robust

1. Robust Design
Robust Design

2. History of Robust Design
History 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).

3. Definition
Definition

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_design
www.amsup.com/robust_design/
/).
).

4. Taguchi Method
Taguchi 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).

5. Taguchi’s Approach
Taguchi’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_design
www.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).

6. Problems Using Robust Design
Problems 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)?

7. Robust Design & Engineers
Robust 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 reliable
user’s conditions in their life cycle which is durable and reliable

To maximize robustness engineers improve the intended
To maximize robustness engineers improve the intended
function of the product and increase their noise to factors which
function of the product and increase their noise to factors which
can lead to a decrease in performance.
can lead to a decrease in performance.

Engineers can change the product formulas and process settings
Engineers can change the product formulas and process settings
to gain their desired performance level in the shortest time with
to gain their desired performance level in the shortest time with
the lowest cost.
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_design
www.amsup.com/robust_design/
/).
).

8. Results from Robust Design
Results 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 knowledge
New knowledge
(
(www.amsup.com/robust_design
www.amsup.com/robust_design/
/)
)

9. References
References

www.amsup.com/robust_design/
www.amsup.com/robust_design/

www.orszulik.free-online.co.uk/page5.html
www.orszulik.free-online.co.uk/page5.html

http://www.isixsigma.com/library/content/
http://www.isixsigma.com/library/content/
c020311a.asp
c020311a.asp