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Taguchi Robust Design for Optimal Setting of Process Wastes Parameters in an Automotive Parts Manufacturing Company
Abstract:
As a technique that reduces variation in a product by lessening the sensitivity of the design to sources of variation, rather than by controlling their sources, Taguchi Robust Design entails the designing of ideal goods, by developing a product that has minimal variance in its characteristics and also meets the desired exact performance. This paper examined the concept of the manufacturing approach and its application to brake pad product of an automotive parts manufacturing company. Although the firm claimed that only defects, excess inventory, and over-production were the few wastes that grossly affect their productivity and profitability, a careful study and analysis of their manufacturing processes with the application of Single Minute Exchange of Dies (SMED) tool showed that the waste of waiting is the fourth waste that bedevils the firm. The selection of the Taguchi L9 orthogonal array which is based on the four parameters and the three levels of variation for each parameter revealed that with a range of 2.17, that waiting is the major waste that the company must reduce in order to continue to be viable. Also, to enhance the company’s throughput and profitability, the wastes of over-production, excess inventory, and defects with ranges of 2.01, 1.46, and 0.82, ranking second, third, and fourth respectively must also be reduced to the barest minimum. After proposing -33.84 as the highest optimum Signal-to-Noise ratio to be maintained for the waste of waiting, the paper advocated for the adoption of all the tools and techniques of Lean Production System (LPS), and Continuous Improvement (CI), and concluded by recommending SMED in order to drastically reduce set up time which leads to unnecessary waiting.
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References:

[1] Ihueze, C., Okpala, C., Okafor, C., Ogbobe, P. (2013), “Robust Design and Optimization of Production Wastes: An Application for Industries” World Academy of Science Engineering and Technology vol. 7, no. 4.
[2] Maurer, K. and Lau, S. (2000), “Robust Design” (Online). Assessed on 24 May 2018, from http://www.public.iastate.edu/~vardeman/IE361/s00mini/maurer.htm.
[3] Ibrahim, S., Ahmed, S., and Hameed, I. (2016), “Evaluated of Mechanical Properties for Aluminum Alloy Using Taguchi Method” International Journal of Modern Studies in Mechanical Engineering, vol. 2, iss. 1.
[4] Billamoria, M. (2014), “What is Robust Design” (Online), Assessed on 15 May 2018, from https://www.anovatm.com/what-is-robust-design/.
[5] Ihueze, C. and Okpala, C. (2012), “Application of Taguchi Robust Design as Optimized Lean Production System in Manufacturing Companies” Research Journal of Engineering and Applied Sciences. Vol. 1, Iss. 1.
[6] Tsui, K. (2010), “A Critical Look at Taguchi’s Modelling Approach for Robust Design” Journal of Applied Statistics. Vol. 23, Iss. 1.
[7] Okpala, C. (2013a), “The World’s Best Practice in Manufacturing” International Journal of Engineering Research and Technology. Vol. 2, 1ss. 10.
[8] Ihueze, C. and Okpala, C. (2014), “The Tools and Techniques of Lean Production System of Manufacturing” International Journal of Advanced Engineering Technology. Vol. 5. Iss. 6.
[9] Shingo, S. (1985), “A Revolution in Manufacturing: The SMED System” Productivity Inc. USA.
[10] Okpala, C. (2013b), “The Status of Lean Manufacturing Initiatives in the UK Small and Medium-Sized Enterprises – A Survey” International Journal of Engineering Research and Technology. Vol. 2, Iss. 10.
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