Similar to previous study, [16] used C-Mold to explore the effect of four processing parameters and some interaction effects on shrinkage and warpage. Nevertheless, the optimal parameters setting has successfully improved the surface roughness to 6.89 and melt temperature was found to be the most significant factor affecting surface roughness followed by gas injection delay time. Moreover, the adjustments and modifications of processing parameters rely heavily on the experience and intuition of the moulding personnel [20]. Typically, injection moulding process is a cyclic process which consists of four significant phases: filling, cooling, packing, and ejection [3]. So, we can say that the Taguchi method makes a process which otherwise would have been complicated more easier and simpiler in nature to carryout. Neural network approach was coupled with Taguchi method in building a process model for quality control in injection moulding. H. Li, Z. Guo, and D. Li, Reducing the effects of weldlines on appearance of plastic products by Taguchi experimental method, International Journal of Advanced Manufacturing Technology, vol. 23, no. Last updated on Jul 1, 2023 The Taguchi method is a popular approach for quality optimization that aims to reduce the variation and defects in a product or process. Hence, the GRA was first proposed by [46] to optimize the multiresponse problem by making use of the grey relational coefficient and grey relational grade. Advantages and disadvantages of the Taguchi methodology The learning process will be supported by simple practical examples Certificates Wales Quality Centre Certificates will be provided for this training. For example, environmental engineers have used these methods to treat industrial resins found in wastewater from factories. In answer to this problem, many studies devised a new experiment design methodology that optimize multiple quality characteristics simultaneously while provide accurate results to the robust design of products and process by integrating Taguchi method with other techniques. Another study with similar aim, which was conducted by [15], also indicated that the optimal combination of processing parameters managed to reduce the warpage of the initial thin shell plastic model significantly by 51%. The Role of Taguchi Methods in Product Management & Innovation But is it their only option? A. L. Andrady and M. A. Neal, Applications and societal benefits of plastics, Philosophical Transaction of the Royal Society B, vol. Moreover, they may not take into account all aspects of quality such as reliability, durability, safety, and aesthetics that may be important for the customer or market. They include a series of tools and methods, such as orthogonal arrays, signal-to-noise ratios, parameter design, and tolerance design, that help to optimize the design of products and processes by reducing variability and increasing robustness. M.-C. Huang and C.-C. Tai, Effective factors in the warpage problem of an injection-molded part with a thin shell feature, Journal of Materials Processing Technology, vol. Many researchers have attempted various approaches in the determination of process parameters for injection moulding in order to obtain consistent quality of moulded parts. He wanted to eliminate extraneous parts and create a suction system that led to long-term product use. For the eBook edition, go to: http://ebooks.asmedigitalcollection.asme.org/book.aspx?bookid=325 The Taguchi method was developed by Dr. Genichi Taguchi of Japan who maintained that variation. Taguchi method is a robust statistical tool that allows the independent evaluation of the responses with minimum number of experiments. Taguchi's 3 Fundamental Concepts Accendo Reliability The Taguchi L8 OA was used for initial screening of seven processing variables with respect to their relative impact on the sink mark. In reality the application of statistical techniques and experimentation are not widely being used in the industrial organization. INTRODUCTION TO TAGUCHI METHOD - IIT Bombay In this article, you will learn about the benefits and challenges of using Taguchi methods for robust design in the context of quality control. Communication Preferences. Engineering managers use Taguchi methods to quickly filter possibilities for solutions to problems. J.-R. Shie, Optimization of injection-molding process for mechanical properties of polypropylene components via a generalized regression neural network, Polymers for Advanced Technologies, vol. The application of Taguchi method has attracted more attention in the literature for the past 20 years and nowadays the Taguchi method has been widely applied to various fields, such as manufacturing system [28], mechanical component design [29], and process optimization [30, 31]. ASME Membership (1 year) has been added to your cart. Some Artificial Intelligence (AI) techniques such as ANN and GA are emerging as the new approaches in the optimization of processing parameters for injection moulding. What are the benefits of the Taguchi method? The process iterated until a maximum number of generations that has been produced, or an optimum or near optimum parameter setting is found. Another disadvantage of these methods is their limited impact on the entire production cycle. 