Avinash Singh CA-2

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Design Of Experiments

Q1. Explain the implementation process of Taguchi method with examples

Taguchi methods are statistical methods, sometimes called robust design methods,
developed by Genichi Taguchi to improve the quality of manufactured goods, and more recently also
applied to engineering, biotechnology, marketing and advertising. Professional statisticians have
welcomed the goals and improvements brought about by Taguchi methods, particularly by Taguchi’s
development of designs for studying variation, but have criticized the inefficiency of some of Taguchi’s
proposals.

Taguchi’s work includes three principal contributions to statistics:

• A specific loss function
• The philosophy of off-line quality control; and
• Innovations in the design of experiments.

Taguchi’s rule for manufacturing

Taguchi realized that the best opportunity to eliminate variation of the final product quality is
during the design of a product and its manufacturing process. Consequently, he developed a
strategy for quality engineering that can be used in both contexts. The process has three stages:

• System design
• Parameter (measure) design
• Tolerance design

Taguchi method is one of a design of experimental , by using statistical approach to optimize

the process parameters and maintaining the minimum variability and also improve the quality
of product. Based on data characterisation, Nominal is Best in Taguchi methods is suitable
application in this study. Its describe the procedures and steps that occur in DOE to find an
optimum quality parameter corresponding quality characterisation. Nominal is the best applied
in milling process of pulp on the hydrapulper with pulp freeness 650 Canadian Standard
Freeness . The result is shown by orthogonal array, Signal-to-Noise Ratio and analysis of
variances . Three factors considered in this study and namely the composition of pulp (waste
paper), pulp consistency and milling time. The experiment will conducted after determination
of each level and the appropriate orthogonal array was selected. After measuring of pulp
freeness produced by the pulp milling on the hydrapulper, then Signal-to-Noise Ratio is
calculated. As the conclusion, the factors and levels of optimum freeness obtained, pulp
composition in level 1 , pulp consistency at level 2 and milling time factor in level 2 . The result
of experimental verification was interpreted in the conclusion.

Q2. Explain the confirmation test and level of parameters in Taguchi method with
examples?
In Taguchi’s methods of parameter design, a confirmation test is usually necessary to
remove concerns about the choice of control parameters, experimental design, or assumptions
about responses. This paper investigated the use of artificial neural-networks simulation to
validate the set of control parameters identified as significant through Taguchi’s methods, and to
verify that the recommended settings for the control parameters are indeed optimal or near-
optimal. Using the experimental layout and measured responses from a Taguchi parameter-
design experiment, we applied cross-validate training to ascertain that the trained neural-network
can reproduce acceptable results on unseen experimental layouts. We then used the trained
neural-network to simulate and search for the global optimal settings for the control parameters,
and the results compared with the recommended settings from the Taguchi parameter-design
experiment.
Classical experimental design methods are too complex and are not Easy to use. A
large number of experiments have to be carried out when the Number of process parameters
increase. To solve this problem, the Taguchi Method uses a special design of orthogonal arrays
to study the entire Parameter space with only a small number of experiments. Three
superplastic Forming parameters are considered as controlling factors. They are Pressure,
Temperature and Time. Each parameter has three levels – namely low, Medium and high,
denoted by 1, 2 and 3 respectively. According to the Taguchi method, if three parameters and 3
levels for each parameters L9 Orthogonal array should be employed for the experimentation.
Table Shows the Superplastic forming parameters and their levels considered for the
Experimentation.

Orthogonal arrays are special standard experimental design that Requires only a small number
of experimental trials to find the main factors Effects on output. Before selecting an orthogonal
array, the minimum number Of experiments to be conducted is to be fixed based on the
formula below
N Taguchi = 1+ NV (L – 1) N Taguchi = Number of experiments to be conducted
V = Number of parameters L = Number of levels In this work

NV = 3 and L = 3, Hence
N Taguchi = 1+ 4 (3-1) = 9
Hence at least 9 experiments are to be conducted. Based on this Orthogonal array (OA) is to be
selected which has at least 9 rows i.e.,9 Experimental runs.

The following standard orthogonal arrays are commonly used to Design experiments:
➢ 2-Level Arrays: L4, L8, L12, L16, L32
➢ 3-Level Arrays: L9, L18, L27
➢ 4-Level Arrays: L16, L32

In this work L9 is sufficient. It would require a total of 27 Experiments to optimize the

parameters. Taguchi experimental design of Experiments suggests L9 orthogonal array, where 9
experiments are sufficient To optimize the parameters. Based on main factor, the variables are
assigned At columns, as stipulated by orthogonal array. The last column can be kept Dummy,
but no row should be left out. Once the orthogonal array is selected, The experiments are
selected as per the level combinations. It is important that All experiments are conducted. The
performance parameter (output) is noted For each experimental run for analysis.
Q3. Explain the application of Taguchi method with examples.

1) Taguchi method is used to find the optimal cutting parameters for surface
roughness in turning. The orthogonal array, the signal-to-noise ratio, and
analysis of variance are employed to study the performance characteristics
in turning operations of AISI 1030 steel bars using TiN coated tools. Three
cutting parameters namely, insert radius, feed rate, and depth of cut, are
optimized with considerations of surface roughness. Experimental results
are provided to illustrate the effectiveness of this approach.

2) Taguchi Method is a process/product optimization method that is based on

8-steps of planning, conducting and evaluating results of matrix
experiments to determine the best levels of control factors. The primary
goal is to keep the variance in the output very low even in the presence of
noise inputs.

3) Taguchi method has been used for half century in the optimization of
parameters of manufacturing processes; the technique itself is not new.
However, a review of the literature has revealed that there are, in
particular, successful industrial applications of Taguchi-based optimization
approaches in determining the optimal settings of process variables for
injection moulding due to its practicality and robust in designing and
optimizing the experiment. Considering the distinctive features of Taguchi
method in simplifying the experiment yet leading to the accurate results,
Taguchi method is not only applicable as a standalone method but it is
viable to be integrated with other approaches to combine their unique
features to strengthen the integrated Taguchi-based approach for truly
effective optimization.