L = 40,000 𝑦 − 0.0
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CASE STUDY: Tool Wear in a Process
Now the loss associated with any part can be computed depending on the value of its
diameter.
For instance, a part with diameter of + 0.003 in (+ 0.08 mm) costs
2
L = 40,000 0.003 − 0.0
L = $ 0.36
This is the loss per unit for each part shipped with an outer diameter of +0.003 in.
Similarly for a part diameter of -0.002 in which are 11 quantities in number the cost
incurred would be,
2
L ( - 0.002 ) = $ 40,000 −0.002 − 0.0
= $ 0.16 x 11
= 19$1.76
CASE STUDY: Tool Wear in a Process
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THE DOE (DESIGN OF EXPERIMENTS PROCESS)
Orthogonality is represented as: ∑ xi . yj = 0, for all the pair of levels, where i, j represent high
& low (+1, -1) levels.
Controllable factors, with their levels, form the Inner array Factor-1: Wire diameter (1: 5 mm, -1-: 0 mm)
These factors are the design parameters in the selected process Factor-2: Wire length (1: 200 mm, -1: 500 mm)
design concept Factor-3: Wire Material (1: Cu, -1: l)
Noise: Ambient Temperature (1: 50C, -1: 350C)
Optimum levels for these factors are to be achieved which will
Control factors Responses
maximize the Response and minimize the effect of Noise factors.
Wire
Diameter Length At Temp-1 At Temp-2
Materi
al
The Noise factors form the Outer array
Cu[1] 5 [1] 200 [1] 101.5 107.9
These factors influence the Response (Output) but are not
Cu[1] 5 [1] 500 [-1] 100.8 102.1
controlled during the use of the product
Cu[1] 10 [-1] 200 [1] 99.7 104.6
Noise factors are forced to vary & based on the optimum response Cu[1] 10 [-1] 500 [-1] 98.4 101.7
values, the optimal control factor settings are identified. Al [-1] 5 [1] 200 [1] 104.5 108.9
Such optimal settings make the product/ process resistant to noise Al [-1] 10 [-1] 200 [1] 103.2 108.3
where,
S = number of levels for each factor
k = maximum number of factors whose effects can be estimated without
any interaction
N = total number of trials during experimentation
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ORTHOGONAL ARRAYS
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ORTHOGONAL ARRAYS: EXAMPLE
24 Factorial Design
23 Factorial Design
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ORTHOGONAL ARRAYS: EXAMPLE
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ORTHOGONAL ARRAYS: CASE STUDY II
Consider a process, of producing steel springs, is generating considerable scrap due to cracking after heat
treatment. A study is planned to determine better operating conditions to reduce the cracking problem.
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ORTHOGONAL ARRAYS: CASE STUDY II
Problem:
- Quench Temperature?
- Carbon Content?
- Steel chemistry?
- Spring type?
Factorial Approach:
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ORTHOGONAL ARRAYS: CASE STUDY II
INTERACTING COLUMNS OF THE ORTHOGONAL ARRAY
The above eight runs constitute a FULL FACTORIAL DESIGN. The design is
balanced for every factor. This means 4 runs have T at 1450 and 4 have T at 1600.
Same is true for C and O. 30
ORTHOGONAL ARRAYS: CASE STUDY II
•A full factorial design is a design in which researchers measure responses at all combinations
of the factor levels.
•The number of runs necessary for a 2-level full factorial design is 2k where k is the number of
factors. As the number of factors in a 2-level factorial design increases, the number of runs
necessary to do a full factorial design increases quickly. For example,
•A 2-level full factorial design with 6 factors requires 64 runs; a design with 9 factors requires
512 runs.
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EFFICIENT TEST STRATERGIES
•Fractional factorial designs
•A fractional factorial design uses a subset of a full factorial design, so some of the main
effects and 2-way interactions are confounded and cannot be separated from the effects of
other higher-order interactions. Usually experimenters are willing to assume the higher-
order effects are negligible in order to achieve information about main effects and low-order
interactions with fewer runs.
• Instead of varying one factor at a time, here multiple factors are varied to find the effect of
one on another.
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EFFICIENT TEST STRATERGIES
A factorial design is type of designed experiment that lets you study of the effects that several factors can have on a
response.
When conducting an experiment, varying the levels of all factors at the same time instead of one at a time lets you study
the interactions between the factors. 34
REFERENCES
3. Park, Sung H, “Robust Design and Analysis for Quality Engineering”, Chapman
& Hall, London, 1996.