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Improvement of product quality based on Taguchi method

Conference Paper · May 2009

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ModTech International Conference - New face of TMCR
Modern Technologies, Quality and Innovation - New face of TMCR
21-23th May 2009

IMPROVEMENT OF PRODUCT QUALITY BASED ON TAGUCHI METHOD

Nadia Belu1, Daniel-Constantin Anghel1, Ilarion Banu1 & Sorin Ilie2
1
University of Pitesti, Faculty of Mechanics and Technology, Technology and Management Department
2
University of Pitesti, Faculty of Mechanics and Technology, Automotive Department

Nadia Belu, [email protected]

Abstract: Quality has emerged as one of the major industrial studies in order to increase the quality of
competitive issues of the 1990s. As the competitive products with reduced costs. Generally, when a
pressure in today's global markets increases, the need for dispersion or an instability of the production
quality improvement is painfully evident to most company. characteristics of a product are detected, one
Taguchi methods have proved to be successful over the last
identifies and reduces or eliminates the causes that
years or so for the improvement of product quality and
process performance. This method combines the produced them. The ways to reduce or to eliminate
engineering techniques with statistical techniques in order these causes may be often very expensive.
to improve the quality costs through optimization of the Taguchi method works totally different: instead of
design of the product and of the manufacturing process. removing the disturbing factors, this method tries to
This paper presents the role of Taguchi methods in minimize the impact of them on the system, that is, a
continuous improvement of quality products. combination of system parameters (controlled
Key words: parameter optimization, quality improvement, factors) is looked for so that the system becomes
planning of experiments, Taguchi methods insensible to the disturbing factors. The seeking of
the good combination of system parameters
1. INTRODUCTION (controlled factors) in order to optimize the system so
that it becomes insensible to disturbing factors, is
Quality represents the set of characteristics of an experimentally performed with reduced costs (Alexis,
entity which confer it the ability to satisfy expressed 1999).
or implied needs. The implementation of robust Taguchi engineering
A low quality product, which doesn’t meet the keeps to Deming’s principle P-D-C-A (Demonsant,
customers’ requirements or which does not meet their 2007), figure 1.
level of expectation, will determine them to orientate The PDCA cycle involves four basic steps – Plan –
to the competitive products. This will bring losses for Do - Check and Act. These are:
the company. Plan – To identify and recognize a particular
The quality of a product must be carried out from the problem, select one for improvement and outline the
design stage of a product’s life cycle. Among the methods and solutions that can be taken to solve this
stages of a product’s life cycle, the design phase is problem;
considered a very important factor in achieving a Do – This stage involves testing the proposed
certain quality level. solution;
The level of product quality is established by means Check - An evaluation of the tests carried out;
of constructive technological solutions adopted by Act - An implementation of the proposed changes in
designer during the design stage. case the tests prove successful.
The studies revealed that the product design is
responsible for only 5% of a product's cost; it can,
however, determine 75% of all manufacturing costs
and 80% of a product's quality performance (Perrin
2001).
An important instrument used for quality assurance in
the design stage of product is Taguchi method. This
method is robust in the design or production stage, so
that manufacturers can produce higher quality
products at a lower cost and in less time.
The Taguchi method is used for more than 20 years
in the developed countries for experimental and Fig. 1. The four basic steps of PDCA cycle
For Taguchi method the Plan - Do - Check - Act Ev[+1] = Mv[+1] – M [dB] (2)
phase comprises the following steps (Demonsant, Erε [-1] = M rε [-1] – M [dB]
2007): Erε [+1] = M rε [+1] – M [dB]

