Robust Design History of Robust Design Robust Design method is essential to improving engineering productivity. It was pioneered by Dr. Genichi Taguchi.

Robust DesignRobust Design

History of Robust DesignHistory of Robust Design

Robust Design method is essential to improving Robust Design method is essential to improving engineering productivity. It was pioneered by Dr. engineering productivity. It was pioneered by Dr. Genichi Taguchi after the end of the Second World Genichi Taguchi after the end of the Second World War. This method has evolved over the last five War. This method has evolved over the last five decades. Companies around the world have saved decades. Companies around the world have saved millions of dollars by using the method in diverse millions of dollars by using the method in diverse industries such as automobiles, xerography, industries such as automobiles, xerography, telecommunications, electronics, software, etc telecommunications, electronics, software, etc (http://www.isixsigma.com/library/content/c020311a.(http://www.isixsigma.com/library/content/c020311a.asp).asp).

DefinitionDefinition

Robust has many definitions here are a few Robust has many definitions here are a few that we found.that we found.

A process that does not change with changing A process that does not change with changing noise.noise.

Designing products and processes that are Designing products and processes that are minimally impacted by external forces such as minimally impacted by external forces such as environment, customer use, or manufacturing environment, customer use, or manufacturing conditions (conditions (www.amsup.com/robust_designwww.amsup.com/robust_design//). ).

Taguchi MethodTaguchi Method The Robust Design method can also be called the Taguchi The Robust Design method can also be called the Taguchi

Method, and was pioneered by Dr. Genichi Taguchi. Robust Method, and was pioneered by Dr. Genichi Taguchi. Robust Design greatly improves engineering productivity by Design greatly improves engineering productivity by consciously considering the noise factors: environmental consciously considering the noise factors: environmental variation during the product's usage, manufacturing variation, variation during the product's usage, manufacturing variation, and component deterioration. The cost of failure in the Robust and component deterioration. The cost of failure in the Robust Design method helps ensure customer satisfaction. Robust Design method helps ensure customer satisfaction. Robust Design focuses on improving the fundamental function of the Design focuses on improving the fundamental function of the product or process. Robust Design facilitates flexible designs product or process. Robust Design facilitates flexible designs and concurrent engineering. It is the most powerful method and concurrent engineering. It is the most powerful method available to reduce product cost, improve quality, and reduce available to reduce product cost, improve quality, and reduce development interval development interval ((http://www.isixsigma.com/library/content/c020311a.asp).http://www.isixsigma.com/library/content/c020311a.asp).

Taguchi’s ApproachTaguchi’s Approach

Taguchi’s Quote: “Robust Design: Not just strong. Flexible! Taguchi’s Quote: “Robust Design: Not just strong. Flexible! Idiot Proof! Simple! Efficient! A product/process that Idiot Proof! Simple! Efficient! A product/process that produces consistent, high level performance despite being produces consistent, high level performance despite being subjected to a wide range of changing client and subjected to a wide range of changing client and manufacturing conditions manufacturing conditions ((www.amsup.com/robust_designwww.amsup.com/robust_design//).”).”

This approach costs more, takes more time, and isn’t always This approach costs more, takes more time, and isn’t always successful (successful (www.orszulik.free-online.co.uk/page5.html).www.orszulik.free-online.co.uk/page5.html).

This approach allows experiments to be performed and the This approach allows experiments to be performed and the product/process becomes insensitive to use-conditions and product/process becomes insensitive to use-conditions and other uncontrollable factors other uncontrollable factors ((www.orszulik.free-online.co.uk/page5.html).www.orszulik.free-online.co.uk/page5.html).

Problems Using Robust DesignProblems Using Robust Design An example of a problem with Robust Design: A team of engineers was An example of a problem with Robust Design: A team of engineers was

working on the design of a radio receiver for ground to aircraft working on the design of a radio receiver for ground to aircraft communication. This receiver required high reliability, and low bit error communication. This receiver required high reliability, and low bit error rate for data transmission. Building series of prototypes to sequentially rate for data transmission. Building series of prototypes to sequentially eliminate problems would be expensive. The other problem was that eliminate problems would be expensive. The other problem was that computer simulation effort for evaluating a single design was time computer simulation effort for evaluating a single design was time consuming and expensive. So, how can you speed up development but consuming and expensive. So, how can you speed up development but assure reliability assure reliability (http://www.isixsigma.com/library/content/c020311a.asp)?(http://www.isixsigma.com/library/content/c020311a.asp)?

Another example: A manufacturer introduced a high speed copy machine Another example: A manufacturer introduced a high speed copy machine only to find that the paper feeder jammed almost ten times more frequently only to find that the paper feeder jammed almost ten times more frequently than what was planned. The traditional method for evaluating the than what was planned. The traditional method for evaluating the reliability of a single new design idea took several weeks. How can the reliability of a single new design idea took several weeks. How can the company conduct the needed research in a short time and come up with a company conduct the needed research in a short time and come up with a design that would not embarrass the company design that would not embarrass the company (http://www.isixsigma.com/library/content/c020311a.asp)?(http://www.isixsigma.com/library/content/c020311a.asp)?

Robust Design & EngineersRobust Design & Engineers

Robust design allows engineers to develop products and Robust design allows engineers to develop products and processes which perform as intended through a wide range of processes which perform as intended through a wide range of user’s conditions in their life cycle which is durable and user’s conditions in their life cycle which is durable and reliablereliable

To maximize robustness engineers improve the intended To maximize robustness engineers improve the intended function of the product and increase their noise to factors function of the product and increase their noise to factors which can lead to a decrease in performance.which can lead to a decrease in performance.

Engineers can change the product formulas and process Engineers can change the product formulas and process settings to gain their desired performance level in the shortest settings to gain their desired performance level in the shortest time with the lowest cost. time with the lowest cost.

Engineers can simplify their designs and the process to reduce Engineers can simplify their designs and the process to reduce the cost (the cost (www.amsup.com/robust_designwww.amsup.com/robust_design//).).

Results from Robust DesignResults from Robust Design

Improvement through quality, reliability, and Improvement through quality, reliability, and durability.durability.

Manufacturing cost reduction.Manufacturing cost reduction. Design cycle time reduction.Design cycle time reduction. New knowledgeNew knowledge

((www.amsup.com/robust_designwww.amsup.com/robust_design//))

ReferencesReferences

www.amsup.com/robust_design/www.amsup.com/robust_design/ www.orszulik.free-online.co.uk/page5.htmlwww.orszulik.free-online.co.uk/page5.html http://www.isixsigma.com/library/content/http://www.isixsigma.com/library/content/

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