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Importance of Experimental Design in the Development of Products and Processes: Application in a Factory in the Automobile Industry

Year 2020, Issue: 24, 527 - 558, 01.10.2020

Abstract

Improvement of product/service and production processes within the enterprise is one of the important activities and elements to survive in the rivalry world. As the quality level of the product/service is improved, the profitability of the enterprise increases. Using the Design of Experimental methods to develop and improve the products and processes of manufacturing in production systems and to expand the application-implementation areas in production, increase the level of product quality. Thus, customer satisfaction is ensured and the profitability of the enterprise increases. Within the scope of the research, basic concepts about the design of experimental methods and studies-research in literature are presented-mentioned.

References

  • Andersson, P. (1997). On Robust Design in the Conceptual Design Phase: A Qualitative Approach, Journal of Engineering Design, 8(1), 75-89.
  • Antony, J. ve Capon, N. (1998). Teaching Experimental Design Tech- niques to Industrial Engineers, International Journal of Engineering Education, 14(5), 335-343.
  • Bahloul, R., Mkaddem, A., Santo, P.D. ve Potiron, A. (2006). Sheet metal bending optimisation using response surface method, nu- merical simulation and design of experiments, Internationl Journal of Mechanical Sciences, 48, 991-1003.
  • Baray, A. ve Sarı, T. (2006). Kalite Geliştirmede Deney Tasarımı Yön- temi ve Otomotiv Sektöründe Bir Uygulama, İstanbul Üniversitesi İşletme Fakültesi Dergisi, 35 (2), 37–62.
  • Beal, A., Claeys-Bruno, M. ve Sergent, M. (2014). Constructing space- filling designs using an adaptive WSP algorithm for spaces with constraints. In Chemometrics and intelligent laboratory Systems, 133, 84–91.
  • Bernd, A.Behrens, Poisse, O., Milch, M. ve Helms, G. (2007). Internati- onal Journal of Prod. Eng. Res. Devel 1, s.3–8, Optimization of ironing process by means of DOE, Production Process.
  • Box, G. E. P., Hunter, W. G. and Hunter, J. S. (1978). Statistics for Expe- rimenters an Introduction to Design, Data Analysis and Model Buil- ding, John Wiley& Sons..
  • Certified Welding Inspector and Educator Package, American Weldin Society, LeJeune Road, Miami, Florida, Erişim Tarihi: 12.05.2019, https://app.aws.org/certification/docs/packages/cwi_cwe_pkg. pdf.
  • Cheng, W.T., Li, H.C. ve Huang, C.N. (2008). Simulation and optimiza- tion of silicon thermal CVD through CFD integrating Taguchi method. Chemical Engineering Journal, 7 (3), 603-613.
  • Davim J. P., (2001). A note on the determination of optimal cutting conditions for surface finish obtained in turning using design of experiments, Journal of Materials Processing Technology, 116, 305- 308.
  • Design-Ease(R) software, Stat-Ease, Inc., Minneapolis, MN, http://www.statease.com, Erişim Tarihi: 20.05.2019.
  • Dizdar, E.N. (1998). Üretim sistemlerinde olası iş kazaları için bir erken uyarı modeli. Yayınlanmamış Doktora Tezi. Gazi Üniversitesi, Fen Bilimleri Enstitüsü, Endüstri Mühendisliği ABD.
  • Garud, S. S., Karimi, I. A., ve Kraft, M. (2017). Design of computer experiments: A review. In Computers and chemical engineering, 106, 71–95.
  • Griffiths, C. A; Howarth, J; De Almeida-Rowbotham, G.; Rees, A. ve Kerton, R. (2016). A design of experiments approach for the opti- misation of energy and waste during the production of parts ma- nufactured by 3D printing, Journal of Cleaner Production, 1-41.
  • Gore, D. W. ve Langston, D. R. (2006). Unıversity And Industry Colla- boration to Solve Welding Quality Problem Using Design Of Experıments https://cdnm.statease.com/pubs/CIEC_paper_Gore&Langston. pdf. s.1-5 2006 CIEC Conference,
  • Hamzaçebi, C., Kutay, F. (2003). Taguchi metodu: bir uygulama. Tekno- loji, (3-4), 7-17.
  • Izgız, S. (2001). Deney Tasarımı ve Taguchi Metodu Ürün ve Proseslerin Optimizasyonu, Federal Mogul, Istanbul.
  • Karimshoushtari, M. ve Novara, C. (2020). Design of experiments for nonlinear system identification: A set membership approach. Au- tomatica, 119, 109036.
  • Kim, W., Jeon, W. H., Hur, N. ve Hyun, J.J.(2011). Development of a low-noise cooling fan for an alternator using numerical and Doe methods, International Journal of Automotive Technology, 12 (2), 307−314.
