Taguchi's Quality Engineering Handbook

by Taguchi, Genichi; Chowdhury, Subir; Wu, Yuin

• ISBN13: 9780471413349
• ISBN10: 0471413348
• Edition: 1st
• Format: Hardcover
• Copyright: 2004-11-08
• Publisher: Wiley-Interscience

Summary

"This book is a great demonstration of this powerful approach and how it can make a meaningful difference in any type of business. It takes a dedicated engineering approach to implement, but the payback in customer satisfaction and growth is dramatic." -Lou Giuliano, chairman, president, and CEO, ITT IndustriesNo other single volume presents the full breadth of founding beliefs behind the successful engineering practices used by today's leading companies. Helpful to companies in both manufacturing and service industries, Taguchi's Quality Engineering Handbook provides accessible material on such topics as: Quality loss function On-line quality engineering Signal-to-noise ratio Robust engineering Design of experiments (known as the "Taguchi method") Mahalanobis-Taguchi Systems (MTS) and more.Prize or Award AAP Awards for Excellence in Professional and Scholarly Publishing, 2006

Author Biography

GENICHI TAGUCHI, DSc, is Executive Director of the American Supplier Institute (ASI). Dr. Taguchi, an international authority in quality engineering, was awarded the prestigious Deming Prize in 1960 and the Willard F. Rockwell Medal in 1986. He was inducted into the World Level of the Hall of Fame for Engineering, Science, and Technology in 1998, and the Automotive Hall of Fame in 1997. He authored or coauthored forty books and more than 400 technical articles in leading journals. <p>SUBIR CHOWDHURY, DEng, is Chairman and CEO of ASI Consulting Group. He is one of the world's foremost authorities in helping leaders achieve positive and measurable results in business process improvement. He has been awarded the Willard F. Rockwell Medal and was inducted into the World Level of the Hall of Fame for Engineering, Science, and Technology in 2004. Hailed by the New York Times as the "Leading Quality Expert," he is the author of eleven books, including The Power of Six Sigma, which has sold more than a million copies and has been translated into twenty languages. <p>The late YUIN WU was executive director of ASI. He penned the first English (and Chinese) translations of Taguchi's work, and is credited with conducting the first Taguchi Methods experiments in the United States while working with private industry in California. He was active as a consultant in North America as well as many countries in Europe, South America, and Asia. He was the author of several books and hundreds of technical papers.

