Taguchi DOE

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STATEMENT OF THE PROBLEM
A problem can be viewed as any difference that exists between an ideal situation and the actual situation. Process Steps Collect the data that characterize the problem as it occurs Describe how the problem is observed Determine when the problem occurs Describe the severity and extent of the problem Describe where the problem occurs Write down the problem statement

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TAGUCHI METHODS
STATEMENT OF THE OBJECTIVE
The experimental objective provides exit criteria for the experiment; Determine when the experimental process should be stopped and other, more important problems are addressed. Process Steps Gather competitive benchmark information concerning the problem Gather customer information concerning the problem Define what deliverables will be achieved after running the experiment

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TAGUCHI METHODS
QUALITY CHARACTERISTICS
A QUALITY CHARACTERISTICS is the object of interest of a product or process. It may also be called a functional characteristic. Process Steps Determination Determination Determination Determination of of of of the the the the quality characteristic(s) to measure appropriate measurement system(s) people who will do the measurements method for measuring

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Notes on Quality Characteristics Multiple quality characteristics may be evaluated in the same experiment. Each of the characteristics will require a separate analysis of results or an overall analysis. Prior to experimentation, it is recommended to perform a measurement system repeatability and reproducibility to understand the measurement system contribution. This applies to both types of data attribute or variable. Whenever possible, convert attribute data to a variable data. If necessary, use semivariable (or multiple classes of attribute) data.

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FACTOR SELECTION AND LEVELS 1. Process Steps 1. Select the factors that may influence the selected quality characteristic(s) 2. Identify control and noise factors 3. Select levels for the factors

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Classification of Factors
A number of other factors can influence the quality characteristic (response variable) of a product, as shown in the figure below.

NOISE FACTORS

SIGNAL FACTORS (M)

f (X, M, Z, R)

RESPONSE (y)

CONTROL FACTORS (Z)

SCALING FACTORS (R )

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ORTHOGONAL ARRAYS SELECTION AND FACTOR ASSIGNMENTS Process Steps Determine the number of control and noise factors Determine the number of levels for the specific factors Determine the experimental resolution desired Select interaction that may influence the selected quality characteristics Select Orthogonal Array . Determine columns for interactions Assign factors or interaction on the orthogonal array

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ORTHOGONAL ARRAYS AND MATRIX EXPERIMENTS
A matrix is an array of numbers that have a special meaning. A matrix experiment consists of a set of experiments where the factors and levels are changed according to the matrix. These factors and levels are typically the settings of the various process or product parameters we wish to study. Conducting matrix experiments using special matrices, called orthogonal arrays, allows the effects of -several parameters to be determined efficiently and is an important technique in Robust design. OAs were a mathematical invention recorded as early as 1897 by Jacques Hadamard, a French mathematician. After World War II, British statisticians Plackett and Burman explored the utilities of orthogonal arrays Taguchi matrices are identical mathematically with Hadamard matrices; the column and rows are rearranged.

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a. One-Factor Ex periment
TRIAL NO. 1 2 FACTOR LEVEL 1 2 TEST RESULTS ** **

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b. Several Factors, One at a Time

TRIAL NO. 1 2 4 4 5 FACTOR LEVEL A 1 2 1 1 1 B 1 1 2 1 1 C 1 1 1 2 1 D 1 1 1 1 2 TEST RESULTS ** ** ** ** **

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c. Several Factors, All at the Sam e Tim e

TRIAL NO. 1 2 FACTOR LEVEL A 1 2 B 1 2 C 1 2 D 1 2 TEST RESULTS ** **

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a. One-Factor Ex periment
TRIAL NO. 1 2 FACTOR LEVEL 1 2 TEST RESULTS ** **

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TAGUCHI METHODS

a. One-Factor Ex periment
TRIAL NO. 1 2 FACTOR LEVEL 1 2 TEST RESULTS ** **

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a. Full Factorial Experiment

TRIAL NO. 1 2 3 4 FACTOR LEVEL A 1 1 2 2 B 1 2 1 2 y data 76 78 77 78 73 74 79 80

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Exam ple of Full Factorial Experim ent Factor A Lime content B Granularity C Agalmatolite D Agalmatolite type E Charge quantity F Waste return G Feldspar content Level 1 A1 5% B1 coarse C1 43% D1 current mixture E1 1300 kg F1 0% G1 0%
A2 1% B2 fine C2 53% D2 cheaper mixture E2 1200 kg F2 4% G2 55

