METALLURGICAL

ENGINEERING 14

Metallurgical
Engineering Design

Lecture 11
Taguchi Technique II
Signal-to-Noise Ratio
Genichi Taguchi

TLFMenor Department of Mining, Metallurgical and Materials Engineering

Taguchi Principle
aimed to introduce a method that would improve the
efficiency and decrease the cost associated with
experimentation
manufacturing planning and activity should be
centered on prevention rather than detection
methods

TLFMenor Department of Mining, Metallurgical and Materials Engineering

Taguchi says..

...removing the cause of

variation can be prohibitively
expensive or impractical

TLFMenor Department of Mining, Metallurgical and Materials Engineering

Taguchi says...

The goal of manufacturing should be

to remove or to dampen the effect of
the causes, instead of removing the
causes themselves.

TLFMenor Department of Mining, Metallurgical and Materials Engineering

Taguchi-sensei says...

ROBUST

TLFMenor Department of Mining, Metallurgical and Materials Engineering

Taguchi asks...

Would you rather have 100%

improvement in 5 years or 60-90%
improvement in 5 weeks?

TLFMenor Department of Mining, Metallurgical and Materials Engineering

Signal-to-Noise Ratio (S/N ratio)

defined as mean divided

by the standard
deviation

a response variable that

takes both the mean
and the variation into
consideration

TLFMenor Department of Mining, Metallurgical and Materials Engineering

Signal-to-Noise Ratio (S/N ratio)

made up of the mean level

and the variation around
this mean

helps find a setting of the

control factors that give
the best mean level while
keeping variation under
control

TLFMenor Department of Mining, Metallurgical and Materials Engineering

Defining Terms
Control Factor
significantly influences the process variability
determined to reduce effect of noise
Signal Factor
influences the process mean, but does not largely affect the
variability
used to adjust the centering of the process mean

TLFMenor Department of Mining, Metallurgical and Materials Engineering

S/N Formulas
Smaller the Better

1
S / N 10 log ( yi )
2

TLFMenor Department of Mining, Metallurgical and Materials Engineering

S/N Formulas
Larger the Better

1 1
S / N 10 log ( 2 )
n yi

TLFMenor Department of Mining, Metallurgical and Materials Engineering

S/N Formulas
Nominal is Best

1
( S m Ve )
S / N 10 log n
Ve
1
where: Sm ( yi ) 2
n
1
Ve ( yi S m )
2

n 1

TLFMenor Department of Mining, Metallurgical and Materials Engineering

Example
A manufacturer of resistors wants to improve yield
on substrate chips, many of which have been rejected
for thickness problems (tolerance 204). They
decided to run an experimental design on the
following factors:

Factor Level 1 Level 2 Level 3

A Ceramic Material Paraffin Paste Mixture

B Machine Pressure 300 375 450

C Mixing Time 60 90 120

D Temperature 275 350 425

TLFMenor Department of Mining, Metallurgical and Materials Engineering

 Result
L9(34) A B C D Thickness Totals

1 1 1 1 1 27 31 28 86

2 1 2 2 2 16 18 20 54

3 1 3 3 3 19 14 21 54

4 2 1 2 3 23 20 25 68

5 2 2 3 1 25 24 26 75

6 2 3 1 2 19 18 20 57

7 3 1 3 2 29 25 27 81

8 3 2 1 3 15 19 18 52

9 3 3 2 1 16 17 18 51

TLFMenor Department of Mining, Metallurgical and Materials Engineering

Response Table

Response Table (Totals)

Factor A B C D
Level 1 194 235 195 212
Level 2 200 181 173 192
Level 3 184 162 210 174
Total 578 578 578 578

TLFMenor Department of Mining, Metallurgical and Materials Engineering

Solution

(27 16 ... 18) 2

CF 12,373 .5
27
SStotal (27 2 16 2 ... 18 2 ) 12,373 .5 568 .5
( A1 ) 2 ( A2 ) 2 ( A3 ) 2
SS factor CF
n n n
2 2 2
194 200 184
SS A CF 14.5
9 9 9
SSerror SStotal SS A SSB SSC SSD 78.1

TLFMenor Department of Mining, Metallurgical and Materials Engineering

Solution

Source of variation dof SS MS f SS P(%)

