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Article
Publication date: 29 April 2021

Victor Chidiebere Maduekwe and Sunday Ayoola Oke

Key performance indicators (KPIs) of maintenance systems serve as benchmarks to workers and organizations to compare their goals for decision-making purposes…

Abstract

Purpose

Key performance indicators (KPIs) of maintenance systems serve as benchmarks to workers and organizations to compare their goals for decision-making purposes. Unfortunately, the effects of one KPI on the other are least known, restraining decisions on prioritization of KPIs. This article examines and prioritizes the KPIs of the maintenance system in a food processing industry using the novel Taguchi (T) scheme-decision-making trial and evaluation laboratory (DEMATEL) method, Taguchi–Pareto (TP) scheme–DEMATEL method and the DEMATEL method.

Design/methodology/approach

The causal association of maintenance process parameters (frequency of failure, downtime, MTTR, MTBF, availability and MTTF) was studied. Besides, the optimized maintenance parameters were infused into the DEMATEL method that translates the optimized values into cause and effect responses and keeping in view the result of analysis. Data collection was done from a food processing plant in Nigeria.

Findings

The results indicated that downtime and availability have the most causal effects on other criteria when DEMATEL and T-DEMATEL methods were respectively applied to the problem. Furthermore, the frequency of failure is mostly affected by other criteria in the key performance indication selection using the two methods. The combined Taguchi scheme and DEMATEL method is appropriate to optimize and establish the causal relationships of factors.

Originality/value

Hardly any studies have reported the joint optimization and causal relationship of maintenance system parameters. However, the current study achieves this goal using the T-DEMATEL, TP-DEMATEL and DEMATEL methods for the first time. The applied methods effectively ease decisions on prioritization of KPIs for enhancement.

Details

International Journal of Intelligent Computing and Cybernetics, vol. 14 no. 3
Type: Research Article
ISSN: 1756-378X

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Article
Publication date: 10 August 2018

Caner Ekincioğlu and Semra Boran

There can be activities that cannot reduce times by conventional single minute exchange of die (SMED) tools. In this case more advanced tools are needed. The purpose of…

Abstract

Purpose

There can be activities that cannot reduce times by conventional single minute exchange of die (SMED) tools. In this case more advanced tools are needed. The purpose of this paper is to integrate the fuzzy Taguchi method into the SMED method in order to improve the setup time. The reason for using fuzzy logic is the subjective evaluation of factor’s levels assessment by experts. Subjective assessment contains a certain degree of uncertainty and is vagueness. The fuzzy Taguchi method provides to determining optimal setup time parameters in an activity of SMED. So it is possible to reduce time more than the conventional SMED method.

Design/methodology/approach

In this study, the SMED method and the fuzzy Taguchi method are used.

Findings

In this study, it has been shown that the setup time is reduced (from 196 to 75 min) and the optimum value can be given at the intermediate value by the fuzzy Taguchi method.

Originality/value

In this limited literature research, the authors have not found a study using the fuzzy Taguchi method in the SMED method.

Details

Journal of Enterprise Information Management, vol. 31 no. 6
Type: Research Article
ISSN: 1741-0398

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Article
Publication date: 4 September 2020

Benjamin Chukudi Oji and Sunday Ayoola Oke

There is growing evidence of a knowledge gap in the association of maintenance with production activities in bottling plants. Indeed, insights into how to jointly optimise…

Abstract

Purpose

There is growing evidence of a knowledge gap in the association of maintenance with production activities in bottling plants. Indeed, insights into how to jointly optimise these activities are not clear. In this paper, two optimisation models, Taguchi schemes and response surface methodology are proposed.

Design/methodology/approach

Borrowing from the “hard” total quality management elements in optimisation and prioritisation literature, two new models were developed based on factor, level and orthogonal array selection, signal-to-noise ratio, analysis of variance and optimal parametric settings as Taguchi–ABC and Taguchi–Pareto. An additional model of response surface methodology was created with analysis on regression, main effects, residual plots and surface plots.

Findings

The Taguchi S/N ratio table ranked planned maintenance as the highest. The Taguchi–Pareto shows the optimal parametric setting as A4B4C1 (28 h of production, 30.56 shifts and 37 h of planned maintenance). Taguchi ABC reveals that the planned maintenance and number of shifts will influence the outcome of production greatly. The surface regression table reveals that the production hours worked decrease at a value of planned maintenance with a decrease in the number of shifts.

Originality/value

This is the first time that joint optimisation for bottling plant will be approached using Taguchi–ABC and Taguchi–Pareto. It is also the first time that response surface will be applied to optimise a unique platform of the bottling process plant.

Details

The TQM Journal, vol. 33 no. 2
Type: Research Article
ISSN: 1754-2731

Keywords

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Article
Publication date: 1 October 2005

John G. Vlachogiannis and Ranjit K. Roy

The aim of the paper is the fine‐tuning of proportional integral derivative (PID) controllers under model parameter uncertainties (noise).

