The present paper proposes a systematic design framework for cost of quality that embeds Taguchi’s method and other robustness criteria to reduce the overall COQ of a product.
Robust Design is defined as reducing variation in a product without eliminating the causes of the variation. In other words, making the product or process insensitive to variation. This in turn increases the overall quality of a product making the product robust.
Table of Contents
1. Introduction
2. Literature Review
3. Research Methodology
4. Reduction in COQ by implementing Robust Design
5. Results and Calculations
6. Conclusion
7. Paper Published
8. References
Research Objectives and Key Topics
This thesis aims to develop a systematic design framework for reducing the Cost of Quality (COQ) in the automotive industry by integrating Taguchi’s Robust Design methodology into the gear manufacturing process. The primary research focus is to address dimensional variations that lead to product rejections and increased quality costs, ultimately striving to align manufacturing outputs more closely with target design specifications.
- Integration of Robust Design and Cost of Quality frameworks.
- Optimization of gear hobbing process parameters.
- Reduction of dimensional tolerances to minimize quality loss.
- Analysis of conformance vs. non-conformance quality costs.
- Implementation of Taguchi-based parameter design for process robustness.
Excerpt from the Book
Reduction in COQ by using Robust Design
The objective of this case study is to reduce Cost of Quality by using Robust Design in Bharat Gears Limited.
Even though gear where within the quality range as per specification, it had many errors such as P.C.D error, lead error, etc. which affected the quality of the gears produced.
Hence, the idea of implementing robust design to reduce the dimensional tolerance and thereby decreasing the cost of quality of a product.
Various control factors such as hob speed, in feed and axial feed of tool were identified as control factors and levels of control factors were set.
Discussion with the workers and engineers helped us determine the various noise factors such as vibration in hobbing machine, coolant used, grain structure of the gear material, initial casting methods used to produce blanks, etc.
Summary of Chapters
1. Introduction: Defines the core concepts of quality, robust design, and the necessity of linking quality metrics to financial terms to improve organizational performance.
2. Literature Review: Provides a comprehensive survey of existing research regarding COQ models, Taguchi’s method, and their successful applications in diverse manufacturing sectors.
3. Research Methodology: Details the systematic framework combining theoretical study and empirical observations, including the flowchart for implementing robust design steps.
4. Reduction in COQ by implementing Robust Design: Describes the practical case study at Bharat Gears Limited, identifying control factors, noise factors, and specific gear dimensions for improvement.
5. Results and Calculations: Presents the experimental data, Minitab analysis, and the calculation of Signal-to-Noise ratios to identify optimal manufacturing parameters.
6. Conclusion: Summarizes how the integration of robust design and COQ successfully reduced tolerance deviations and overall quality costs for the manufacturing process.
7. Paper Published: Lists the academic publications derived from the research findings presented in the thesis.
8. References: Compiles the scholarly sources and industry documentation utilized throughout the research.
Keywords
Robust Design, Cost of Quality, Taguchi Method, Gear Hobbing, Dimensional Tolerance, Automotive Industry, Signal to Noise Ratio, Process Optimization, Quality Loss Function, Manufacturing Systems, Conformance Cost, Non-conformance Cost, Internal Rejection, External Rejection, Parameter Design.
Frequently Asked Questions
What is the primary focus of this research?
The research focuses on reducing the Cost of Quality (COQ) in the automotive gear manufacturing industry by utilizing Robust Design principles to minimize dimensional variations.
Which methodology is employed to achieve the research goals?
The study primarily uses Taguchi’s Robust Design methodology, integrating parameter design and signal-to-noise ratio analysis to optimize manufacturing processes.
What are the central themes of the work?
The central themes include quality loss function, identification of conformance and non-conformance costs, and the practical application of design robustness to mitigate the effects of uncontrollable noise factors.
What is the key objective regarding the gear manufacturing process?
The main objective is to identify and set optimal parameters (such as hob speed and feed rates) to ensure gears are produced as close to the target dimensions as possible.
How is the success of the implementation measured?
Success is measured by comparing the reduction in total Cost of Quality, specifically observing the decrease in both internal and external rejections and the tightening of dimensional tolerances.
What distinguishes this research from previous studies?
This work specifically addresses the gap in practical applications of robust design concerning dimensional tolerances in gears, which directly impacts their durability and cost of quality.
What specific dimension was identified as critical for the root diameter of the spur gear?
The study identified that the root diameter with a high tolerance limit of 0.2 mm was a primary driver of quality costs, leading to gear failures and high rejection rates.
How did the application of robust design impact the tolerance levels?
Through the implementation of the robust design approach, the tolerance range was successfully reduced from 0.2 mm to 0.1 mm, resulting in higher product quality and reduced quality loss.
- Citation du texte
- Jalal Khan (Auteur), 2015, Reduction in cost of quality by using robust design, Munich, GRIN Verlag, https://www.grin.com/document/339506