  • King, DW., DeVor, RE., Chang, T. ve Sutherland, JW. Statistical qua- lity design and control, Technometrics, 35 (1993), s. 331.
  • Laurent, E. C., HEC Paris, Fall 2011, Topic 4. Multivariate Regressions, Erişim https://www.coursehero.com/file/27185656/Topic4- MultivariateRegressionspdf. 15.05.2019.
  • Montgomery, D. C., (2012). Design and analysis of experiments, 8th Edi- tion, John Wiley, Wiley & Sons, New York, 1-19.
  • Montgomery, D.C.(2001). Design and Analysis of Experiments, 5th Edi- tion, John Wiley&Sons.
  • Montgomery, D. C. (1999b). Experimental Design for Product and Process Design and Development, The Statistician, 49, Part 2, 159- 177.
  • Montgomery, D. C. (2001a). Design and Analysis of Experiment, New York, John Wiley&Sons.
  • Montgomery, D. C. (2005c). Introduction to Statistical Quality Control, Fifth Edition, John Wiley&Sons. Normal Test Plot, Skymark, Erişim Tarihi: 12.03.2019, http://www.skymark.com/resources/tools/normal_test_plot.as p.
  • Oudjene, M. ve Ben-Ayed, L. (2008). On the parametrical study of clinch joining of metallic sheets using the Taguchi method. Engi- neering Structures, 30 (6), 1782-1788.
  • Peltier, J. (2010). Main Effects and Interaction Plots, Erişim tarihi: 24.05.2019, http://peltiertech.com/WordPress/main-effects-and- interaction-plots.
  • Robert L. M., Richard F. G. ve James L. H. (2003). Statistical Design and Analysis of Experiments with Applications to Engineering and Science, John Wiley & Sons Ltd Publications.
  • Ross, P. J. (1989). Taguchi techniques for quality engineering, loss function, orthogonal experiments, parameter and tolerance design, McGraw-Hill International Book Company, 1-66, 167-202.
  • Rosa, J. L., Robin, A., Silva, M.B., Baldan, C.A. ve Peres. M.P. (2009). Electrodeposition of copper on titanium wires: Taguchi experi- mental design approach. Journal of Materials Processing Technology, 209(3), 1181-1188. Scatter Plot, Erişim tarihi: 24.05.2019, http://www.netmba.com/statistics/plot/scatter.
  • Schäfer, C. ve Finke, E. (2008). Shape optimisation by design of experiments and finite element methods—an application of steel wheels, Struct Mul- tidisc Optim, 36, 477–491.
  • Schindler, S., Bauer, M., Cheetamun, H. ve Danzer, M. A. (2018). Fast charging of lithium-ion cells: Identification of aging-minimal cur- rent profiles using a design of experiment approach and a mecha- nistic degradation analysis. Journal of Energy Storage, 19, 364-378.
  • Shaw, M. (1984). Metal Cutting Principles, Oxford University Press, Oxford, s. 450-542.
  • Shivhare, M. ve McCreath, G. (2010). Practical Considerations for DoE Implementation in Quality By Design, BioProcess International, Bi- oProcess. https://bioprocessintl.com/manufacturing/information- technology/practical-considerations-for-doe-implementation-in- quality-by-design-297328. Tarihi: 12.05.2019,
  • Subbarao, PMV. Mechanical Engineering Department, Selection of Significant Parameters for Experimentation, Erişim Tarihi: 14.04.2019, https://slideplayer.com/slide/5935873.
  • Suhartono, Suhermi, N. ve Prastyo, D. D. (2018). Design of Experiment to Optimize the Architecture of Deep Learning for Nonlinear Ti- me Series Forecasting. Procedia Computer Science, 144, 269–276.
  • Taguchi, G. (1990). Introduction to quality engineering, Asian Productivity Organisation, Japan, 97-132.
  • Taguchi, G. ve Konishi, S. (1987). Taguchi Methods, Orthogonal Arrays and Linear Graphs, Tools for Quality Engineering, American Supp- lier Institute, s. 35-38.
  • Thompson, V. S., Gupta, M., Jin, H., Vahidi, E., Yim, M. ve Jindra, M. A. (2018). Techno-economic and life cycle analysis for bioleaching rare-earth elements from waste materials, ACS Sustainable Che- mistry & Engineering, 6 (2), 1602-1609.
  • Kırıs, S., Anagün, A.S. ve Yüzügüllü, N. (2009). Bir kalite karakteristi- ğinin deney tasarımı ile iyileştirilmesi, c. 1-5, Erişim tarihi: 20.01.2009, http://mmf.ogu.edu.tr/sanagun/Docs/Dok34.pdf.
  • Yang, W. H. ve Tarng ,Y. S., (1998). Design optimization of cutting parameters for turning operations based on the Taguchi method, Jounal of Materials Processing Technology, 84, 122-129.
  • Yondo, R., Andrés, E. ve Valero, E. (2018). A review on design of expe- riments and surrogate models in aircraft real-time and many- query aerodynamic analyses. Progress in Aerospace Sciences, 96, 23– 61.

