Taguchi Techniques

+Experimental design methods to improve product

& process design
+ Identify key component & process variables affecting
product variation
+Taguchi Concepts
+ Quality robustness
+ Quality loss function
+ Target specifications
+ Ability to produce
products uniformly
regardless of
manufacturing conditions
+ Put robustness in House
of Quality matrices
besides functionality
1984-1994 T/Maker Co.
Quality Robustness
+Shows social cost ($) of deviation from target value
+Assumptions
+ Most measurable quality characteristics (e.g., length, weight)
have a target value
+ Deviations from target value are undesirable
+Equation: L = D
2
C
+ L = Loss ($); D = Deviation; C = Cost
Quality Loss Function
Quality Loss Function
F
r
e
q
u
e
n
c
y
Target Upper Lower
Target-oriented quality
yields more product in
the "best" category
Distribution of Specifications for Products Produced
Conformance-oriented
quality keeps products
within 3 standard
deviations

L
o
s
s
High Loss
Low Loss
Unacceptable
Poor
Fair
Good
Best
The specifications for the
diameter of a gear are 25.00
0.25 mm.
If the diameter is out of
specification, the gear must
be scrapped at a cost of
$4.00. What is the loss
function?
1984-1994 T/Maker Co.
Quality Loss Function Example
+L = D
2
C = (X - Target)
2
C
+ L = Loss ($); D = Deviation; C = Cost
+4.00 = (25.25 - 25.00)
2
C
+ Item scrapped if greater than 25.25
(USL = 25.00 + 0.25) with a cost of $4.00
+C = 4.00 / (25.25 - 25.00)
2
= 64
+L = D
2

64 = (X - 25.00)
2
64
+ Enter various X values to obtain L & plot
Quality Loss Function Solution
Freq.
X
Target USL LSL
A study found U.S. consumers preferred Sony TVs
made in Japan to those made in the U.S. Both factories
used the same designs & specifications. The difference
in quality goals made the difference in consumer
preferences.
Japanese factory
(Target-oriented)
U.S. factory
(Conformance-
oriented)
Target Specification Example
Quality Loss Function; Distribution of
Products Produced
Low loss
High loss
Frequency
Lower Target Upper
Specification
Loss (to
producing
organization,
customer, and
society)
Quality Loss Function (a)
Unacceptable
Poor
Fair
Good
Best
Target-oriented
quality yields more
product in the
best category
Target-oriented quality
brings products toward
the target value
Conformance-oriented
quality keeps product
within three standard
deviations
Distribution of
specifications for product
produced (b)
Process Capability Ratio, C
p
process the of deviation standard
6
ion Specificat Lower ion Specificat Upper
=

=
o
p
C
Process Capability C
pk

population process the of deviation standard
mean process x where
Limit ion Specificat Lower x

or ,
x Limit ion Specificat Upper
of minimum
=
=
(

=
o
o
o
3
3
pk
C
Assumes that the process is:
under control
normally distributed
Meanings of C
pk
Measures
C
pk
= negative number
C
pk
= zero
C
pk
= between 0 and 1
C
pk
= 1
C
pk
> 1
Six Sigma
+A process for developing and delivering near
perfect products and services
+Measure of how much a process deviates from
perfection
+3.4 defects per million opportunities
+Champion
+ an executive responsible for project success



Process Capability Index Examples
Computation of C
pk

Black Belts and
Green Belts
+Black Belt
+ project leader
+Master Black Belt
+ a teacher and mentor for
Black Belts
+Green Belts
+ project team members
3.4 DPMO
67,000 DPMO
cost = 25% of sales
DEFINE CONTROL IMPROVE ANALYZE MEASURE
Six Sigma: DMAIC