Robust Design and Optimization of Production Wastes: An Application for Industries
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.
[1] Womack, J. Jones, D. and Roos, D. (1990) The Machine that Changed
the World Rawson Associates, New York, USA.
[2] Hunter, S. (2003). An Introduction to Lean Production Systems. FDM
Journal, Vol. 75, Iss.13; pg. 58.
[3] Ihueze, C. and Okpala, C. (2012). Application of Taguchi Robust Design
as Optimized Lean Production in Manufacturing Companies. Research
Journal in Engineering and Applied Sciences
http://rjeas.emergingresource.org/issuesview.php?id=100&issue_name=
Volume%201%20Number%201&issue_month=January&issue_year=20
12.
[4] Taguchi, G. (1987). The Taguchi Approach to Parameter Design.
Quality Progress Publications, Okinawa, Japan.
[5] Ihueze, C.C., Obiuto, C.C., and Okpala, C.C. (2012), "Quality
improvement of process product value through robust design of control
parameters" Research journal in Engineering and Applied sciences (1),
2012, 70-76.
[6] Montgomery, D.C. (2009). Design and Analysis of Experiments; 7th
edition. Hoboken, NJ: Wiley.
[7] Box GEP, Wilson KB (1951). "On the Experimental attainment of
Optimum Conditions" Journal of the Royal Statistical Society B, 13th
Edition, 1-45.
[8] Montgomery, D.C. (2009). Design and Analysis of Experiments; 7th
edition. Hoboken,NJ:Wiley.
[9] Hill WJ, Hunter WG (1989). "A Review of Response Surface
Methodology: A literature Review." Technometrics, Vol 8, 571-590.
[10] Mead R, and Pike D J (1975) "A Review of Response Surface
Methodology from a Biometric View Point" Biometrics Vol 31, No 4,
803-851.
[11] Obiuto C.C, (2012) M.Eng Thesis, Submitted to the Industrial and
Production Engineering Department of Nnamdi Azikiwe University,
Awka.
[12] Myers R H, Montgometry, D C, Anderson-Cook C M, (2009) "Response
Surface Methodology: Process and product Optimization using Designed
Experiments. John Wiley and Sons.
[13] Taguchi G., Elsayed A.E., Hsiang T.C., (1989) "Quality Engineering in
Production Systems," McGraw-Hill book Company, New York.
[14] Taguchi G., Chowdhury S., Wu Y. (2004), "Taguchi-s Quality
Engineering handbook," Edition 2004, pp. 21.
[15] Shinkle, G. Gooding, R. and Smith, M. (2004). Transforming Strategy
Into Success: How to Implement a Lean Management System.
Productivity Press, New York.
[16] Hines, P. (1994). Creating World Class Suppliers. Pitman Publishing,
London, UK.
[17] Box, G., Bisgaard, S., and Fung, C. (1988). Quality Practices in Japan.
Quality Progress Publications, Okinawa, Japan.
[18] Shingo, S. (1985). A Revolution in Manufacturing: The SMED System.
Productivity Inc. USA.
[1] Womack, J. Jones, D. and Roos, D. (1990) The Machine that Changed
the World Rawson Associates, New York, USA.
[2] Hunter, S. (2003). An Introduction to Lean Production Systems. FDM
Journal, Vol. 75, Iss.13; pg. 58.
[3] Ihueze, C. and Okpala, C. (2012). Application of Taguchi Robust Design
as Optimized Lean Production in Manufacturing Companies. Research
Journal in Engineering and Applied Sciences
http://rjeas.emergingresource.org/issuesview.php?id=100&issue_name=
Volume%201%20Number%201&issue_month=January&issue_year=20
12.
[4] Taguchi, G. (1987). The Taguchi Approach to Parameter Design.
Quality Progress Publications, Okinawa, Japan.
[5] Ihueze, C.C., Obiuto, C.C., and Okpala, C.C. (2012), "Quality
improvement of process product value through robust design of control
parameters" Research journal in Engineering and Applied sciences (1),
2012, 70-76.
[6] Montgomery, D.C. (2009). Design and Analysis of Experiments; 7th
edition. Hoboken, NJ: Wiley.
[7] Box GEP, Wilson KB (1951). "On the Experimental attainment of
Optimum Conditions" Journal of the Royal Statistical Society B, 13th
Edition, 1-45.
[8] Montgomery, D.C. (2009). Design and Analysis of Experiments; 7th
edition. Hoboken,NJ:Wiley.
[9] Hill WJ, Hunter WG (1989). "A Review of Response Surface
Methodology: A literature Review." Technometrics, Vol 8, 571-590.
[10] Mead R, and Pike D J (1975) "A Review of Response Surface
Methodology from a Biometric View Point" Biometrics Vol 31, No 4,
803-851.
[11] Obiuto C.C, (2012) M.Eng Thesis, Submitted to the Industrial and
Production Engineering Department of Nnamdi Azikiwe University,
Awka.
[12] Myers R H, Montgometry, D C, Anderson-Cook C M, (2009) "Response
Surface Methodology: Process and product Optimization using Designed
Experiments. John Wiley and Sons.
[13] Taguchi G., Elsayed A.E., Hsiang T.C., (1989) "Quality Engineering in
Production Systems," McGraw-Hill book Company, New York.
[14] Taguchi G., Chowdhury S., Wu Y. (2004), "Taguchi-s Quality
Engineering handbook," Edition 2004, pp. 21.
[15] Shinkle, G. Gooding, R. and Smith, M. (2004). Transforming Strategy
Into Success: How to Implement a Lean Management System.
Productivity Press, New York.
[16] Hines, P. (1994). Creating World Class Suppliers. Pitman Publishing,
London, UK.
[17] Box, G., Bisgaard, S., and Fung, C. (1988). Quality Practices in Japan.
Quality Progress Publications, Okinawa, Japan.
[18] Shingo, S. (1985). A Revolution in Manufacturing: The SMED System.
Productivity Inc. USA.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:56961", author = "Christopher C. Ihueze and Charles C. Okpala and Christian E. Okafor and Peter O. Ogbobe", title = "Robust Design and Optimization of Production Wastes: An Application for Industries", 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.", keywords = "Excess-inventory, setup time, single minute exchange of dies, optimal value, over-production, robust design.", volume = "7", number = "4", pages = "590-8", }