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1950

Abstract

Purpose

The aim of the paper is the fine‐tuning of proportional integral derivative (PID) controllers under model parameter uncertainties (noise).

Design/methodology/approach

The fine‐tuning of PID controllers achieved using the Taguchi method following the steps given: selection of the control factors of the PID with their levels; identification of the noise factors that cause undesirable variation on the quality characteristic of PID; design of the matrix experiment and definition of the data analysis procedure; analysis of the data; decision regarding optimum settings of the control parameters and predictions of the performance at optimum levels of control factors; calculation of the expected cost savings under optimum condition; and confirmation of experimental results.

Findings

An example of the proposed method is presented and demonstrates that given certain performance criteria, the Taguchi method can indeed provide sub‐optimal values for fine PID tuning in the presence of model parameter uncertainties (noise). The contribution of each factor to the variation of the mean and the variability of error is also calculated. The expected cost savings for PID under optimum condition are calculated. The confirmation experiments are conducted on a real PID controller.

Research limitations/implications

As a further research it is proposed the contiguous fine‐tuning of PID controllers under a number of a variant controllable models (noise).

Practical implications

The enhancement of PID controllers by Taguchi method is proposed with the form of a hardware mechanism. This mechanism will be incorporated in the PID controller and automatically regulate the PID parameters reducing the noise influence.

Originality/value

Application of Taguchi method in the scientific field of automation control.

Details

The TQM Magazine, vol. 17 no. 5
Type: Research Article
ISSN: 0954-478X

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Article
Publication date: 1 April 2000

Hefin Rowlands, Jiju Antony and Graeme Knowles

Dr Taguchi is a Japanese engineer and an international quality consultant who has made breakthrough improvements in product and process quality through the use of…

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2117

Abstract

Dr Taguchi is a Japanese engineer and an international quality consultant who has made breakthrough improvements in product and process quality through the use of statistical design of experiments (SDOE). The Taguchi method became popular in the West in the 1980s as a means to design robust products and processes. Although many companies and industries have used the method with success, the real benefits of the approach were not realised and fully understood in many cases. This lack of success could be attributed to a number of factors, but mainly because the experiments were treated in isolation and not integrated into a continuous improvement strategy. This paper briefly presents the results of the application of the Taguchi methodology in the UK industry. The paper also illustrates the application of the Taguchi method for optimising the production process of retaining a metal ring in a plastic body in a braking system.

Details

The TQM Magazine, vol. 12 no. 2
Type: Research Article
ISSN: 0954-478X

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Article
Publication date: 1 June 2005

Wimalin Sukthomya and James D.T. Tannock

The paper describes the methods of manufacturing process optimization, using Taguchi experimental design methods with historical process data, collected during normal production.

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2297

Abstract

Purpose

The paper describes the methods of manufacturing process optimization, using Taguchi experimental design methods with historical process data, collected during normal production.

Design/methodology/approach

The objectives are achieved with two separate techniques: the Retrospective Taguchi approach selects the designed experiment's data from a historical database, whilst in the Neural Network (NN) – Taguchi approach, this data is used to train a NN to estimate process response for the experimental settings. A case study illustrates both approaches, using real production data from an aerospace application.

Findings

Detailed results are presented. Both techniques identified the important factor settings to ensure the process was improved. The case study shows that these techniques can be used to gain process understanding and identify significant factors.

Research limitations/implications

The most significant limitation of these techniques relates to process data availability and quality. Current databases were not designed for process improvement, resulting in potential difficulties for the Taguchi experimentation; where available data does not explain all the variability in process outcomes.

Practical implications

Manufacturers may use these techniques to optimise processes, without expensive and time‐consuming experimentation.

Originality/value

The paper describes novel approaches to data acquisition associated with Taguchi experimentation.

Details

International Journal of Quality & Reliability Management, vol. 22 no. 5
Type: Research Article
ISSN: 0265-671X

Keywords

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Article
Publication date: 1 January 2006

Tolga Taner and Jiju Antony

The aim of this article is to show how Taguchi methods can be applied to health care.

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1815

Abstract

Purpose

The aim of this article is to show how Taguchi methods can be applied to health care.

Design/methodology/approach

The quadratic loss function is at the heart of Taguchi methods. It is a powerful motivator for a quality strategy and can be used to adequately model the loss to society in health care. It also establishes a relationship between cost and variability. Therefore, it can be integrated with the performance and parameters of the design of medical applications. Signal‐to‐noise ratios give a sense of how close is the performance to the ideal. By maximizing the signal‐to‐noise ratio, quality‐engineering activities can be aimed at identifying near‐optimum levels of factors and making quality equal to zero.

Findings

This article shows that, when the patients' requirements are consistently met, lower losses can provide an impetus to improve patient satisfaction.

Originality/value

The article outlines areas in health care where Taguchi methods can easily be applied.

