This document discusses optimizing the mix proportions of fly ash bricks using the Taguchi method. Experiments were conducted with four factors (water/binder ratio, fly ash percentage, coarse sand percentage, and stone dust percentage) at three levels each. Analysis of variance showed that water/binder ratio, fly ash percentage, and stone dust percentage significantly affected compressive strength. The optimal settings found were a water/binder ratio of 0.4, fly ash percentage of 39%, coarse sand percentage of 24%, and stone dust percentage of 30%, resulting in a predicted maximum compressive strength of 166.22 kg/cm2. A 6-step methodology for applying Taguchi's robust design of experiments was used.

1. Process parameter optimization for fly
ash brick by Taguchi method
Saurabh Anand (PGDM)
Institute for Future Education, Entrepreneurship and Leadership – iFEEL,
Lonavala, 410405.
ABSTRACT
This reportis on experimental investigation is carried out to optimize the mix
proportions of the fly ash brick by Taguchi method of parameter design. The
experiments have been designed using an orthogonalarray with four factors
and three levels each. Cement has been mixed as binding materials and water
binder ratio has been considered as one of the controlfactors. The effects of
water/binder ratio, fly ash, coarsesand, and stone duston the performance
characteristic are analysed using mean responsedata. According to result
water/binder ratio of 0.4, fly ash of 39%, coarsesand of 24%, and stone dust of
30%. The mean value of optimal strength is predicted as 166.22 kg.cm–2
.

2. 1. Introduction
Profile of the assumed Company
Companywhich is assumedis in manufacturingof fly ashbrick. Hereit has
the process for compressivestrength of fly ash brick where there are no.
of factorswhich are responsiblefor the manufacturingof fly ash brickand
giving it durability/stability.
Literature Review
Taguchi is a statistical method developed by Genichi Taguchi which is
useful to improve quality of manufactured goods.
Taguchi is used to develop designs for studying variations in the process.
It includes innovations and specific loss function.
Problem Statement
To find thecombination forsetting up the binding ratio and increasing the
compressive strength of fly ash brick.
2. Design of Experiment
It is a systematic method to determine the relationship between factors
which affects a strength as well as the durability of fly ash brick.
Also we have calculated signal to noise ratio on the basis of ANOVA.
In this paper we have used 6 step methodology for deploying robust
Taguchi design in process optimization of brewing process using Minitab
software

3. 3. Methodology Selected for Solving Above Problem
Methodology for deploying robust Taguchi approach for process
optimization (6 step methodology)
Identification of control factors and their levels that are to be optimized
Identification of thecontrollable and noisefactorsthatareinfluencing the
above identified performancecharacteristics and determination of levels
and values for all identified controllable and noise factors
Developing Design of Experiment (DOE)with the help of Minitab software
Conducting the experiments as per design analysing the results produced
as per designed experiment for the compressive strength of brick
specimens and posting the values in Minitab worksheet
Prediction of the expected results for optimal settings with the help of
Minitab
Validation of optimal setting by conformation of trails.

4. 4. General Linear Model
Inner Array Outer Array
Serial No.
Controllable
Factors
Levels
Compressive
strength of brick
(abv) (%)
1 2 3 R1 R2
1 A 0.40 0.42 0.45
2 B 35 37 39
3 C 20 22 24
4 D 28 30 32
Analysis Of Variance
Source DF Adj SS Adj MS F-Value P-Value
A 2 395.11 197.56 5.03 0.034
B 2 61.44 30.72 0.78 0.486
C 2 448.78 224.39 5.71 0.025
D 2 6328.11 3164.06 80.56 0.000
Error 9 353.50 39.28
Total 17 7586.94
Herethe ANOVA resultshowsthatthe p-valuewhich can be seen is 0.000,0.025
and 0.034 which is below the significance level and is considered as good factor
to be taken into considerationwhich areWater/binderratio, Fly ash%and Stone
dust%.

5. 5. Analysis, Results and Discussion
Testing Machine has been used to measure the compressivestrength of brick
specimens. Three readings are recorded for each experimental condition. Data
from a designed experiment are used to analyse the mean objective/response
function. In Taguchi technique, the variation of the response is also examined
using an appropriately chosen S/N ratio. Broadly speaking, the S/N ratio is the
ratio of the mean (signal) to the standard deviation (noise).
6. Implications
The above 6 step methodology which is used in this paper can be used for any
manufacturing processes of the fly ash brick industry. The results are highly
specific to this industry butthe methodology is generic and can be used in the
manufacturing process.
References
1. Chang PK, Hou WM. A study on the hydration properties of high
performance slag concrete analysed by SRA. Cement and Concrete
Research 2003; 33(2):183–189.
2. Chang PK, Peng YN, Hwang CL. A design consideration for durability of
high performance concrete. Cement and Concrete Composites 2001;
23(4–5):375–380.
3. Smith LA. The design of fly ash concretes. In: ProceedingsInstitute of Civil
Engineering; 1967. p. 770–789.

6. Appendix
Table 1 – Factor and Factor Levels
Inner Array Outer Array
Serial No.
Controllable
Factors
Levels
Compressive
strength of brick
(abv) (%)
1 2 3 R1 R2
1 A 0.40 0.42 0.45
2 B 35 37 39
3 C 20 22 24
4 D 28 30 32
Controllable and Noise Factors and Factor Levels
Inner Array Outer Array (abv)
Serial
No.
A B C D Noise R1 R2
1 0.40 35 20 28 113 117
2 0.42 37 22 30 113 100
3 0.45 39 24 32 113 110
4 0.40 35 20 28 123 117
5 0.42 37 22 30 117 133
6 0.45 39 24 32 133 147
7 0.40 35 20 28 163 163
8 0.42 37 22 30 143 147
9 0.45 39 24 32 163 160

7. Optimal setting is arrived after considering main effect plots and delta values
The graph shows atmaximum measurewhere Water/binder ratio is to be
taken at 0.45, Fly ash% at 39, CoarseSand % at 20 and Stone dust% at 30.