What is Robust Design or

Taguchis method?
An experimental method to achieve product
and process quality through designing in an
insensitivity to noise based on statistical
principles.

History of the method

Dr. Taguchi in Japan: 1949-NTT
develops Quality Engineering
4 time winner of Demming Award

Ford Supplier Institute, early 1980s

American Supplier Institute, ASI
Engineering Hall of Fame

Statistics Community
DOE
S/N Ratio

Who uses Taguchis Methods

Lucent
Ford
Kodak
Xerox
Whirlpool
JPL
ITT

Toyota
TRW
Chrysler
GTE
John Deere
Honeywell
Black & Decker

Documented Results from Use

96% improvement of NiCAD
battery on satellites (JPL/ NASA)
10% size reduction, 80%
development time reduction and
20% cost reduction in design of a
choke for a microwave oven (L.G.
Electronics)
$50,000 annual cost savings in
design of heat staking process
(Ann Arbor Assembly Corp)
60% reduction in mean response
time for computer system (Lucent)

$900,000 annual savings in the

production of sheet-molded
compound parts (Chrysler)
$1.2M annual savings due to
reduction in vacuum line
connector failures (Flex
Technologies)
66% reduction in variability in
arrival time and paper
orientation (Xerox)
90% reduction in encapsulation
variation (LSI Corp)

Insensitivity to Noise
Noise = Factors which the engineer can not or
chooses not to control
Unit-to-unit
Manufacturing variations
Aging
Corrosion
UV degradation
wear
Environmental
human interface
temperature
humidity

How Noise Affects a System

Noise

Useful Energy
Energy
Signal Factor, M

Ideal Function of
Product or Process

Quality Characteristic, y

Harmful Energy
Caused by Noise

Control
Factors

Step 1: Define the Project Scope 1/2

A gyrocopter design is to be published in a Sunday Comics
section as a do-it-yourself project for 6-12 year old kids
The customers (kids) want a product they can easily build
and have a long flight time.
| WW |
--WL

----1/4

---

BL

----

Step 1: Define the Project Scope 2/2

This is a difficult problem from an engineering standpoint
because:
hard to get intuitive feel for effect of control variables
cant control materials, manufacturing or assembly
noise factors are numerous and have strong effect on
flight.

Step 2: Identify Ideal Function

Time of Flight

Ideally want the most flight time (the quality characteristic

or useful energy) for any input height (signal or input
energy)
Minimize Noise Effect
Maximize Slope

Drop Height

Step 3: Develop Noise Strategy 1/2

Goal is to excite worst possible noise conditions
Noise factors
unit-to-unit

aging

environment

Step 3: Develop Noise Strategy 2/2

Noise factors
unit-to-unit
Construction accuracy
Paper weight and type

angle of wings

aging
damage from handling

environment
angle of release
humidity content of air
wind

+ many, many others

Step 4: Establish Control Factors and Levels

1/4
Want them independent to minimize interactions
Dimensionless variable methods help
Design of experiments help
Confirm effect of interactions in Step 7

Want to cover design space

may have to guess initially and perform more
than one set of experiments. Method will help
determine where to go next.

Step 4: Establish Control Factors and Levels

2/4

Methods to explore the design space

shot-gun
one-factor-at-a-time
full factorial
orthogonal array (a type of fractional factorial)

Step 4: Establish Control Factors and Levels

3/4
Control factor array for the paper gyrocopter parameter optimization
experiment
1
Run
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2

2
WL
1.0/ww
1.0/ww
1.0/ww
1 .5/ww
1.5/ww
1.5/ww
2.0/ww
2.0/ww
2.0/ww
1.0/ww
1.0/ww
1.0/ww
1.5/ww
1.5/ww
1.5/ww
2.0/ww
2.0/ww
2.0/ww

3
WW
0.50
0.75
1.00
0.50
0.75
1.00
0.50
0.75
1.00
0.50
0.75
1.00
0.50
0.75
1.00
0.50
0.75
1.00

4
BL
1.33 x WL
1.67 x WL
2.00 x WL
1.33 x WL
1.67 x WL
2.00 x WL
1.67 x WL
2.00 x WL
1.33 x WL
2.00 x WL
1.33 x WL
1.67 x WL
1.67 x WL
2.00 x WL
1.33 x WL
2.00 x WL
1.33 x WL
1.67 x WL

