International Conference on

Advances in Materials Processing & Manufacturing Applications

iCADMA 2020
5th – 6th November 2020
Paper Id: 94

Framework and case study for optimizing target value of a process using
Taguchi’s asymmetric loss function
Anoop Pandey and Dr. Manish Chaturvedi

Presented by: Anoop Pandey

Affiliation of Presenter:
(ABES Engineering College, Ghaziabad)
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Content
1. Introduction
2. Literature Review
3. Problem Formulation
4. Methodology
5. Results and Discussion
6. Conclusion
7. References

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Introduction
• Evolution of Quality
• Taguchi’s Loss Function
• Asymmetric nature of the
Taguchi’s loss function in
manufacturing pertaining to
rework and scrap cost usually Evolution of Quality

ignored by the users

Taguchi’s Asymmetric and Symmetric Loss Functions

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Literature Review
• This increases loses [1]
• Trade-off can be established by optimizing total loss function suggested by Taguchi [2]
• Process optimum mean value can be determined considering quality loss and cost related to
manufacturing [3] and a tolerance design that is unbalanced [4], [5].
• The function also widely used for determining optimum process parameters and tolerances with
suggestions related to inspection plans during the design stage of a product [6].
• The function also been used in conjunction with the Analytical Hierarchy Process and VIKOR for
supplier selection [7] and airport evaluation [8] respectively.
• The function also been effectively used in quality control and management by designing
economic control charts [9]

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Problem Formulation
• Piston rings being rejected due to CTQ of thickness in a renowned piston and rings manufacturing
company
• QC tools used to improve existing process [11]
• But the overall loss being yielded by the process was not optimized in the study.
• Data Collection:
• Following data was collected from the operations department of the company:
• Batch size of piston rings = 300 pieces
• Permissible piston ring thickness value (Specification limit as VOC): 2.9 + 0.1 mm
• The detailed manufacturing process of the piston rings
• Manufacturing cost for one ring – Rs 5/piece
• Average rework cost (R) for one ring per unit thickness = 40% of manufacturing
cost/mm = Rs 2/piece/mm
• Process target value ‘m’ = 2.9 mm, USL = 3.0 mm and LSL = 2.8 mm
• Scrap cost per ring (S) =manufacturing cost by the point of scrapping = Rs 5/piece
• Total loss = loss due to rework + loss due to scrap
• The average number of rings reworked per batch = 12 pieces per batch
• The average number of rings scrapped per batch = 8 pieces per batch
• Total average loss per batch = 12*2 + 8*5 = 64 Rs per batch

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S.
Methodology
Point Description Coordinates
No.

1. P (target value, loss yielded) (2.9, 0)

2. A (3, 2*0.1) = (3, 0.2)

3. B (observed dimension, loss yielded) (3.1, 2*0.2) = (3.1,

0.4)

4. C (2.8, 5)

• The points P, A, B, and C were plotted using the MS EXCEL line graph, and then a The CAIV Cycle
2-degree polynomial trend line was imposed on the graph shown in figure 2.
• The equation of the 2-degree polynomial trend line was also obtained shown in
following equation. Loss Function
• y = 1.3x2 - 7.86x + 11.3 = k(x-m) 2
• The value of ‘x’ for which the loss function ‘y’ as obtained by equation number 6
1 gets minimized should be the target value for the process. 5 5
• The factors of equation number 1 were obtained to get the two values of the f(x) = 1.3 x² − 7.86 x + 11.3
process for which the loss function should be minimized. 4 Loss Function
• This is again evident from the graph that two real values of the factors can be Polynomial (Loss
3 Function)
obtained for the purpose as the curve is intersecting the y = 0 line at two places
for y>0. 2
• The two factors of the equation x1 and x2 obtained are 2.94 and 3.06
1
respectively.
0.4
• Since the second factor x2 is slightly above the USL thus is not considered 0 0 0.2
2.8 2.9 3 3.1

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Methodology Contd….
Implementation
• The mrevised value was set as the target value for the process by making suitable adjustments in
the process parameters
• Following data was collected from the operation department of the company to analyze the
effect of changing the target value on the total loss function:
• The average number of rings reworked per batch = 15 pieces per batch
• The average number of rings scrapped per batch = 5 pieces per batch
• Total average loss per batch = 15*2 + 8*5 = 55 Rs per batch
• % reduction in average loss per batch = 9/64*100 = 14.0625%
• The above data was estimated with the help of 20 random samples of piston ring batches
produced after revising the target value.
• The average loss per batch for all the 20 samples was obtained.
• The data obtained was analyzed to observe that the average loss per batch was Rs 55 with a
standard deviation of 2.1.

