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T5.Taguchi Approach To Quality Engineering

The document discusses Genichi Taguchi's approach to quality engineering, which focuses on designing quality into a product through robust design and parameter design rather than inspecting quality in. It introduces Taguchi's use of loss functions and experimental design methods to optimize products and processes to be less sensitive to variation. Taguchi's approach aims to produce high quality, low-cost products that satisfy customers with lower development and manufacturing costs.

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88 views

T5.Taguchi Approach To Quality Engineering

The document discusses Genichi Taguchi's approach to quality engineering, which focuses on designing quality into a product through robust design and parameter design rather than inspecting quality in. It introduces Taguchi's use of loss functions and experimental design methods to optimize products and processes to be less sensitive to variation. Taguchi's approach aims to produce high quality, low-cost products that satisfy customers with lower development and manufacturing costs.

Uploaded by

Al Aiden
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Principles of Quality Engineering in

Design and Manufacturing – Part II

Taguchi Approach to Quality


Engineering

Genichi Taguchi
Taguchi Approach to Quality
Engineering

 Quality engineering is an interdisciplinary science


which is concerned with not only producing
satisfactory products for customers but also
reducing the total loss.
 Deming observed that 85% of poor quality is attributed to
the manufacturing process for which managers are
responsible, and only 15% to the workers.
 Similarly, Taguchi states that product and process
design have a much greater impact on product
quality than manufacturing and inspection. Quality
should be designed into the product and not
inspected into it.
GENICHI TAGUCHI
 Born in Japan, 1924

 Electrical Engineer

 Worked during 1950’s to improve


Japan’s post-WWII telephone
communication system

 Father of the “Taguchi Method” and


“Robust Engineering”
Taguchi Method
 Robust design / Design of Experiments
 improving design quality
 Robust design is an engineering methodology for
optimizing the product and process conditions
 which are minimally sensitive to the various
causes of variation,
 and which produce high-quality products with low
development and manufacturing costs.
 Improving manufacturing processes to make
a quality product
Taguchi Method
To consider quality implications during design, the design process can be
segmented into three stages.
1.The first stage, system design:
Establishes the functionality of the product, the physical product envelope, and
general specifications.
2.The second stage, parameter design:
Establishes specific values for design parameters related to physical and
functional specifications.
It is during these first two stages that the designer has the greatest opportunity
to reduce product costs through effective functional design and parameter
specification.
3.The third stage, tolerance design:
Establishes the acceptable tolerances around each parameter or target.
The third stage typically will add costs to the product through efforts to ensure
compliance with the tolerances associated with product parameters.
Robust Engineering

“To compete successfully in the global


marketplace, organizations must have the
ability to produce a variety of high-quality,
low-cost products that fully satisfy
customers’ needs.”
Basic Ideas:
 CUSTOMER SATISFACTION
 Design to the highest standards early in the
process to eliminate all non-random errors
 Quality Loss = Loss to Society quantified
through “Quality Loss Function”
 Variation (+/-) from optimal measure results
in a loss.
 For best results, GET HELP.
Resources Expended on Quality

Cost VS Quality Triangle


How to measure
quality?
Customer Satisfaction

 Ways to measure service:

1. Returning customers

2. Number of complaints (1:10)

3. Number of compliments

4. Employee attitude
Genichi Taguchi

TAGUCHI’S
QUALITY
LOSS
FUNCTION
Taguchi Loss Function Definition

 Taguchi defines Quality as “the loss imparted


by the product to society from the time the
product is shipped.”
 LOSS = Cost to operate, Failure to function,
maintenance and repair cost, customer
satisfaction, poor design.
 Product to be produced “being within
specification”
Taguchi’s Vs Traditional Approach

Taguchi’s Traditional
When a product There is Good or Bad
moves from its Target Products only as per
will cause the loss Limits
even if the product
lies or not within
Limits
Quality Loss Concept

 Deviation from
target results in
loss.
 Lower than target

 Greater than
target

 Both lose
Taguchi’s Quadratic Quality Loss
Function

 Quality Loss Occurs when a product’s


deviates from target or nominal value.
 Deviation Grows, then Loss increases.
 Taguchi’s U-shaped loss Function Curve.
Taguchi’s U-shaped loss Function
Curve.