1. Defining the project aim; with: M – average of aggregate tests.

2. Defining the system limits; The interactions were calculated with a relation
3. Defining the M entry signal, the y exit signal and (Alexis, 1999) like:
the ideal function;
4. Developing signal and noise strategies; I(t-s-) = (t-s-) - M - E(t-) - E(s-)
5. Defining the controlled factors and their levels; I(t+s-) = (t+s-) - M - E(t+) - E(s-)
6. Formulating the experiment and preparing for it; I(t-s+) = (t-s+) - M - E(t-) - E(s+)
7. Doing the experiment, collecting data; I(t+s+) = (t+s+) - M - E(t+)- E(s+)
8. Analyzing data; I(t-v-) = (t-v-) - M - E(t-) - E(v-)
9. Doing a confirmation experiment; I(t+v-) = (t+v-) - M - E(t+) - E(v-)
10. Documentation and implementation of the results; I(t-v+) = (t-v+) - M - E(t-) - E(v+) (3)
11. Planning the next steps. I(t+v+) = (t+v+) - M - E(t+)- E(v+)
I(s-v-) = (s-v-) - M - E(s-) - E(v-)
The paper analyzes the influence of the processing I(s+v-) = (s+v-) - M - E(s+) - E(v-)
parameters (cutting depth t, feed s, cutting speed v I(s-v+) = (s-v+) - M - E(s-) - E(v+)
and radius of the tool point rε) on the roughness Ra. I(s+v+) = (s+v+) - M - E(s+)- E(v+)
The test bars were made of Fgn 700-2 iron.
The analysis was done using an orthogonal 3. THE METHODS, TOOLS
experiments plan. AND REGIMES USED
There were emphasized significant parameters that
act on the processed surface quality. The measuring method was the direct one, using for
the measurement of the quality indexes an electronic
2. CONSIDERATIONS roughness tester (Surtronic 4, manufactured by Rank
ON THE EXPERIMENTS Taylor Hubson Limited).
The process was done using: parallel lathe (SN 400)
The study of possibilities for improving the quality of and lathe tool with exchangeable ceramic plates
surfaces processed by turning must be realized by CC670 (Al2O3+SiCW reinforced ceramic material,
experiments using orthogonal plane, according equal where the whiskers are randomly orientated within
chances for each parameter. the host material.
The planning of experiments relies on some CC670 is particularly well suited for machining heat
objectives: the experimental plan must provide the resistant super alloys and hardened materials),
proposed aim (obtain a better quality of the surface in manufactured by Sandvik Coromant company, with
the existent conditions), must provide a minimum the end cutting edge angles (-)χ1 = 15o, respectively
amount of experiments for minimum costs, and must (+)χ1 = 45o, radius of tool point (-)rε = 0,5 mm,
provide the traceability of the significant and non- respectively (+)rε = 3 mm.
significant influences of input variables (t, s, v, rε,) on
The regimes used were: cutting speeds (-)v = 82,896
the output values Ra.
m/min and (+)v = 103,62 m/min; cutting depths (-)t =
For this study we used the concept of quality surface
0,5 mm and (+)t =1,00 mm.
loss, using decision criteria that must be minimized
for the signal-to-noise ratio (Alexis, 1999). The test bars were made of Fgn 700-2, cast in the
For the signal-noise rate (Alexis, 1999) we used the same charge in order to have no structural and
relation: hardness differences after thermal treatment. The
hardness obtained after hardening treatment is 52 - 54
HRC. The bars’ diameter was 22 mm.
S/N = −10 ⋅ log(s 2 + y 2 ) [dB] (1)
4. ANALYSIS OF
with: s – mean square deviation of output values Ra, EXPERIMENTAL RESULTS
y - average of output values.
The effects were calculated with a relation (Alexis, In the analysis of the signal-to-noise ratio
1999) like: (input/output) we analyzed the influence of the
processing parameters cutting depth t, feed s, cutting
Et[-1] = Mt[-1] – M [dB] speed v and radius of the tool point rε on the
Et[+1] = Mt[+1] – M [dB] roughness Ra.
Es[-1] = Ms[-1] – M [dB] The results obtained by processing made for each
Es[+1] = Ms[+1] – M [dB] experiment are presented in Table 1.
Ev[-1] = Mv[-1] – M [dB]
Using this value we made the graphic of S/N ratio – Ra, presented in the figure 2.

Table 1. The experimental plan and measured values -Ra.

Controlled factors Interactions Measured values–Ra
t s= t v= t rε = Standard S/N
Exp. t s v rε Nr.1 Nr.2 Nr.3 Nr.4 Nr.5 Average deviadtion
v rε s rε sv [dB]
1 -1 -1 -1 -1 1 1 1 0.42 0.41 0.46 0.47 0.44 0.44 0.025495 7.11639
2 1 -1 -1 1 -1 -1 1 1.4 1.61 0.85 0.67 0.78 1.062 0.416137 -1.14282
3 -1 1 -1 1 -1 1 -1 1.81 2.03 2.59 2.04 1.79 2.052 0.322986 -6.34983
4 1 1 -1 -1 1 -1 -1 1.68 1.89 1.7 2.01 1.92 1.84 0.144049 -5.32289
5 -1 -1 1 1 1 -1 -1 2.48 1.91 2 1.77 1.94 2.02 0.270647 -6.1843
6 1 -1 1 -1 -1 1 -1 0.96 0.89 1.13 0.96 1.05 0.998 0.093113 -0.02025
7 -1 1 1 -1 -1 -1 1 1.78 1.79 1.5 1.83 1.62 1.704 0.139392 -4.65836
8 1 1 1 1 1 1 1 3.66 3.59 3.6 2.95 3.17 3.394 0.315801 -10.6517
The average of outputs 1,6887 -3,40172

10
8
7.1164
6
4
Ratio S/N_Ra

2
-0.0203
0
-2 1 2 3 4 5 6 7 8
-1.1428
-4 -4.6584
-6
-5.3229 -6.1843
-8 -6.3498
-10 -10.6517
-12
Experiment

Fig. 2. Graphic of S/N Ratio - Ra.