7, pp. {{activeProduct.CurrencySymbol}}{{ formatPrice(activeProduct.ListPrice) }} Strengths and limitations of taguchi's contributions to quality Graduate Diploma in Engineering Management, Executive Master of Health Administration. Taguchi argued for off-line design and testing processes that improves quality from product 1 to product 1,000,000. Taguchi methods are beneficial in many circumstances but engineers should be aware of both their advantages and disadvantages. Practical Applications of Taguchi Method for Optimization of - Hindawi This problem has been alleviated by integrating Taguchi method with the numerical simulation to reduce the simulation experiments and analyze the results towards the optimization. However, there are some contradictions occurring in ANOVA indicating that all the interaction effects excluding the interaction of packing pressure and injection speed for 19, 2001. Y. K. Shen, J. J. Liu, C. T. Chang, and C. Y. Chiu, Comparison of the results for semisolid and plastic injection molding process, International Communications in Heat and Mass Transfer, vol. Any team can use the acronyms prompts to identify needs fulfilled by a future project: Engineering teams spend considerable time envisioning how project plans can be fully realized. Each neuron receives total input from all of the neurons in the preceding layer and processes the input through an activation function in order to produce its output to the following layer. Although the implementations of GRA and PCA are different, both techniques have a similarity in which the response variables are uncorrelated and hence no engineering judgement is involved during the multi-response optimization. What are the benefits and challenges of integrating QFD and FMEA in lean operations? 299305, 2008. 221227, 2004. 42, no. Research: Will the end product be useful, original, and attractive? 11-12, pp. This method also has other advantages, such as . In addition, the optimal parameters setting was not limited to only specified levels of factors but can be at any point within the level range. The layers include processing units known as neurons. As a result, Taguchi method is considered to be an important approach to minimize performance variation and hence, the interest in the literature of Taguchi method continues to grow. With the similar integration method, [54] performed experiments on four common polymers (PP, PC, PS, and POM), comparing the effects that moulding process parameters had on their degree of warpage formation, pressure distribution, temperature distribution, and fill time of the parts. Why is a Masters in Engineering Management Worth It? 7, pp. Subsequently, the same data was analyzed applying Taguchi's L9 orthogonal array. Y. C. Lam, L. Y. Zhai, K. Tai, and S. C. Fok, An evolutionary approach for cooling system optimization in plastic injection moulding, International Journal of Production Research, vol. 171, no. By answering these questions, you can use the Taguchi method as a tool to optimize the quality of your product or process and achieve process efficiency. Taguchis work focused on creating target values and stripping away obstacles to those values. Liu and J.-H. Chang, Application of the Taguchi method to optimize the surface quality of gas assist injection molded composites, Journal of Reinforced Plastics and Composites, vol. Blog: Project Management Trends for Engineering Managers. 599604, 2010. It consists of several functional elements that can provide the necessary contribution needed to enhance the optimization implementation. 3, pp. How do you manage quality changes and innovations? The Taguchi method is used mostly in the optimization of single quality characteristic. -axis by manipulating four processing parameters, including mould temperature, melt temperature, packing pressure, and packing time via MoldFlow software and applied Taguchi method to analyze the simulation results. 445454, 2004. The simulation results showed that the part thickness is the most significant parameter to the moulding of ultra-thin wall plastic parts where increasing part thickness can make a rapid increase in the filling ratio. In this article, you will learn about the benefits and limitations of using the Taguchi method for quality optimization. 1, pp. 769777, 2006. This button displays the currently selected search type. 303314, 2011. Grey relational analysis (GRA) was developed by Deng Julong of Huazhong University of Science and Technology.It is one of the most widely used models of grey system theory. Taguchi methods are beneficial in many circumstances but engineers should be aware of both their advantages and disadvantages. The section will conclude with a listing of some useful orthogonal three-level and mixed-level designs (a few of the so-called Taguchi "L" orthogonal array designs), and a brief discussion of their benefits and disadvantages. The analyzing step involves using statistical methods to evaluate the results and determine the optimal levels of the factors that minimize the variation and defects. Nevertheless, the