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Methodology Contd….
  Validation
• The t-student test was used
• Null hypothesis: Total average loss due to scrap and rework before and after the adjustment of
the target value to mrevised are the same.
Ho:
• Alternative Hypothesis: Total average loss due to scrap and rework after the adjustment of the
target value to mrevised is lesser than that before the adjustment of the target value to m revised.
Ha:
• Test statistics:
• Rs
• = 55 Rs

• n = 20
• degree of freedom = 19
• confidence level (α) = 95%
• Calculated t value: = -18.681
• Tabulated t value for a left tailed test = -1.729.

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Result
• Since the calculated value falls in the critical region, the null hypothesis was rejected and
the alternative hypothesis was accepted.
• Thus it was validated that the total average loss due to scrap and rework after the
adjustment of the target value to mrevised is lesser than that before the adjustment of the
target value to mrevised.
• % reduction in average loss per batch = 9/64*100 = 14.0625%

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Conclusion
• Taguchi’s loss function equation is a proven and reliable method that can be used for
optimizing the loss caused due to rework and scrap.
• The systematic framework of CAIV suggested in the paper with the help of a practical case
study can help the users in implementing the same in manufacturing industries to reduce the
overall loss.
• As observed the total average loss was brought down by more than 14% by implementing the
technique systematically.
• Also, the hypothesis testing validated the modality and credibility of the method

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References
[1] J. Zhang, W. Li, K. Wang, and R. Jin, “Process adjustment with an asymmetric quality loss function,” J. Manuf. Syst., vol. 33, no.
1, pp. 159–165, 2014
[2] A. Pandey, N. K. Pandey, and H. Ahmed, “Review of Symmetricity in Taguchi ’ s Loss Function for Performance Measurement to
Monitor Cost of Rejection,” Trends Mech. Eng. Technol., vol. 9, no. 1, pp. 59–68, 2019.
[3] C. H. Chen and M. T. Lai, “Determining the optimum process mean based on quadratic quality loss function and rectifying
inspection plan,” Eur. J. Oper. Res., vol. 182, no. 2, pp. 755–763, 2007
[4] M. H. C. Li, “Unbalanced tolerance design and manufacturing setting with asymmetrical linear loss function,” Int. J. Adv. Manuf.
Technol., vol. 20, no. 5, pp. 334–340, 2002
[5] M. H. C. Li, “Quality loss function based manufacturing process setting models for unbalanced tolerance design,” Int. J. Adv.
Manuf. Technol., vol. 16, no. 1, pp. 39–45, 2000
[6] A. Jeang, “Optimal parameter and tolerance design with a complete inspection plan,” Int. J. Adv. Manuf. Technol., vol. 20, no. 2,
pp. 121–127, 2002
[7] C. N. Liao and H. P. Kao, “Supplier selection model using Taguchi loss function, analytical hierarchy process and multi-choice
goal programming,” Comput. Ind. Eng., vol. 58, no. 4, pp. 571–577, 2010
[8] P. Shojaei, S. A. Seyed Haeri, and S. Mohammadi, “Airports evaluation and ranking model using Taguchi loss function, best-
worst method and VIKOR technique,” J. Air Transp. Manag., vol. 68, pp. 4–13, 2018, doi: 10.1016/j.jairtraman.2017.05.006.
[9] S. M. Alexander, M. A. Dillman, J. S. Usher, and B. Damodaran, “Economic design of control charts using the Taguchi loss
function,” Comput. Ind. Eng., vol. 28, no. 3, pp. 671–679, 1995, doi: 10.1016/0360-8352(94)00219-D.
[10] V. V. Dunaevsky, “Analysis of distortions of cylinders and conformability of piston rings,” Tribol. Trans., vol. 33, no. 1, pp. 33–40,
1990, doi: 10.1080/10402009008981927.
[11] P. Anoop and V. Harsh, “Using qc tools to investigate the problem of rejection of piston rings - A case study of engine
component manufacturing organization,” International Journal of Scientific and Technology Research, vol. 9, no. 4. pp. 2410–2416,
2020.

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Thank You…
Q&A

anooppandeyeck@gmail.com,
anoop.pandey@abes.ac.in
8802738589
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