For the most used quality index Ra, there were The radius of the tool rε has no significant influence
presented both tabular and graphical the effects and on the quality index Ra.
interactions between the input and output parameters. In the graph presented in figure 4, we observe that the
In the graph presented in figure 3, we observe that the greatest influence on the signal-to-noise ratio is of the
greatest influence on the signal-to-noise ratio is of the s-v interactions then the t-v interactions and the t-s
feed s then the cutting speed v and the cutting depth t. interactions.

Table 3. - Effects of processing parameters

interactions - calculated values.
Table 2. Effects of processing parameters
on S/N Ratio - calculated values.
Nr. position of Effect on S/N ratio
experiment
Parameter S/N absolut S/N %
Effect on S/N ratio
Nr. position 1_5 t-s-= -0,358902097 10,55062
of experiment S/N 2_6 t+s-= 0,358902097 -10,5506
Parameter S/N %
absolut 3_7 t-s+= 0,358902097 -10,5506
1_3_5_7 t-= 0,882693 -25,9484 4_8 t+s+= -0,358902097 10,55062
2_4_6_8 t+= -0,88269 25,94844 1_3 t-v-= 0,925374876 -27,2032
1_2_5_6 s-= 3,343972 -98,3025 3_4 t+v-= -0,925374876 27,20317
3_4_7_8 s+= -3,34397 98,30247 5_7 t-v+= -0,925374876 27,20317
1_2_3_4 v-= 1,976928 -58,1156 6_8 t+v+= 0,925374876 -27,2032
5_6_7_8 v+= -1,97693 58,1156 1_2 s-v-= 1,067601773 -31,3842
1_4_7_8 rε-= 0,022584 -0,66389 3_4 s+v-= -1,067601773 31,3842
2_3_5_6 rε+= -0,02258 0,663886 5_6 s-v+= -1,067601773 31,3842
7_8 s+v+= 1,067601773 -31,3842
 4 3.3440

2 1.9769

Effects S/N-factors
1 0.8827
0.0226 -0.0226
0

-1 -0.8827

-2 -1.9769

-3 -3.3440

-4
E(t-)=

E(t+)=

E(s-)=

E(s+)=

E(v-)=

E(v+)=

E(rε-)=

E(rε-)=
Factors

Fig. 3. The effects of processing parameters (t, s, v, r, rε) on S/N ratio for Ra.

1.5

1 1.0676 1.0676
0.9254 0.9254
Effects S/N -interactions

0.5 0.3589 0.3589

-0.5 -0.3589
-0.3589

-1 -0.9254 -0.9254
-1.0676 -1.0676

-1.5
I(t-s-)=

I(t+s-)=

I(t-s+)=

I(t+s+)=

I(t-v-)=

I(t+v-)=

I(t-v+)=

I(t+v+)=

I(s-v-)=

I(s+v-)=

I(s-v+)=

I(s+v+)=

Interactions

Fig. 4. The effects of processing parameters (t, s, v, r, rε) interactions on S/N ratio for Ra.

5. CONCLUSIONS because it permits fast tracing of the inputs influence

with minimum costs.
From the analyze of the study we have done, the
conclusions are: 6. REFERENCES
- there must be done such experiments in order to
find out the input parameters that could determine the 1. Perrin, J., (2001). Concevoir l’innovation
quality surface loss during cutting of Fgn 700-2 iron; industrielle. Méthodologie de conception de
- radius of the tool rε has no significant influence on l’innovation, CNRS Editions, ISBN 2-271-05822-8,
quality loss, for all the output values; Paris
- interactions s-v and t-v determine quality loss so 2. Demonsant, J., (2007). Qualité totale et plans
they must be keep under observation in order to d’expériences. Revista Asigurarea CalităŃii, anul XIII,
reduce their cumulative influence; nr.52, pp.2-6, ISSN 1224 - 5410
Utilization of the experimental method in studying 3. Alexis, J. (1999). Metoda Taguchi în practica
the input parameters that determine quality loss is industrială -planuri de experienŃe, Editura Tehnică,
needed in the actual industrial development state, ISBN 973-31-1352-2, Bucureşti

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