Table of Contents

Preface	xxv
Acknowledgments	xxix
About the Authors	xxxi
SECTION 1 THEORY
Part I Genichi Taguchi's Latest Thinking	3	(122)
The Second Industrial Revolution and Information Technology	5	(20)
Management for Quality Engineering	25	(14)
Quality Engineering: Strategy in Research and Development	39	(17)
Quality Engineering: The Taguchi Method	56	(69)
Part II Quality Engineering: A Historical Perspective	125	(44)
Development of Quality Engineering in Japan	127	(26)
History of Taguchi's Quality Engineering in the United States	153	(16)
Part III Quality Loss Function	169	(52)
Introduction to the Quality Loss Function	171	(9)
Quality Loss Function for Various Quality Characteristics	180	(12)
Specification Tolerancing	192	(16)
Tolerance Design	208	(13)
Part IV Signal-to-Noise Ratio	221	(90)
Introduction to the Signal-to-Noise Ratio	223	(16)
SN Ratios for Continuous Variables	239	(51)
SN Ratios for Classified Attributes	290	(21)
Part V Robust Engineering	311	(84)
System Design	313	(5)
Parameter Design	318	(22)
Tolerance Design	340	(12)
Robust Technology Development	352	(25)
Robust Engineering: A Manager's Perspective	377	(12)
Implementation Strategies	389	(6)
Part VI Mahalanobis--Taguchi System (MTS)	395	(28)
Mahalanobis--Taguchi System	397	(26)
Part VII Software Testing and Application	423	(12)
Application of Taguchi Methods to Software System Testing	425	(10)
Part VIII On-Line Quality Engineering	435	(48)
Tolerancing and Quality Level	437	(17)
Feedback Control Based on Product Characteristics	454	(14)
Feedback Control of a Process Condition	468	(6)
Process Diagnosis and Adjustment	474	(9)
Part IX Experimental Regression	483	(18)
Parameter Estimation in Regression Equations	485	(16)
Part X Design of Experiments	501	(128)
Introduction to Design of Experiments	503	(3)
Fundamentals of Data Analysis	506	(9)
Introduction to Analysis of Variance	515	(8)
One-Way Layout	523	(5)
Decomposition to Components with a Unit Degree of Freedom	528	(24)
Two-Way Layout	552	(11)
Two-Way Layout with Decomposition	563	(10)
Two-Way Layout with Repetition	573	(11)
Introduction to Orthogonal Arrays	584	(13)
Layout of Orthogonal Arrays Using Linear Graphs	597	(12)
Incomplete Data	609	(8)
Youden Squares	617	(12)
SECTION 2 APPLICATION (CASE STUDIES)
Part I Robust Engineering: Chemical Applications	629	(86)
Biochemistry
Optimization of Bean Sprouting Conditions by Parameter Design	631	(6)
Optimization of Small Algae Production by Parameter Design	637	(6)
Chemical Reaction
Optimization of Polymerization Reactions	643	(8)
Evaluation of Photographic Systems Using a Dynamic Operating Window	651	(8)
Measurement
Application of Dynamic Optimization in Ultra Trace Analysis	659	(7)
Evaluation of Component Separation Using a Dynamic Operating Window	666	(6)
Optimization of a Measuring Method for Granule Strength	672	(7)
A Detection Method for Thermoresistant Bacteria	679	(7)
Pharmacology
Optimization of Model Ointment Prescriptions for In Vitro Percutaneous Permeation	686	(9)
Separation
Use of a Dynamic Operating Window for Herbal Medicine Granulation	695	(10)
Particle-Size Adjustment in a Fine Grinding Process for a Developer	705	(10)
Part II Robust Engineering: Electrical Applications	715	(78)
Circuits
Design for Amplifier Stabilization	717	(15)
Parameter Design of Ceramic Oscillation Circuits	732	(3)
Evaluation Method of Electric Waveforms by Momentary Values	735	(6)
Robust Design for Frequency-Modulation Circuits	741	(5)
Electronic Devices
Optimization of Blow-off Charge Measurement Systems	746	(7)
Evaluation of the Generic Function of Film Capacitors	753	(5)
Parameter Design of Fine-Line Patterning for IC Fabrication	758	(6)
Minimizing Variation in Pot Core Transformer Processing	764	(7)
Optimization of the Back Contact of Power MOSFETs	771	(9)
Electrophoto
Development of High-Quality Developers for Electrophotography	780	(8)
Functional Evaluation of an Electrophotographic Process	788	(5)
Part III Robust Engineering: Mechanical Applications	793	(376)
Biomechanical
Biomechanical Comparison of Flexor Tendon Repairs	795	(11)
Machining
Optimization of Machining Conditions by Electrical Power	806	(13)
Development of Machining Technology for High-Performance Steel by Transformability	819	(8)
Transformability of Plastic Injection-Molded Gear	827	(9)
Material Design
Optimization of a Felt-Resist Paste Formula Used in Partial Felting	836	(5)
Development of Friction Material for Automatic Transmissions	841	(7)
Parameter Design for a Foundry Process Using Green Sand	848	(4)
Development of Functional Material by Plasma Spraying	852	(6)
Material Strength
Optimization of Two-Piece Gear Brazing Conditions	858	(5)
Optimization of Resistance Welding Conditions for Electronic Components	863	(6)
Tile Manufacturing Using Industrial Waste	869	(6)
Measurement
Development of an Electrophotographic Toner Charging Function Measuring System	875	(7)
Clear Vision by Robust Design	882	(8)
