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Chapter2IntroductiontoTaguchiMethod
CHAPTER2
INTRODUCTIONTOTAGUCHIMETHOD
2.1Background
Thetechniqueoflayingouttheconditionsofexperiments[6]involvingmultiplefactorswasfirstproposed
bytheEnglishman,[Link].A
[Link]
experimentsusuallyinvolveasignificantnumberoffactors,afullfactorialdesignresultsinalargenumber
[Link],onlyasmallsetfromallthe
[Link]
[Link],thereareno
generalguidelinesforitsapplicationortheanalysisoftheresultsobtainedbyperformingtheexperiments.
Taguchiconstructedaspecialsetofgeneraldesignguidelinesforfactorialexperimentsthatcovermany
applications.
2.2Basicconcepts
2.2.1Definition
Taguchihasenvisagedanewmethodofconductingthedesignofexperimentswhicharebasedonwell
[Link]
stipulatesthewayofconductingtheminimalnumberofexperimentswhichcouldgivethefullinformation
[Link]
choosingthelevelcombinationsoftheinputdesignvariablesforeachexperiment.
2.2.2Atypicalorthogonalarray
Whiletherearemanystandardorthogonalarraysavailable,eachofthearraysismeantforaspecificnumber
[Link],ifonewantstoconductanexperimentto
understandtheinfluenceof4differentindependentvariableswitheachvariablehaving3setvalues(level
values),thenanL9orthogonalarraymightbetherightchoice.TheL9orthogonalarrayismeantfor
[Link]
[Link],nointeractionmodelassumptionis
valid,[Link]
betheinteractionbetweenthematerialpropertiesandtemperature.
L9(34)Orthogonalarray
Performance
IndependentVariables
Experiment#
1
2
3
4
5
6
7
8
Variable1
1
1
1
2
2
2
3
3
Variable2
1
2
3
1
2
3
1
2
[Link]
Variable3
1
2
3
2
3
1
3
1
ParameterValue
Variable4
1
2
3
3
1
2
2
3
p1
p2
p3
p4
p5
p6
p7
p8
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Table2.1LayoutofL9orthogonalarray.
TheTable2.1showsanL9orthogonalarray.Therearetotally9experimentstobeconductedandeach
[Link],thethird
experimentisconductedbykeepingtheindependentdesignvariable1atlevel1,variable2atlevel3,
variable3atlevel3,andvariable4atlevel3.
2.2.3Propertiesofanorthogonalarray
Theorthogonalarrayshasthefollowingspecialpropertiesthatreducesthenumberofexperimentstobe
conducted.
[Link]
[Link].ForL9arrayundervariable4,
level1,[Link].
[Link].
[Link]
notconductexperiment1withvariable1,level2setupandexperiment4withvariable1,level1
[Link]
[Link].Iftheabove3
levelsarenormalizedbetween1and1,thentheweighingfactorsforlevel1,level2,level3are1,0
,1respectively.Hencetheinnerproductofweighingfactorsofindependentvariable1and
independentvariable3wouldbe
(1*1+1*0+1*1)+(0*0+0*1+0*1)+(1*0+1*1+1*1)=0
2.2.4Minimumnumberofexperimentstobeconducted
Thedesignofexperimentsusingtheorthogonalarrayis,inmostcases,efficientwhencomparedtomany
[Link]
methodcanbecalculatedbasedonthedegreesoffreedomapproach.
Forexample,incaseof8independentvariablesstudyhaving1independentvariablewith2levelsand
remaining7independentvariableswith3levels(L18orthogonalarray),theminimumnumberof
[Link]
arrays,[Link]
theabovecaseis18.
2.3AssumptionsoftheTaguchimethod
Theadditiveassumptionimpliesthattheindividualormaineffectsoftheindependentvariableson
[Link],theeffectofeachfactorcanbelinear,quadratic
orofhigherorder,butthemodelassumesthatthereexistsnocrossproducteffects(interactions)amongthe
individualfactors.Thatmeanstheeffectofindependentvariable1onperformanceparameterdoesnot
[Link],this
assumptionisviolated,thentheadditivityofthemaineffectsdoesnothold,andthevariablesinteract.
2.4Designinganexperiment
Thedesignofanexperimentinvolvesthefollowingsteps
[Link]
[Link]
[Link]
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[Link]
[Link]
[Link]
[Link]
[Link]
Thedetailsoftheabovestepsaregivenbelow.
2.4.1Selectionoftheindependentvariables
Beforeconductingtheexperiment,theknowledgeoftheproduct/processunderinvestigationisofprime
[Link]
listoffactors,theinputtotheexperimentisgenerallyobtainedfromallthepeopleinvolvedintheproject.