A 2 14.5 7.25 1.67 5.82 1

B 2 318.72 159.36 36.72 310.04 55

C 2 76.94 38.47 8.86 68.26 12

D 2 80.28 40.14 9.25 71.16 13

error 18 78.06 4.34 112.86 20

Total 26 568.5

Reponse Table, Averages

Factor A B C D
target thickness values
nearest 20 Level 1 21.6 26.1 21.7 23.6
Level 2 22.2 20.1 19.2 21.3
Level 3 20.4 18 23.3 19.3
Optimum
A3 B2 C2 D3
Settings

TLFMenor Department of Mining, Metallurgical and Materials Engineering

Solution
Compute for the corresponding S/N Ratios
Nominal is Best (as required by the problem)

1
( S m Ve ) 1
(2,465.33 4.34)
S / N 10 log n S / N 10 log 3 22.76
Ve 4.34
1 1
S m ( yi ) 2 S m (27 31 28) 2 2,465.33
n 3
1
1 Ve [(27 2 312 28 2 ) 2,465.33] 4.34
Ve ( yi S m )
2
2
n 1

TLFMenor Department of Mining, Metallurgical and Materials Engineering

Solution

L9(34) A B C D S/N Ratio

1 1 1 1 1 22.8
2 1 2 2 2 19.1
3 1 3 3 3 13.9
4 2 1 2 3 19.1
5 2 2 3 1 28.0
6 2 3 1 2 25.6
7 3 1 3 2 22.6
8 3 2 1 3 18.4
9 3 3 2 1 24.6

TLFMenor Department of Mining, Metallurgical and Materials Engineering

Solution

Response Table (S/N Totals)

Factor A B C D
Level 1 55.8 64.5 66.8 75.4
Level 2 72.7 65.5 62.8 67.3
Level 3 65.6 64.1 64.5 51.4
Total 194.1 194.1 194.1 194.1
Original Settings A3 B2 C2 D3
Revised Settings A2 B2 C1 D1

choose highest
S/N ratio

TLFMenor Department of Mining, Metallurgical and Materials Engineering

Solution

Source of
SS dof MS f SS P(%)
Variation
A 48.0 2 24.0 30.0 46.4 30.9

B 0.3 (2)

C 2.7 (2)

D 99.4 2 49.7 62.1 97.8 65

error 3.0 4 0.8 6.2 4.1

Total 150.4 8 100

Therefore, choosing the correct settings for the ceramic material (A) and
the heat treat temperature (D) will reduce the variation in the thickness of
the substrate chips. Machine pressure (B) and mixing time (C) will be
adjusted to move the process mean to the target value.

TLFMenor Department of Mining, Metallurgical and Materials Engineering

Summary of Steps for Analysis
Identify control factors
Determine optimum levels for signal factors
Identify signal factors using raw data ANOVA
Determine optimum levels for control factors
Perform confirmation run
Control critical factors and signal factors

TLFMenor Department of Mining, Metallurgical and Materials Engineering

Additional Notes
The first ANOVA table is used to determine the signal factors
while the second ANOVA table is used to identify the control
factors.
Factor settings that will be considered in the process line
would depend on the revised setting, and the signal factors
may be adjusted to produce results close to the desired value.

TLFMenor Department of Mining, Metallurgical and Materials Engineering

Homework
A manufacturer of rubber hosing wants to increase the strength
of his product. He determines four factors that could influence
his process. He sets them at the following levels:

Factor Level 1 Level 2 Level 3

A Machine Temperature 300 350 400

B Reaction Time 5 10 15

C Agitation Speed 100 150 200

D Silicon Excess Rate 10 20 30

TLFMenor Department of Mining, Metallurgical and Materials Engineering

Homework (Results)

L9(34) A B C D Burst Strength

1 1 1 1 1 15 19

2 1 2 2 2 22 26

3 1 3 3 3 5 7

4 2 1 2 3 40 38

5 2 2 3 1 16 17

6 2 3 1 2 17 20

7 3 1 3 2 8 11

8 3 2 1 3 30 25

9 3 3 2 1 28 29

TLFMenor Department of Mining, Metallurgical and Materials Engineering

 THANK YOU FOR LISTENING!

TLFMenor Department of Mining, Metallurgical and Materials Engineering