Processing
Optimization of Adhesion Condition of Resin Board and Copper Plate	890	(5)
Optimization of a Wave Soldering Process	895	(5)
Optimization of Casting Conditions for Camshafts by Simulation	900	(4)
Optimization of Photoresist Profile Using Simulation	904	(7)
Optimization of a Deep-Drawing Process	911	(5)
Robust Technology Development of an Encapsulation Process	916	(10)
Gas-Arc Stud Weld Process Parameter Optimization Using Robust Design	926	(14)
Optimization of Molding Conditions of Thick-Walled Products	940	(5)
Quality Improvement of an Electrodeposited Process for Magnet Production	945	(5)
Optimization of an Electrical Encapsulation Process through Parameter Design	950	(7)
Development of Plastic Injection Molding Technology by Transformability	957	(8)
Product Development
Stability Design of Shutter Mechanisms of Single-Use Cameras by Simulation	965	(8)
Optimization of a Clutch Disk Torsional Damping System Design	973	(11)
Direct-Injection Diesel Injector Optimization	984	(21)
Optimization of Disk Blade Mobile Cutters	1005	(6)
D-VHS Tape Travel Stability	1011	(7)
Functionality Evaluation of Spindles	1018	(7)
Improving Minivan Rear Window Latching	1025	(7)
Linear Proportional Purge Solenoids	1032	(18)
Optimization of a Linear Actuator Using Simulation	1050	(9)
Functionality Evaluation of Articulated Robots	1059	(10)
New Ultraminiature KMS Tact Switch Optimization	1069	(15)
Optimization of an Electrical Connector Insulator Contact Housing	1084	(16)
Airflow Noise Reduction of Intercoolers	1100	(6)
Reduction of Boosting Force Variation of Brake Boosters	1106	(6)
Reduction of Chattering Noise in Series 47 Feeder Valves	1112	(10)
Optimal Design for a Small DC Motor	1122	(6)
Steering System On-Center Robustness	1128	(13)
Improvement in the Taste of Omelets	1141	(7)
Wiper System Chatter Reduction	1148	(9)
Other
Fabrication Line Capacity Planning Using a Robust Design Dynamic Model	1157	(12)
Part IV Mahalanobis--Taguchi System (MTS)	1169	(130)
Human Performance
Prediction of Programming Ability from a Questionnaire Using the MTS	1171	(7)
Technique for the Evaluation of Programming Ability Based on the MTS	1178	(11)
Inspection
Application of Mahalanobis Distance for the Automatic Inspection of Solder Joints	1189	(7)
Application of the MTS to Thermal Ink Jet Image Quality Inspection	1196	(12)
Detector Switch Characterization Using the MTS	1208	(12)
Exhaust Sensor Output Characterization Using the MTS	1220	(13)
Defect Detection Using the MTS	1233	(5)
Medical Diagnosis
Application of Mahalanobis Distance to the Measurement of Drug Efficacy	1238	(6)
Use of Mahalanobis Distance in Medical Diagnosis	1244	(14)
Prediction of Urinary Continence Recovery among Patients with Brain Disease Using the Mahalanobis Distance	1258	(9)
Mahalanobis Distance Application for Health Examination and Treatment of Missing Data	1267	(10)
Forecasting Future Health from Existing Medical Examination Results Using the MTS	1277	(11)
Product
Character Recognition Using the Mahalanobis Distance	1288	(5)
Printed Letter Inspection Technique Using the MTS	1293	(6)
Part V Software Testing and Application	1299	(66)
Algorithms
Optimization of a Diesel Engine Software Control Strategy	1301	(9)
Optimizing Video Compression	1310	(14)
Computer Systems
Robust Optimization of a Real-Time Operating System Using Parameter Design	1324	(11)
Software
Evaluation of Capability and Error in Programming	1335	(8)
Evaluation of Programmer Ability in Software Production	1343	(8)
Robust Testing of Electronic Warfare Systems	1351	(9)
Streamlining of Debugging Software Using an Orthogonal Array	1360	(5)
Part VI On-Line Quality Engineering	1365	(34)
On-Line
Application of On-Line Quality Engineering to the Automobile Manufacturing Process	1367	(9)
Design of Preventive Maintenance of a Bucket Elevator through Simultaneous Use of Periodic Maintenance and Checkup	1376	(7)
Feedback Control by Quality Characteristics	1383	(6)
Control of Mechanical Component Parts in a Manufacturing Process	1389	(6)
Semiconductor Rectifier Manufacturing by On-Line Quality Engineering	1395	(4)
Part VII Miscellaneous	1399	(219)
Miscellaneous
Estimation of Working Hours in Software Development	1401	(5)
Applications of Linear and Nonlinear Regression Equations for Engineering	1406	(17)
SECTION 3 TAGUCHI'S METHODS VERSUS OTHER QUALITY PHILOSOPHIES
Quality Management in Japan	1423	(19)
Deming and Taguchi's Quality Engineering	1442	(7)
Enhancing Robust Design with the Aid of TRIZ and Axiomatic Design	1449	(21)
Testing and Quality Engineering	1470	(8)
Total Product Development and Taguchi's Quality Engineering	1478	(14)
Role of Taguchi Methods in Design for Six Sigma	1492	(126)
APPENDIXES
A Orthogonal Arrays and Linear Graphs: Tools for Quality Engineering	1525	(73)
B Equations for On-Line Process Control	1598	(4)
C Orthogonal Arrays and Linear Graphs for Chapter 38	1602	(16)
Glossary	1618	(7)
Bibliography	1625	(4)
Index	1629