growing demand in industry for expert moulding personnel far exceeds the supply and it needs more than 10 years experiences for an amateur moulding personnel to become an expert [21]. Published in: SAIEE Africa Research Journal ( Volume: 108 . Nevertheless, tremendous efforts are still required to find optimal parameters setting due to horde of simulation analyses without a systematic design of experiments. Learn from the communitys knowledge. Taguchi Robust Design and Loss Function - Six Sigma Study Guide Robustness is also a keyfocus of the Taguchi approach. The Taguchi method is a great tool for quality optimization, as it reduces the cost and time of experimentation, improves the performance and reliability of the product or process, and enhances customer satisfaction and loyalty. The disadvantages of the Taguchi Method include the fact that factor interactions are normally not accounted for, there are zero degrees of freedom if all of the possible factors are used, and randomization is normally not used to prevent environmental biasing. S. Datta, A. Bandyopadhyay, and P. K. Pal, Grey-based taguchi method for optimization of bead geometry in submerged arc bead-on-plate welding, International Journal of Advanced Manufacturing Technology, vol. The expert author describes how to conduct robust technology development in a time- and cost-efficient manner, as originated by Dr. Taguchi in the early 1990s, and includes all aspects for the development of robust technology and robust products: quality philosophy, quality strategies/planning, management and organization, robust design methods/tools, and real-life case studies from industry. Strengths and Limitations of Taguchi's Contributions to Quality 3, pp. 3, pp. The popularity of Taguchi method is due to its practicality in designing high quality systems that provide much-reduced . The former study focused on the concurrent improvement of yield stress and elongation of PC/ABS blend whereas the latter study examined the effect of processing parameters on the mechanical and tribological properties of PC composites, including ultimate stress, surface roughness, and friction coefficient. Product managers and engineers should become familiar with: The Taguchi loss function is a formula for calculating the impacts of product flaws on society. Copyright 2013 Ng Chin Fei et al. How do you cope with the changes or revisions in quality control standards and guidelines over time? Generally, the processing parameters involved in injection moulding can be grouped into four basic categories: temperature, pressure, time, and distance [6]. On the other hand, GRA and PCA are widely integrated with the Taguchi method to tackle the multiresponse problems. Figures 1, 2 and 3 are from that source. As noted by [4], there are many factors contributing to the occurrence of defects that affect the quality of injection-moulded parts during the production. this study, three design parameters were selected with three levels each. B. Ozcelik and I. Sonat, Warpage and structural analysis of thin shell plastic in the plastic injection molding, Materials and Design, vol. S. Dowlatshahi, An application of design of experiments for optimization of plastic injection molding processes, Journal of Manufacturing Technology Management, vol. When expanded it provides a list of search options that will switch the search inputs to match the current selection. Typical numerical simulation models are developed and based on the finite element method for solving pressure, flow, and temperature fields. It reduces the variability of the product and thus makes it robust. Finally, it may not address root causes or sources of variation and defects, which could require further investigation and improvement. R. S. Rao, C. G. Kumar, R. S. Prakasham, and P. J. Hobbs, The Taguchi methodology as a statistical tool for biotechnological applications: a critical appraisal, Biotechnology Journal, vol. ANOVA was utilized to exclude the insignificant process parameters in the prediction of neural network system to skip the vain analysis on those trivial factors. Taguchi method is a technique widely used in industries to attain a reliable quality even under existence of various noise variables. His goal was to achieve consistent quality by minimizing external impacts on the production process. H. Singh and P. Kumar, Optimizing cutting force for turned parts by Taguchi's parameter design approach, The Indian Journal of Engineering and Materials Sciences, vol. C.-F. J. Kuo and T.-L. Su, Optimization of injection molding processing parameters for LCD light-guide plates, Journal of Materials Engineering and Performance, vol. Taguchi methods offer several benefits for quality control and improvement, such as efficient and systematic experimentation with multiple factors and levels, using orthogonal arrays to reduce the number of trials needed. 29, no. His namesake methods provide actionable recommendations for engineering managers and project stakeholders. 