Download - I.3 Philosophy and History
I.3 Philosophy and I.3 Philosophy and HistoryHistory
Some Goals of ManufacturingSome Goals of Manufacturing Various ParadigmsVarious Paradigms Some Aspects of Taguchi’s Philosophy Some Aspects of Taguchi’s Philosophy
– On-Line and Off-Line Quality ControlOn-Line and Off-Line Quality Control– Design AspectsDesign Aspects
Some GoalsSome GoalsThe Quality TimelineThe Quality Timeline
1980
1920
1940
Manufacturing Process Design Product Design
Inspection
Process ControlQuality Control
Design Improvements
ParadigmsParadigmsThe Inspection ParadigmThe Inspection Paradigm
Inspect Output To RemoveInspect Output To RemoveUnsatisfactory ProductUnsatisfactory Product
Process Output Monitor
ParadigmsParadigmsShewhart’s ParadigmShewhart’s Paradigm
““Can’t Inspect Quality Into A Product”Can’t Inspect Quality Into A Product” Detect And Correct Quality Problems By Detect And Correct Quality Problems By Monitoring The Manufacturing Process Monitoring The Manufacturing Process
Two Types Of Variation In A Two Types Of Variation In A Manufacturing ProcessManufacturing Process
Variation ACV CCV= +
ParadigmsParadigmsShewhart’s ParadigmShewhart’s Paradigm - - TerminologyTerminology
Shewhart: Assignable Cause Shewhart: Assignable Cause Variation (ACV) and Chance Causes Variation (ACV) and Chance Causes Of Variation (CCV)Of Variation (CCV)
Deming: ACV=Local Faults, Special Deming: ACV=Local Faults, Special Causes, CCV=Common Cause Causes, CCV=Common Cause VariationVariation
Juran:Juran: ACV=Sporadic Problems ACV=Sporadic Problems CCV=Chronic CCV=Chronic ProblemsProblems
Variation ACV CCV= +
ParadigmsParadigmsShewhart’s ParadigmShewhart’s Paradigm
ObjectiveObjective
Monitor The Process To Detect When ACV Is Present.Monitor The Process To Detect When ACV Is Present.– How Do You Detect ACV? How Do You Detect ACV?
Control ChartsControl Charts
Process Output Monitor
Control
ParadigmsParadigmsShewhart’s ParadigmShewhart’s Paradigm
Two Ways To Improve QualityTwo Ways To Improve Quality Eliminate Assignable Causes To Eliminate Assignable Causes To Bring Process Into Statistical Bring Process Into Statistical ControlControl
Improve The System By Reducing Improve The System By Reducing Common Cause VariationCommon Cause Variation
ParadigmsParadigmsTweaking The Variation Paradigm:Tweaking The Variation Paradigm:The Variation/Complexity ParadigmThe Variation/Complexity Paradigm
Variation ACV CCV= +
Variation = Controllable Variation
+ Uncontrollable Variation
Complexity of the
Process= Unnecessary
Complexity + Inherent Complexity
ParadigmsParadigmsThe Variation/Complexity ParadigmThe Variation/Complexity Paradigm
Paraphrase Deming - “Reduce Paraphrase Deming - “Reduce Variation And Complexity And Variation And Complexity And You Improve Quality”You Improve Quality”
ParadigmsParadigmsDeming and JuranDeming and Juran
Originally Found That 80 to 85% Originally Found That 80 to 85% Of The Quality Problems Of The Quality Problems Required Management’s Input In Required Management’s Input In Order To Correct.Order To Correct.
Over The Years This Percentage Over The Years This Percentage Increased To Where They Found Increased To Where They Found That 94 to 96% Of Quality That 94 to 96% Of Quality Problems Were Systemic!Problems Were Systemic!
ParadigmsParadigmsDeming And Juran’s ExtensionDeming And Juran’s Extension
Need Management’s Need Management’s InvolvementInvolvement
Process Output Monitor
ControlManagement
ParadigmsParadigmsDeming and TaguchiDeming and Taguchi
Customer Satisfaction is the Customer Satisfaction is the Determining Factor in Product Determining Factor in Product DesignDesign– Taguchi - Quality is measured in terms Taguchi - Quality is measured in terms of loss to societyof loss to society
-Wring Out the Variation-Wring Out the Variation– Deming and Juran - Controlling the Deming and Juran - Controlling the Process (On-Line QC)Process (On-Line QC)
– Taguchi - Design Robust (Rugged) Taguchi - Design Robust (Rugged) Processes and Products (Off-Line QC)Processes and Products (Off-Line QC)
ParadigmsParadigmsTaguchi - Another Way To Improve QualityTaguchi - Another Way To Improve Quality
Build Rugged/Robust Products Build Rugged/Robust Products And Processes By Making Things And Processes By Making Things Insensitive To Unknown Or Insensitive To Unknown Or Uncontrollable Sources Of Uncontrollable Sources Of VariationVariation
Some Aspects of Taguchi’s Some Aspects of Taguchi’s PhilosophyPhilosophy
Prevention Rather Than DetectionPrevention Rather Than Detection Rather Than Detecting Defects, Let’s Design Quality Into The Rather Than Detecting Defects, Let’s Design Quality Into The Product Right From The Beginning.Product Right From The Beginning. “An Ounce of Prevention “An Ounce of Prevention...”...”
Process Output Monitor
ControlManagement
EngineeringCustomer
Some AspectsSome AspectsTaguchi’s ApproachTaguchi’s Approach
During the 50’s and 60’s During the 50’s and 60’s Developed A Philosophy and Developed A Philosophy and Methodology Concerning Product Methodology Concerning Product Design and ProductionDesign and Production
Some AspectsSome AspectsDesign Aspects of Taguchi’s PhilosophyDesign Aspects of Taguchi’s Philosophy
Robust Products And Processes Robust Products And Processes Through “Engineering Design” Through “Engineering Design” (Statistical Design Of (Statistical Design Of Experiments, DOE, Plays A Role Experiments, DOE, Plays A Role Here)Here)– Parameter DesignParameter Design
Choose Parameter (Factor) Levels ToChoose Parameter (Factor) Levels To– Optimize Process or Product PerformanceOptimize Process or Product Performance– Mitigate Uncontrollable FactorsMitigate Uncontrollable Factors
Some AspectsSome AspectsDesign Aspects of Taguchi’s Philosophy:Design Aspects of Taguchi’s Philosophy:
FactorsFactors
Control FactorsControl Factors– ““Easily” controlled sources of variationEasily” controlled sources of variation
NoiseNoise– UncontrollableUncontrollable
External - EnvironmentalExternal - Environmental
Goal - Design Product to Be Goal - Design Product to Be Insensitive to Noise FactorsInsensitive to Noise Factors