Taguchi loss Fn

Scrap or Rework Cost.

Loss

Measured
characteristic

LTL Nominal UTL


Formula to find Taguchi’s Loss Fn
 Taguchi uses Quadratic Equation to determine
loss Curve.
 It can be expressed as:
L(y) = k(y-m)2
L(y) = Loss function
k = proportionality constant
= Loss associated with sp limit / (tolerance)2
y = reported value
m = mean value (average)
(y-m) = Deviation of specification from target value
Example
 Company C received an average of 10 complaints
per month last year. In November they received 15
complaints (y). Management sets an acceptable
level at 2 (tolerance).

 It costs the company $50 directly per complaint to


correct the problems. They determined the cost in
lost sales to be $100.

 Total cost per complaint: $150


Example continued:

k = C/T²
= $150/22
= $37.50

L(y) = k(y-m)2
= 37.50 (15-10)2
= $937.50 is loss for the month of November
Quality Loss Function II
The equation of the lost function can be
further simplified to become:
L(y) = kv2

L(y) = Loss
k = C/T²
v = mean squared deviation from target m
Example
Quality Loss Function Based on
the Number of Measurement
 When the deviation of a product is not given in terms of
an average where the data of the measurements are
being given instead; the mean squared deviation has to
be estimated using the available data as follows:

^2
v 
1

y  m  
2
 y  m
2

 ......... y
where nnis the number of measurements available,
1 2 n
 m 
2

 and yi
is the value of the measurement i.
Example
A manufacturer of ball bearings used in gas turbines requires that
tolerance of the diameter of each ball be as follow:
Tolerance of diameter m 0.6 μm
where m is the target value of the diameter. The production rate is
80,000 balls per day at a cost of RM 0.30 per ball. Defective balls
cannot be reworked and are scrapped. The following deviations from
the diameter target value were recorded.
Deviations from the target diameter (μm):
0.3 0.0 -0.1 0.0 0.3 0.2 0.1 -0.2 0.6 0.4
-0.2 0.1 0.0 -0.4 0.5 0.4 -0.2 0.0 0.0 0.2
Based on the diameter measurements recorded above, determine
the expected losses caused by deviations.
Solution
C = RM 0.30
T = 0.6
^2
v 
1
20
 2 2 2

 0.3   0.0  .    0.1 ........  0.2  0.075
2

The quality level of the diameter of the balls, as


measured by the loss function, is:

0.30
L  0.075  RM 0.0625 per unit
 0.6 2
Example
A manufacturer of gauge blocks requires that the blocks meet
specified length between the ends of each block. The loss caused by
unacceptable length is RM20. The specifications of a 25 mm block is
as follows:

Length: 25.00000 0.00250 mm



The following length measurements were taken:
25.00025 25.00050 24.99975 24.99988 25.00025
25.00013 25.00050 25.00000 24.99995 24.99975

What is the expected loss caused by deviations?

C = RM20; T = 0.00250 mm; v2 = 78.38x10-9; L = RM 0.25


Exploring the Taguchi Method

Considering the Loss Function, it is quantifiable


 Larger is Better:  
L( y )  k  1
 y 2


 Smaller is Better: L( y )  ky 2

L( y )  k  y  m 
2

 Nominal is Best:
where :
m is the target of the
process specification
Conclusion:

 Best improvement is early in the


process.
 Use expert consulting help for full
experiment and implementation.
 Successfully used in airlines,
insurance, hotels and restaurants.
 Quality is a major feature that sets a
service apart from the rest.
Citations:
 Foster, S. Thomas Jr. Ph. D.: “Designing and
Initiating A Taguchi Experiment in a Services
Setting” OM Review – Refereed: Volume 9, No. 3.

 Taguchi, Genichi: Taguchi on Robust Technology


Development: Bringing Quality Engineering
Upstream; Asme Press, New York, 1993

 Taguchi, Chowdhury, Taguchi: Robust


Engineering: Learn how to boost quality while
reducing costs and time to market; McGraw-Hill,
New York, 2000
Recommended Reading:
 In addition to cited works:
 Visit American Supply Institute (ASI)
website at www.amsup.com

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