2.4.2Decidingthenumberoflevels
Oncetheindependentvariablesaredecided,[Link]
[Link]
theperformanceparameterisalinearfunctionoftheindependentvariable,thenthenumberoflevelsetting
[Link],iftheindependentvariableisnotlinearlyrelated,thenonecouldgofor3,4orhigher
levelsdependingonwhethertherelationshipisquadratic,cubicorhigherorder.
Intheabsenceofexactnatureofrelationshipbetweentheindependentvariableandtheperformance
parameter,[Link],onecandecidewhether
theassumptionoflevelsettingisrightornotbasedonthepercentcontributionandtheerrorcalculations.
2.4.3Selectionofanorthogonalarray
Beforeselectingtheorthogonalarray,theminimumnumberofexperimentstobeconductedshallbefixed
basedonthetotalnumberofdegreesoffreedom[5][Link]
[Link]
countingthetotaldegreesoffreedomtheinvestigatorcommits1degreeoffreedomtotheoverallmeanof
[Link]
[Link]
interactioneffectis1+[Link],incaseof11independentvariables,
eachhaving2levels,[Link]
least12experiments.AnL12orthogonalsatisfiesthisrequirement.
Oncetheminimumnumberofexperimentsisdecided,thefurtherselectionoforthogonalarrayisbasedon
thenumberofindependentvariablesandnumberoffactorlevelsforeachindependentvariable.
2.4.4Assigningtheindependentvariablestocolumns
[Link]
mixedlevelvariablesandinteractionbetweenvariables,thevariablesaretobeassignedatrightcolumnsas
stipulatedbytheorthogonalarray[3].
Finally,beforeconductingtheexperiment,[Link]
shallbenotedthatthesignificanceandthepercentcontributionoftheindependentvariableschanges
[Link].
2.4.5Conductingtheexperiment
Oncetheorthogonalarrayisselected,[Link]
[Link]
notbeconsideredforconductingtheexperiment,butareneededwhileanalyzingthedatatounderstandthe
[Link]
sensitivityanalysis.
2.4.6Analysisofthedata
[Link]
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Sinceeachexperimentisthecombinationofdifferentfactorlevels,itisessentialtosegregatetheindividual
[Link]
[Link],inordertofindoutthemaineffectoflevel1settingofthe
independentvariable2(referTable2.1),sumtheperformanceparametervaluesoftheexperiments1,4and
7.Similarlyforlevel2,sumtheexperimentalresultsof2,5and7andsoon.
Oncethemeanvalueofeachlevelofaparticularindependentvariableiscalculated,thesumofsquareof
[Link]
aparticularvariableindicateswhethertheperformanceparameterissensitivetothechangeinlevelsetting.
Ifthesumofsquaredeviationisclosetozeroorinsignificant,onemayconcludethatthedesignvariablesis
[Link],byconductingthesensitivityanalysis,and
performinganalysisofvariance(ANOVA),onecandecidewhichindependentfactordominatesoverother
[Link]
dealtinchapter5.
2.4.7Inference
Fromtheaboveexperimentalanalysis,itisclearthatthehigherthevalueofsumofsquareofanindependent
variable,[Link]
individualsumofsquareofaparticularindependentvariabletothetotalsumofsquaresofallthevariables.
Thisratiogivesthepercentcontributionoftheindependentvariableontheperformanceparameter.
Inadditiontoabove,[Link]
[Link],thesolutioncanbeusedasaninitial/startingvalueforthe
standardoptimizationtechnique.
2.5RobustDesign
[Link]
variationsincludevariationintemperatureorhumidity,variationinrawmaterials,anddriftofprocess
[Link]/variationarethevariablesthatareimpossibleorexpensivetocontrol.
Theobjectiveoftherobustdesign[4]istofindthecontrollableprocessparametersettingsforwhichnoiseor
variationhasaminimaleffectontheproduct'sorprocess'[Link]
aimisnottofindtheparametersettingsfortheuncontrollablenoisevariables,butthecontrollabledesign
[Link],thecontrolparameters,alsoknownasinnerarrayvariables,are
[Link],a
seriesofnewexperimentsareconductedbyvaryingthelevelsettingsoftheuncontrollablenoisevariables.
Thelevelcombinationsofnoisevariablesaredoneusingtheouterorthogonalarray.
Theinfluenceofnoiseontheperformancecharacteristicscanbefoundusingtheratio[4]whereSisthe
standarddeviationoftheperformanceparametersforeachinnerarrayexperimentandNisthetotalnumber
[Link]
thisresult,itispossibletopredictwhichcontrolparametersettingswillmaketheprocessinsensitiveto
noise.
However,whenthefunctionalcharacteristicsarenotaffectedbytheexternalnoises,thereisnoneedto
[Link]
conductedusingthecomputersimulationastherepeatabilityofacomputersimulatedexperimentsisvery
high.
[Link]
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