5
Size
100%
75%
50%
75%
50%
100%
100%
75%
50%
50%
100%
75%
50%
100%
75%
75%
50%
100%

6
1
2
3
2
3
1
3
1
2
2
3
1
1
2
3
3
1
2

B_Fold
0
15%
30%
30%
0
15%
1 5%
30%
0
15%
30%
0
30%
0
15%

0
15%
30%

8
Gussets
None
45deg
45deg
45deg
None
45deg
45deg
None
45deg
None
45deg
45deg
45 deg
45deg
None
45deg
45deg
None

Step 4: Establish Control Factors and Levels

4/4

Step 5: Conduct Experiment and Collect

Data

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

3 feet
20# paper 24# paper

6 feet
20# paper
24# paper

9 feet
20# paper
24# paper

0.68 s
0.74
0.68
0.58
0.71
0.67
0.65
0.71
0.84
0.74
0.61
0.61
0.87
0.81
0.84
0.68
0.71
0.61

1.48 s
1.19
1.35
1.25
1.58
1.64
1.16
1.93
1.83
1.7
1.22
1.38
1.64
2.09
1.7
1.54
1.54
1.96

2.31s
2.25
1.48
2.34
2.28
2.44
2.68
2.61
2.09
2.09
1.48
2.28
2.02
2.27
1.51
2.44
2.6
2.73

0.55 s
0.58
0.45
0.71
0.68
0.55
0.7
0.6
0.63
0.61
0.45
0.58
0.68
0.65
0.63
0.68
0.68
0.84

1.48 s
1.58
1.03
1.22
1.41
1 .51
1.21
1.75
1.64
1.22
1.03
1.22
1.19
1.51
1.22
1.64
1.51
1.64

2.38 s
2.44
1.96
1.75
2.41
2.08
2.7
2.73
2.5
2.31
1.96
2.3
2.41
2.67
2.5
2.5
2.6
3.05

Data for Runs 5 and 15

2.5

Time (sec)

2
1.5

Run 5
Run 15

1
0.5
0
0

Height (ft)

10

Step 6: Conduct Data Analysis 1/7

Calculate signal-to-noise-ratio (S/N) and Mean
Complete and interpret response tables
Perform two step optimization
Reduce Variability (minimize the S/N ratio)
Adjust the mean
Make predictions about most robust configuration

Step 6: Conduct Data Analysis 2/7

Calculate signal to noise ratio, S/N, a
variability
metric in decibels
S/N gain
reduction
S/N =

Useful output
Harmful output

3
6
12

27%
50%
75%

Effect of Mean
= Variability
around mean
2
y
= 10 log 2
s

Note: This is one of many

forms of S/N ratios.

Step 6: Conduct Data Analysis 3/7

1
Run
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2

Results of the parameter optimization experiment

2
3
4
5
6
7
8
slope
S/N
WL
WW
BL
Size
B_Fold Gussets (sec/ft)
1.0/ww 0.50 1.33 X WL 100% 1
0
None
0.25
6.94 dB
1.0/ww 0.75 1.67 X WL
75%
2
15%
45deg
0.25
2.67 dB
1.0/ww 1.00 2.00 X WL
50%
3
30%
45deg
0.19 -0.24 dB
1.5/ww 0.50 1.33 X WL
75%
2
30%
45deg
0.22
0.69 dB
1.5/ww 0.75 1.67 X WL
50%
3
0
None
0.26
9.04 dB
1.5/ww 1.00 2.00 X WL 100% 1
15%
45deg
0.25
3.81 dB
2.0/ww 0.50 1.67 X WL 100% 3
15%
45deg
0.26 -1.95 dB
2.0/ww 0.75 2.00 X WL
75%
1
30%
None
0.29
4.73 dB
2.0/ww 1.00 1.33 X WL
50%
2
0
45deg
0.26
2.64 dB
1.0/ww 0.50 2.00 X WL
50%
2
15%
None
0.24
2.81 dB
1.0/ww 0.75 1.33 X WL 100% 3
30%
45deg
0.19
0.76 dB
1.0/ww 1.00 1.67 X WL
75%
1
0
45deg
0.24
3.87 dB
1.5/ww 0.50 1.67 X WL
50%
1
30%
45deg
0.24
1.62 dB
1.5/ww 0.75 2.00 X WL 100% 2
0
45deg
0.28
0.87 dB
1.5/ww 1.00 1.33 X WL
75%
3
15%
None
0.23 -3.96 dB
2.0/ww 0.50 2.00 X WL
75%
3
0
45deg
0.27
9.04 dB
2.0/ww 0.75 1.33 X WL
50%
1
15%
45deg
0.28
4.88 dB
2.0/ww 1.00 1.67 X WL 100% 2
30%
None
0.31
2.99 dB