Deney Tasarımının Ürün ve Süreçlerin Geliştirilmesinde Önemi: Otomobil Endüstrisindeki Bir Fabrikada Uygulaması

Year 2020, Issue: 24, 527 - 558, 01.10.2020

Abstract

İşletme bünyesinde ürün/hizmet ve üretim süreçlerinin iyileştirilmesi rekabet dünyasında ayakta kalabilmek için önemli faaliyet ve unsurlardandır. Üretilen ürün/hizmetin kalite düzeyi geliştikçe işletmenin karlılığı artış gösterir. Üretim sistemlerinde ürün ve süreçlerin geliştirilip, iyileştirilmesi için Deney Tasarım yöntemini kullanmak ve üretimdeki uygulama alanlarını genişletmek kaliteyi arttırmaktadır. Böylece müşteri memnuniyeti sağlanmakta ve işletmenin karlılığı artmaktadır. Araştırma kapsamında, deney tasarım yöntemi hakkında temel kavramlara ve literatürde yapılmış çalışmalara değinilmiştir. 23’ lük tam faktöriyel bir deneysel tasarım çalışması, otomobil endüstrisinde faaliyet gösteren bir fabrikada yapılmıştır. Bu fabrikanın üretim süreci; pres, kaynak, talaşlı imalat ve montaj bölümlerinden oluşmaktadır. Yapılan araştırma-uygulama kaynak atölyesinde punta kaynak robotu üzerinde gerçekleşmiştir.

