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INTRODUCTION TOROBUST

ENGINEERING

OBJECTIVE1. To introduce the concepts of Robust Engineeringand initiate the RE initiative

2. To initiate the awareness of RE in productsdevelopment and manufacturing processes inparticipant’s company.

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THE OUTCOME OF THECOURSE IS AS FOLLOWS:

Participant will understand the conceptand philosophy of RE.

Participants will be able to initiate theRE projects by formulate 8 RE steps inresearch

PROF DR GENICHI TAGUCHI 1924-2012

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INTRODUCTION

Robust Engineering also called the Taguchi Method

Not Design of Experiment

Interaction????

• Control factor?• Noise?????

IMPORTANT!!!ROBUST ENGINEERING

• Interested only interaction betweenCONTROL FACTOR TO NOISE FACTOR ONLY!!!

NOT…

CONTROL FACTOR TO CONTROL FACTOR

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NOISE FACTOR1. environmental variation during the product’s usage,2. manufacturing variation, and3. component deterioration

Optimizing the energy function

Result: optimum ideal function which is the outcome of thedesign or processes.

Will enhance the basic and performance need of customers

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MINIMIZED THE COST OF FAILUREIN THE MARKET

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“QUALITY”?1. Customer Quality

• Styling, features, color etc2. Engineered

• Performance, Quietness, Clear Imaging, Handline etc

“THE ENGINEERED QUALITY OF APRODUCT IS ASSESSED BY

ESTIMATING THE LOSS IMPARTEDBY THE PRODUCT TO THE SOCIETY

FROM THE TIME THE PRODUCT ISSHIPPED”.

GENICHI TAGUCHI

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The Taguchi Approach is aimed atminimizing variation in product andprocess performance and thereby

achieves continuous quality improvementof products and processes.

SOME OF THE TYPICALAPPLICATIONS OF THETAGUCHI METHOD:Minimizing the defects on a steel strip that has beenelectrolytically coated with a tin based coating;

Optimize the production process of retaining a metal ring in aplastic body in a braking system;

Investigate an over-adjustment problem in a braking system;

Improve the weld strength of an electrolytic welding processin the joining of steel coils;

Optimization of a spot welding process;

Improve the resistance of conductive plastic tracks.

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OBJECTIVES OFTAGUCHI'S PARAMETERDESIGNMaking products and processes insensitive to environmentalvariations

(e.g. humidity, ambient temperature, dust, electrical supplyvoltage);

Making product and processes insensitive to manufacturingvariations or imperfections;

Making products insensitive to product deterioration(reliability degradation, tool wear, etc.); and

Making products insensitive to unit-to-unit variations(component-to-component variation, shift-to-shift variations,machine-to-machine variations, material-to-material variationand so on).

CONTINUE…The product can be made robust to changes in operating andenvironmental conditions.

Since the method is applied in a systematic way at a pre-production stage (off-line), it can greatly reduce the numberof time-consuming tests, thus saving in costs and wastedproducts.

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DON’T RUN AWAY!

Not a mathematician?

You can still successfully apply TaguchiMethod concepts to your service business.

Basic concepts are simple.

QUALITY DEFINED

“Any engineered system reaches its ‘ideal function’ when allof its applied energy (input) is transformed efficiently intocreating desired output energy.”

Employee energy = inputCustomer satisfied = output

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RESOURCES EXPENDEDON QUALITY

$Design

$$Service Delivered

$$$$$$$$$$Post Service Delivery

WHICH ONE IS IMPORTANT?MONEY OR QUALITY???

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CUSTOMER SATISFACTION

Ways to measure service:

1. Returning customers

2. Number of complaints (1:10)

3. Number of compliments

4. Employee attitude

DESIGN

Equipment – No breakdowns

Specific jobs defined – Need to knowresponsibilities

Policies and Procedures – What do youwant, anyway?

Taguchi Method experiment

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