Details

Leadership in Health Services, vol. 19 no. 1
Type: Research Article
ISSN: 1366-0756

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Article
Publication date: 1 November 2002

Hung‐Chang Liao and Yan‐Kwang Chen

Looks at the Taguchi method, a traditional approach that seeks to obtain the best combination of factors with the lowest societal cost solution to achieve customer…

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1306

Abstract

Looks at the Taguchi method, a traditional approach that seeks to obtain the best combination of factors with the lowest societal cost solution to achieve customer requirements, and also principal component analysis (PCA). States that the Taguchi method can only be used to optimize single response problems and not multi‐response problems and that PCA, although it has been considered to solve multi‐response problems, itself has shortcomings. Proposes a data envelopment analysis ranking (DEAR) approach as an effective means of optimizing the multi‐response problem. Includes a series of steps from the proposed approach which are capable of decreasing uncertainty caused by engineering judgement in the Taguchi method and overcoming the shortcomings of PCA. Concludes that the DEAR approach is more powerful for practical applications.

Details

International Journal of Quality & Reliability Management, vol. 19 no. 7
Type: Research Article
ISSN: 0265-671X

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Article
Publication date: 14 November 2019

Ikuobase Emovon and Rosemary Norman

One of the key elements of a maintenance system is risk analysis because the risk level of an engineering system will determine the maintenance policy required. Failure…

Abstract

Purpose

One of the key elements of a maintenance system is risk analysis because the risk level of an engineering system will determine the maintenance policy required. Failure Mode and Effect Analysis (FMEA) is widely applied in evaluating risk of failure of engineering systems. However, the conventional FMEA used in analyzing risk by most industries has shortcomings such as an inability to utilize imprecise and interval data in prioritizing risk. To overcome these limitations, different variants of FMEA have been reported in the literature. However, these modified approaches are computationally intensive; hence, the purpose of this paper is to develop an efficient FMEA-based methodology that is easy to analyze and implement.

Design/methodology/approach

The proposed technique combines the Taguchi method with FMEA in order to analyze risk of engineering systems easily and effectively. The effectiveness of the approach is demonstrated with a case study of the fuel oil system of a marine diesel engine.

Findings

The results of the integrated Taguchi method and FMEA, when compared with well-known techniques, namely, VIKOR and compromise programming, from the literature are very similar. From the comparative analysis, it was evident that the proposed method is a viable option to the more computationally intensive approaches used in the literature.

Originality/value

The approach proposed is novel and simple and can be implemented more easily than approaches from the literature in analyzing risk.

Details

Journal of Quality in Maintenance Engineering, vol. 26 no. 4
Type: Research Article
ISSN: 1355-2511

Keywords

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Article
Publication date: 24 November 2020

Sakthivel Murugan R. and Vinodh S.

This paper aims to optimize the process parameters of the fused deposition modelling (FDM) process using the Grey-based Taguchi method and the results to be verified based…

Abstract

Purpose

This paper aims to optimize the process parameters of the fused deposition modelling (FDM) process using the Grey-based Taguchi method and the results to be verified based on a technique for order preference by similarity to ideal solution (TOPSIS) and analytical hierarchy process (AHP) calculation.

Design/methodology/approach

The optimization of process parameters is gaining a potential role to develop robust products. In this context, this paper presents the parametric optimization of the FDM process using Grey-based Taguchi, TOPSIS and AHP method. The effect of slice height (SH), part fill style (PFS) and build orientation (BO) are investigated with the response parameters machining time, surface roughness and hardness (HD). Multiple objective optimizations were performed with weights of w1 = 60%, w2 = 20% and w3 = 20%. The significance of the process parameters over response parameters is identified through analysis of variance (ANOVA). Comparisons are made in terms of rank order with respect to grey relation grade (GRG), relative closeness and AHP index values. Response table, percentage contributions of process parameters for both GRG and TOPSIS evaluation are done.

Findings

The optimum factor levels are identified using GRG via the Grey Taguchi method and TOPSIS via relative closeness values. The optimized factor levels are SH (0.013 in), PFS (solid) and BO (45°) using GRG and SH (0.013 in), PFS (sparse-low density) and BO (45°) using TOPSIS relative closeness value. SH has higher significance in both Grey relational analysis and TOPSIS which were analysed using ANOVA.

Research limitations/implications

In this research, the multiple objective optimizations were done on an automotive component using GRG, TOPSIS and AHP which showed a 27% similarity in their ranking order among the experiments. In the future, other advanced optimization techniques will be applied to further improve the similarity in ranking order.

Practical implications

The study presents the case of an automotive component, which illustrates practical relevance.

Originality/value

In several research studies, optimization was done on the standard test specimens but not on a real-time component. Here, the multiple objective optimizations were applied to a case automotive component using Grey-based Taguchi and verified with TOPSIS. Hence, an effort has been taken to find optimum process parameters on FDM, for achieving smooth, hardened automotive components with enhanced printing time. The component can be explored as a replacement for the existing product.

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