Abstract: As a technique that reduces variation in a product by lessening the sensitivity of the design to sources of variation, rather than by controlling their sources, Taguchi Robust Design entails the designing of ideal goods, by developing a product that has minimal variance in its characteristics and also meets the desired exact performance. This paper examined the concept of the manufacturing approach and its application to brake pad product of an automotive parts manufacturing company. Although the firm claimed that only defects, excess inventory, and over-production were the few wastes that grossly affect their productivity and profitability, a careful study and analysis of their manufacturing processes with the application of Single Minute Exchange of Dies (SMED) tool showed that the waste of waiting is the fourth waste that bedevils the firm. The selection of the Taguchi L9 orthogonal array which is based on the four parameters and the three levels of variation for each parameter revealed that with a range of 2.17, that waiting is the major waste that the company must reduce in order to continue to be viable. Also, to enhance the company’s throughput and profitability, the wastes of over-production, excess inventory, and defects with ranges of 2.01, 1.46, and 0.82, ranking second, third, and fourth respectively must also be reduced to the barest minimum. After proposing -33.84 as the highest optimum Signal-to-Noise ratio to be maintained for the waste of waiting, the paper advocated for the adoption of all the tools and techniques of Lean Production System (LPS), and Continuous Improvement (CI), and concluded by recommending SMED in order to drastically reduce set up time which leads to unnecessary waiting.
Abstract: This paper focuses on robust design and optimization
of industrial production wastes. Past literatures were reviewed to case
study Clamason Industries Limited (CIL) - a leading ladder-tops
manufacturer. A painstaking study of the firm-s practices at the shop
floor revealed that Over-production, Waiting time, Excess inventory,
and Defects are the major wastes that are impeding their progress and
profitability. Design expert8 software was used to apply Taguchi
robust design and response surface methodology in order to model,
analyse and optimise the wastes cost in CIL. Waiting time and overproduction
rank first and second in contributing to the costs of wastes
in CIL. For minimal wastes cost the control factors of overproduction,
waiting-time, defects and excess-inventory must be set at
0.30, 390.70, 4 and 55.70 respectively for CIL. The optimal value of
cost of wastes for the months studied was 22.3679. Finally, a
recommendation was made that for the company to enhance their
profitability and customer satisfaction, they must adopt the Shingeo
Shingo-s Single Minute Exchange of Dies (SMED), which will
immediately tackle the waste of waiting by drastically reducing their
setup time.