Unification of robust design and goal programming for multiresponse optimization – a case study

Fixing the levels of input process parameters to meet a required specification of output is a common process quality control problem. Especially when the output has many quality characteristics, and each of these quality characteristics has to satisfy a given specification, difficulties may arise. One such problem was encountered in an injection moulding process. This process was optimized using Taguchi's Robust Design methodology. Details of the process, problems encountered and outcome of optimization are presented in this paper. The optimization study using Taguchi's methodology revealed that the optimum conditions obtained for one response are not completely compatible with those of other responses. So trade-offs were made in selection of levels for factors using engineering judgement. This increases the uncertainty in the decision making process. In this paper, an approach is presented to optimize multiresponses simultaneously using goal programming in conjunction with Taguchi's methodology. Details of modelling, analysis and inferences obtained with relevance to the case are presented. This study revealed that the optimum conditions obtained using goal programming in conjunction with Taguchi's methodology have better goal attainment properties compared to Robust design. To understand goal attainment behaviour of output characteristics for various process conditions, a detailed sensitivity analysis was also conducted. The outcome of this analysis is also discussed in this paper.