References

  • Andersson, P. (1997). On Robust Design in the Conceptual Design Phase: A Qualitative Approach, Journal of Engineering Design, 8(1), 75-89.
  • Antony, J. ve Capon, N. (1998). Teaching Experimental Design Tech- niques to Industrial Engineers, International Journal of Engineering Education, 14(5), 335-343.
  • Bahloul, R., Mkaddem, A., Santo, P.D. ve Potiron, A. (2006). Sheet metal bending optimisation using response surface method, nu- merical simulation and design of experiments, Internationl Journal of Mechanical Sciences, 48, 991-1003.
  • Baray, A. ve Sarı, T. (2006). Kalite Geliştirmede Deney Tasarımı Yön- temi ve Otomotiv Sektöründe Bir Uygulama, İstanbul Üniversitesi İşletme Fakültesi Dergisi, 35 (2), 37–62.
  • Beal, A., Claeys-Bruno, M. ve Sergent, M. (2014). Constructing space- filling designs using an adaptive WSP algorithm for spaces with constraints. In Chemometrics and intelligent laboratory Systems, 133, 84–91.
  • Bernd, A.Behrens, Poisse, O., Milch, M. ve Helms, G. (2007). Internati- onal Journal of Prod. Eng. Res. Devel 1, s.3–8, Optimization of ironing process by means of DOE, Production Process.
  • Box, G. E. P., Hunter, W. G. and Hunter, J. S. (1978). Statistics for Expe- rimenters an Introduction to Design, Data Analysis and Model Buil- ding, John Wiley& Sons..
  • Certified Welding Inspector and Educator Package, American Weldin Society, LeJeune Road, Miami, Florida, Erişim Tarihi: 12.05.2019, https://app.aws.org/certification/docs/packages/cwi_cwe_pkg. pdf.
  • Cheng, W.T., Li, H.C. ve Huang, C.N. (2008). Simulation and optimiza- tion of silicon thermal CVD through CFD integrating Taguchi method. Chemical Engineering Journal, 7 (3), 603-613.
  • Davim J. P., (2001). A note on the determination of optimal cutting conditions for surface finish obtained in turning using design of experiments, Journal of Materials Processing Technology, 116, 305- 308.
  • Design-Ease(R) software, Stat-Ease, Inc., Minneapolis, MN, http://www.statease.com, Erişim Tarihi: 20.05.2019.
  • Dizdar, E.N. (1998). Üretim sistemlerinde olası iş kazaları için bir erken uyarı modeli. Yayınlanmamış Doktora Tezi. Gazi Üniversitesi, Fen Bilimleri Enstitüsü, Endüstri Mühendisliği ABD.
  • Garud, S. S., Karimi, I. A., ve Kraft, M. (2017). Design of computer experiments: A review. In Computers and chemical engineering, 106, 71–95.
  • Griffiths, C. A; Howarth, J; De Almeida-Rowbotham, G.; Rees, A. ve Kerton, R. (2016). A design of experiments approach for the opti- misation of energy and waste during the production of parts ma- nufactured by 3D printing, Journal of Cleaner Production, 1-41.
  • Gore, D. W. ve Langston, D. R. (2006). Unıversity And Industry Colla- boration to Solve Welding Quality Problem Using Design Of Experıments https://cdnm.statease.com/pubs/CIEC_paper_Gore&Langston. pdf. s.1-5 2006 CIEC Conference,
  • Hamzaçebi, C., Kutay, F. (2003). Taguchi metodu: bir uygulama. Tekno- loji, (3-4), 7-17.
  • Izgız, S. (2001). Deney Tasarımı ve Taguchi Metodu Ürün ve Proseslerin Optimizasyonu, Federal Mogul, Istanbul.
  • Karimshoushtari, M. ve Novara, C. (2020). Design of experiments for nonlinear system identification: A set membership approach. Au- tomatica, 119, 109036.
  • Kim, W., Jeon, W. H., Hur, N. ve Hyun, J.J.(2011). Development of a low-noise cooling fan for an alternator using numerical and Doe methods, International Journal of Automotive Technology, 12 (2), 307−314.
  • King, DW., DeVor, RE., Chang, T. ve Sutherland, JW. Statistical qua- lity design and control, Technometrics, 35 (1993), s. 331.
  • Laurent, E. C., HEC Paris, Fall 2011, Topic 4. Multivariate Regressions, Erişim https://www.coursehero.com/file/27185656/Topic4- MultivariateRegressionspdf. 15.05.2019.
  • Montgomery, D. C., (2012). Design and analysis of experiments, 8th Edi- tion, John Wiley, Wiley & Sons, New York, 1-19.
  • Montgomery, D.C.(2001). Design and Analysis of Experiments, 5th Edi- tion, John Wiley&Sons.
  • Montgomery, D. C. (1999b). Experimental Design for Product and Process Design and Development, The Statistician, 49, Part 2, 159- 177.