Level 2

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A1 B1 B2 B1

A2 B2

C1 C2 C1 C2 C1 C2 C1 C2 D1 D2 D1 D2 D1 D2 D1 D2 D1 D2 D1 D2 D1 D2 D1 D2 F1 E1 F2 F1 E2 F2 G1 G2 G1 G2 G1 G2 G1 G2

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A1 B1 B2 B1

A2 B2

C1 C2 C1 C2 C1 C2 C1 C2 D1 D2 D1 D2 D1 D2 D1 D2 D1 D2 D1 D2 D1 D2 D1 D2 F1 E1 F2 F1 E2 F2 G1 G2 G1 G2 G1 G2 G1 G2 1/2 FFE

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A1 B1 B2 B1

A2 B2

C1 C2 C1 C2 C1 C2 C1 C2 D1 D2 D1 D2 D1 D2 D1 D2 D1 D2 D1 D2 D1 D2 D1 D2 F1 E1 F2 F1 E2 F2
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G1 G2 G1 G2 G1 G2 G1 G2 1/4 FFE

TAGUCHI METHODS
CONDUCTING EXPERIMENT
Process Steps 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Prepare trial data sheets Determine the sample size to be used Define a randomization strategy Define material logistics strategy Define data collection strategy Define people roles and responsibilities identified for the duration of the experiment Confirm test equipment availability Run the experimental legs Record the result in every leg Check of errors and missing data. Rerun if necessary

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Total Sample Size L8 1 2 3 4 5 6 1 2 3 4 5 6 8 16 24 32 40 48 L16 16 32 48 64 80 96 1.55 1.06 0.86 0.74 0.66 0.60 1.95 1.32 1.07 0.92 0.82 0.74 2.80 1.84 1.47 1.26 1.12 1.02 2.39 1.55 1.24 1.06 0.95 0.86 3.10 1.95 1.55 1.32 1.17 1.07 4.84 2.80 2.17 1.84 1.63 1.47 Confidence Level* 90% 95% 99%

No. of Repetition

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a. Com plete random ization

A Trial No. 1 2 3 4 5 6 7 8 1 1 1 1 1 2 2 2 B 2 1 1 2 2 1 1 2 2 C 3 1 1 2 2 2 2 1 1 FACTORS D COLUMN NO. 4 1 2 1 2 1 2 1 2 E 5 1 2 1 2 2 1 2 1 F 6 1 2 2 1 1 2 2 1 G 7 1 2 2 1 2 1 1 2 * * * * * * * * y data * * * * * * * * * * * * * * * *

Randomized within first round Randomized within second round Randomized within third round

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b. Sim ple Repetition

A Trial No. 1 2 3 4 5 6 7 8 1 1 1 1 1 2 2 2 B 2 1 1 2 2 1 1 2 2 C 3 1 1 2 2 2 2 1 1 FACTORS D COLUMN NO. 4 1 2 1 2 1 2 1 2 E 5 1 2 1 2 2 1 2 1 F 6 1 2 2 1 1 2 2 1 G 7 1 2 2 1 2 1 1 2 * * * * * * * * y data * * * * * * * * * * * * * * * *

Random order of trials; do all repetitions for a trial

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c. Com plete Random ization w ithin Blocks

A Trial No. 1 2 3 4 5 6 7 8 1 1 1 1 1 2 2 2

B 2 1 1 2 2 1 1 2 2

C 3 1 1 2 2 2 2 1 1

FACTORS D COLUMN NO. 4 1 2 1 2 1 2 1 2

E 5 1 2 1 2 2 1 2 1

F 6 1 2 2 1 1 2 2 1

G 7 1 2 2 1 2 1 1 2 * * * * * * * * y data * * * * * * * * * * * * * * * *

Random order of trials in block 1 Random order of trials in block 2

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ANALYSIS OF RESULTS
Process Steps 1. Complete the set of test result for each and every trial of the experiment and test orderof the trials or repetition 2. Depending of the objective, determine the analysis method to be used (stated prior at the planning stage) 3. Perform data analysis 4. Interpret the results of analysis 5. Make recommendation on the optimum combination

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COLUMNS EFFECTS METHODS

Which factors make a difference The relative importance of those factors Which direction for levels of those factors will lead to further improvement

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A Trial No. 1 2 3 4 5 6 7 8 Sum 1 Sum 2 Delta 1 1 1 1 1 2 2 2 2

1052 864 188

B 2 1 1 2 2 1 1 2 2 860 823
37

FACTORS AND INTERACTION AxB BxD DxE D E BxD COLUMN NO. 3 4 5 6 1 1 2 2 2 2 1 1 864 819
45

G 7 1 2 2 1 2 1 1 2 851 832
19

1 2 1 2 1 2 1 2 828 855
-27

1 2 1 2 2 1 2 1 794 889
-95

1 2 2 1 1 2 2 1 889 889
0

71 72 55 76 78 63 74 75

71 72 55 74 78 69 70 72

72 72 55 74 77 65 72 71

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