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Title: Technology/Quality Engineering - Design Of Experiments, Quality Control And Taguchi Methods A brief, college-level introduction to the Design of Experiments.
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Chp. 7: Design Of Experiments, Qc And Taguchi Methods

DESIGN OF EXPERIMENTS, QC AND TAGUCHI METHODS

Now, more than ever before, processing costs and problems ofrepeatability can stall new composite programs right at the profitline. Marginal improvements in the control of composites manufacturingprocesses, although useful in the short term, will not provide theneeded levels of quality, reliability, or economy of production. Figure7.13 depicts the shift in approaches used toensure product quality as a function of time. Taguchi methods belong tothe class of approaches that attempt to ensure quality through design,in this case through the identification and control of criticalvariables (or noises) that cause deviations to occur in theprocess/product quality.Taguchi methods, developed by Dr. Genichi Taguchi, refer totechniques of quality engineering that embody both statistical processcontrol (SPC) and new quality related management techniques. Most ofthe attention and discussion on Taguchi methods has been focused on thestatistical aspects of the procedure; it is the conceptual framework ofa methodology for quality improvement and process robustness that needsto be emphasized. The entire concept can be described in two basicideas:Quality should be measured by the deviation from a specified targetvalue, rather than by conformance to preset tolerance limitsQuality cannot be ensured through inspection and rework, but mustbe built in through the appropriate design of the process andproduct Figure 7.13. The Evolution of Quality ControlThe first concept underlines the basic difference between Taguchimethods and the SPC methodology. Whereas SPC methods emphasize theattainment of an attribute within a tolerance range and are used tocheck product/process quality, Taguchi methods emphasize the attainmentof the specified target value and the elimination of variation (Figure7.14). In conjunction with the second concept,this assumes great significance for composites manufacturing sinceTaguchi methods emphasize that control factors must be optimized tomake them insensitive to manufacturing transients through design,rather than by trial and error. SPC allows for faults and defects to beeliminated (if detected) after manufacture, whereas what is reallyneeded is a methodology that prevents their occurrence. In this case,the methodology is the use of Taguchi methods. This then presents apowerful tool for composites processing within which there is aninherent variability due to raw material quality and/or noise in theprocess environment itself.Through the proper design of a system, the process can be madeinsensitive to variations, thus avoiding the costly eventualities ofrejection and/or rework. In order to determine and subsequentlyminimize the effect of factors that cause variation, the design cycleis divided into three phases of System Design, Parameter Design, andTolerance Design, as depicted in Figure 7.15. Figure 7.14. A Comparison of Methodologies Figure 7.15. Stages in the Design CycleIt should be mentioned that the application of Taguchi methods toplastics and composites processing has been attempted by a number ofinvestigators (Warner and O'Connor 1989; Steele et al. 1988; Dockum etal. 1990; Karbhari et al. 1992; Slotte 1992). These includeapplications in the areas of injection molding and compression molding,as well as in structural reaction injection molding (SRIM) and RTM.
 

A

brief,

college-level

introduction

to

the

Design

of

Experiments.

http://itri.loyola.edu/polymers/c7_s6.htm

Design Of Experiments, Quality Control And Taguchi Methods 2008 November

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A brief, college-level introduction to the Design of Experiments.

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