  • Montgomery, D. C. (2001a). Design and Analysis of Experiment, New York, John Wiley&Sons.
  • Montgomery, D. C. (2005c). Introduction to Statistical Quality Control, Fifth Edition, John Wiley&Sons. Normal Test Plot, Skymark, Erişim Tarihi: 12.03.2019, http://www.skymark.com/resources/tools/normal_test_plot.as p.
  • Oudjene, M. ve Ben-Ayed, L. (2008). On the parametrical study of clinch joining of metallic sheets using the Taguchi method. Engi- neering Structures, 30 (6), 1782-1788.
  • Peltier, J. (2010). Main Effects and Interaction Plots, Erişim tarihi: 24.05.2019, http://peltiertech.com/WordPress/main-effects-and- interaction-plots.
  • Robert L. M., Richard F. G. ve James L. H. (2003). Statistical Design and Analysis of Experiments with Applications to Engineering and Science, John Wiley & Sons Ltd Publications.
  • Ross, P. J. (1989). Taguchi techniques for quality engineering, loss function, orthogonal experiments, parameter and tolerance design, McGraw-Hill International Book Company, 1-66, 167-202.
  • Rosa, J. L., Robin, A., Silva, M.B., Baldan, C.A. ve Peres. M.P. (2009). Electrodeposition of copper on titanium wires: Taguchi experi- mental design approach. Journal of Materials Processing Technology, 209(3), 1181-1188. Scatter Plot, Erişim tarihi: 24.05.2019, http://www.netmba.com/statistics/plot/scatter.
  • Schäfer, C. ve Finke, E. (2008). Shape optimisation by design of experiments and finite element methods—an application of steel wheels, Struct Mul- tidisc Optim, 36, 477–491.
  • Schindler, S., Bauer, M., Cheetamun, H. ve Danzer, M. A. (2018). Fast charging of lithium-ion cells: Identification of aging-minimal cur- rent profiles using a design of experiment approach and a mecha- nistic degradation analysis. Journal of Energy Storage, 19, 364-378.
  • Shaw, M. (1984). Metal Cutting Principles, Oxford University Press, Oxford, s. 450-542.
  • Shivhare, M. ve McCreath, G. (2010). Practical Considerations for DoE Implementation in Quality By Design, BioProcess International, Bi- oProcess. https://bioprocessintl.com/manufacturing/information- technology/practical-considerations-for-doe-implementation-in- quality-by-design-297328. Tarihi: 12.05.2019,
  • Subbarao, PMV. Mechanical Engineering Department, Selection of Significant Parameters for Experimentation, Erişim Tarihi: 14.04.2019, https://slideplayer.com/slide/5935873.
  • Suhartono, Suhermi, N. ve Prastyo, D. D. (2018). Design of Experiment to Optimize the Architecture of Deep Learning for Nonlinear Ti- me Series Forecasting. Procedia Computer Science, 144, 269–276.
  • Taguchi, G. (1990). Introduction to quality engineering, Asian Productivity Organisation, Japan, 97-132.
  • Taguchi, G. ve Konishi, S. (1987). Taguchi Methods, Orthogonal Arrays and Linear Graphs, Tools for Quality Engineering, American Supp- lier Institute, s. 35-38.
  • Thompson, V. S., Gupta, M., Jin, H., Vahidi, E., Yim, M. ve Jindra, M. A. (2018). Techno-economic and life cycle analysis for bioleaching rare-earth elements from waste materials, ACS Sustainable Che- mistry & Engineering, 6 (2), 1602-1609.
  • Kırıs, S., Anagün, A.S. ve Yüzügüllü, N. (2009). Bir kalite karakteristi- ğinin deney tasarımı ile iyileştirilmesi, c. 1-5, Erişim tarihi: 20.01.2009, http://mmf.ogu.edu.tr/sanagun/Docs/Dok34.pdf.
  • Yang, W. H. ve Tarng ,Y. S., (1998). Design optimization of cutting parameters for turning operations based on the Taguchi method, Jounal of Materials Processing Technology, 84, 122-129.
  • Yondo, R., Andrés, E. ve Valero, E. (2018). A review on design of expe- riments and surrogate models in aircraft real-time and many- query aerodynamic analyses. Progress in Aerospace Sciences, 96, 23– 61.
There are 43 citations in total.

Details

Primary Language Turkish
Journal Section Research Article
Authors

Ayşenur Erdil This is me

Publication Date October 1, 2020
Published in Issue Year 2020 Issue: 24

Cite

APA Erdil, A. (2020). Deney Tasarımının Ürün ve Süreçlerin Geliştirilmesinde Önemi: Otomobil Endüstrisindeki Bir Fabrikada Uygulaması. Iğdır Üniversitesi Sosyal Bilimler Dergisi(24), 527-558.