510523, 2008. There was an argument in the paper where the response values of A3B3C2D3E2F1G3 were conflicting to the calculation in Taguchi method wherein the actual optimal setting supposed to be A3B1C3D1E3F3G2. However, it is very costly and time-consuming [24]. Taguchi, an engineer at Japanese company NTT, re-examined engineering orthodoxy to maximize quality while minimizing costs. There are three components of Taguchi methods that must work in concert to achieve higher product quality. The following checklist is used for engineering projects around the world: These six points provide guidance while allowing for creativity by engineers and their managers. 29252931, 2010. Like or react to bring the conversation to your network. You can update your choices at any time in your settings. Taguchi methods are used by engineers and product managers around the world because product quality is a global concern. Despite of virtual modifications on part and mould designs, numerical simulation can be very useful especially when some quality characteristics involved in the study were difficult to be measured in real practice as the injection moulding is a continuous process from filling to post filling stage. 6, no. 3-4, pp. 1, pp. In this study, multiple quality characteristics such as elasticity module, tensile strength at yield, tensile strain at yield, tensile strain at break, flexural modules, and Izod impact strength were analyzed individually via the main effects for both mould materials. The features, advantages, and connection of these approaches are reviewed in this research. Standalone Taguchi method is adopting the Taguchis elements single-handedly from the experimental designing stage to the final optimization process. Crossover involves splitting two chromosomes and then combining one half of each chromosome with the other pair. During injection moulding process, the material selection, part and mould designs, and the processing parameters interact to determine the quality of plastic product [5]. It employs orthogonal arrays for experimental design and / ratio instead of responses itself to determine the optimum settings of control fac- A number of research works based on standalone Taguchi method and the integration of Taguchi method with various approaches, including numerical simulation, grey relational analysis (GRA), principal component analysis (PCA), artificial neural network (ANN), and genetic algorithm (GA), have been discussed. Systems, parameter, and tolerance design are best handled away from the production line. While KM does have a social dimension to it knowledge sharing creation acquisiti by, Name , I like what you said about the importance of developing a business vision statement otherwise by 9-10, pp. PROS AND CONS OF TAGUCHI: Quality Engineering: Vol 3, No 4 To proceed with either the BSN to MSN FNP or the BSN to DNP FNP, you are required to have a bachelors degree and hold your RN license. What are the best practices and tools for designing and testing DNA origami structures? Lastly, implement and monitor the design by implementing optimal design in production process, monitoring performance and quality over time, and making adjustments as needed. 30, no. Therefore, the effectiveness and reliability of the integration of Taguchi method and GRA are highly doubted and further validation of the optimization results is needed. by encouraging the exploration of different factors and interactions. J. Zhao, R. H. Mayes, G. Chen, H. Xie, and P. S. Chan, Effects of process parameters on the micro molding process, Polymer Engineering and Science, vol. ), reduce the competitive price advantage, and decrease the companys profitability. Furthermore, Taguchi methods may not capture all sources of variation and noise in a system as they focus on a limited number of factors and levels, while ignoring interactions and synergies among them. 36, no. Reference [51] studied the significance of process parameters concerning multiple quality characteristics by employing ANOVA in the application of grey-fuzzy logic on the optimal process design. The quality characteristics can be predicted via the simulation packages, including the prediction of weld-line location, shrinkage with different flow direction, and temperature gradient. Dates This Taguchi Design of Experiments training can also be delivered in house contact us for details. K.-M. Tsai, C.-Y. 3-4, pp. How do you identify and prioritize the critical to quality (CTQ) factors in your processes? This is what Taguchi is saying too. OA provides a set of well-balanced (minimum experimental runs) experiments and Taguchis As an engineer, Taguchi sought a durable and versatile method for improving production processes. B. Ozcelik and T. Erzurumlu, Comparison of the warpage optimization in the plastic injection molding using ANOVA, neural network model and genetic algorithm, Journal of Materials Processing Technology, vol. Existing production data and specifications can be processed through orthogonal arrays without gathering additional information. 1322, 2010. 32, no. 146, no. 656661, 2003. Nevertheless, there are still two obvious shortcomings in performing the Taguchi method single-handedly. 7, pp. I have an engineering (or equivalent) bachelors degree and at least two years of engineering experience.

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