Step 6: Conduct Data Analysis 4/7

Response Table
Factor response averages table for the
parameter optimization experiment
Time Time
Factor
Level
(slope) (S/N)
1.0/ww
0.23
2.80
WL
1.5/ww
0.25
2.01
2.0/ww
0.28
3.72
0.50
0.25
3.19
WW
0.75
0.26
3.82
1.00
0.25
1.52
1.33 X WL 0.24
1.99
BL
1.67 X WL 0.26
3.04
2.00 X WL 0.25
3.50
100%
0.26
2.23
Size
75%
0.25
2.84
50%
0.25
3.46
0%
0.26
5.40
B_Fold
15%
0.25
1.38
30%
0.24
1.76
Gussets None
0.26
3.76
45deg
0.25
2.39

Step 6: Conduct Data Analysis 5/7

Response plot

Step 6: Conduct Data Analysis 6/7

Two Step Optimization
Reduce Variability (minimize the S/N ratio)
look for control factor effects on S/N
Dont worry about mean

Adjust the mean

To get desired response
Use adjusting factors, those control factors
which have minimal effect on S/N

Step 6: Conduct Data Analysis 7/7

For gyrocopter

wing width = .75in

wing length = 2.00/0.75 = 2.67 in
body length = 2.00 x 2.67 = 5.33 in
size = 50%
Predicted Performance
no body folds
no gussets
S/N = 9.44 dB
Slope = .31 sec/ft

Step 7: Conduct Conformation Run

To check validity of results
To check for unforeseen interaction effects
between control factors
To check for unaccounted for noise factors
To check for experimental error
Predicted Confirmed

S/N

9.44 dB

Slope .31sec/ft

9.86
.32 sec/ft

How Taguchis Method Differs from an

Ad-hoc Design Process
Organized Design Space
Search
Clear Critical Parameter
Identification
Focus on Parameter
Variation (Noise)
Clear Stopping Criteria
Robustness centered not
Failure Centered
Reusable Method

Concurrently Addresses
Manufacturing Variation
Concurrent Design-Test
Not Design-Test-Fix
Minimize Development
Time (Stops Fire Fighting)
Corporate Memory
Through Documentation
Encourages Technology
Development Through
System Understanding

How Taguchis Method Differs from

Traditional Design of Experiments
Focused on reducing the
impact of variability rather
than reducing variability
Focused on noise effects
rather than control factor
effects
Clearly focused cost
function - maximizing the
useful energy

Tries to reduce interaction

between control factors
rather than study them
Requires little skill in
statistics
Usually lower cost

How Taguchis Method Differs from

Shainins Method
Focused on both Product
and Process Design rather
than Primarily on Process
Oriented to developing a
robust system not finding
a problem (Red X).
Taguchi tells what
parameter values to set to
make system insensitive to
parameter Shainin
identifies as needing
control.

Widely Used
Internationally
Fire prevention rather than
fire fighting
Accessible
Many Case Studies
Available

Plan for Application at Tektronix

Select a parameter design problem

Design the experiment
Perform the experiment
Reduce data
Report results to Company
Assuming success
design more experiments
train more engineers
Plan for student-run experiments