تعیین ترکیب بهینه فرمولاسیون رنگهای صنعتی و بهبود بهره وری فرایندهای تولیدی مربوطه با بهره گیری از تکنیکهای FMEA و آرایه های متعامد تاگوچی
محورهای موضوعی : مدیریت صنعتی
احمد ابراهیمی
1
,
مهدی رضایی
2
1 - استادیارگروه مدیریت صنعتی،واحدعلوم و تحقیقات،دانشگاه آزاداسلامی،تهران،ایران
2 - کارشناس ارشد مهندسی صنایع ، واحد تهران جنوب، دانشگاه آزاد اسلامی، تهران، ایران
کلید واژه: آرایه های متعامد تاگوچی, تجزیه و تحلیل حالات و آثار خرابی, نمره اولویت ریسک, طراحی آزمایشها,
چکیده مقاله :
در دنیای رقابتی امروز، بهبود فرایندها به منظور افزایش کیفیت در محصولات، همواره یکی از دغدغه های اساسی سازمانها بوده است. طراحی آزمایشها به عنوان یکی از روشهای کنترل کیفیت آماری، افزایش کیفیت محصول و نتیجتا بهره وری در تولید را موجب می گردد. در این مقاله، ابتدا سعی گردیده با استفاده از روش تجزیه و تحلیل حالات و اثرات خرابی (FMEA)، مشکلات رنگهای صنعتی در یکی از شرکتهای تولید کننده رنگهای صنعتی (شرکت پرتو فولاد فام) شناسایی و اولویت بندی شده و سپس با استفاده از روش آرایه های متعامد تاگوچی در طراحی آزمایشها، مقادیر بهینه برای سطوح عوامل موثر شناسایی شده در فرآیند، تعیین شوند. بدین ترتیب که شش عامل سه سطحی و یک عامل دو سطحی تعریف شده و آرایه L18 جهت طراحی آزمون های مورد نیاز انتخاب گردیده است. نتایج نشان می دهد که بهترین سطح کیفیت رنگها مربوط به آزمونی است که در آن: سطح دانه بندی بیش از 10، دمای حداکثر فلز برابر 232 سانتی گراد، پیگمنت از نوع عالی، مقدار رزین برابر 55%، مقدار کاتالیست برابر 4.1%، ورق با کیفیت متوسط و مقدار حداکثر افزودنی در نظر گرفته شود. به منظور تعیین اثربخشی روش به کار گرفته شده، نمره اولویت ریسک(RPN) در روش FMEA، قبل و بعد از به کارگیری روش تاگوچی محاسبه گردید که این امر کاهش 19 واحدی میانگین RPN را به دنبال داشت. این موضوع تاثیر روش تاگوچی را در کاهش ریسک های ناشی از خرابی محصول و نیجتا افزایش کیفیت محصول بیان داشته است.
In today's competitive world, various organizations have been constantly concerned with improving production processes as a way to enhance product quality. Experiment design is a statistical quality control method leading to increased product quality, and thereby, enhanced manufacturing productivity. The present study set out to identify and prioritize the defects in industrial paints produced by Partofooldam industrial paint manufacturing company through failure mode and effects analysis (FMEA) and to determine optimal value levels for the identified effective factors using Taguchi Orthogonal Array Method. To serve the purpose, six trihedral factors and one dihedral factor were defined and the L18 array was selected for designing the required experiments. The findings indicated that the best paint quality was obtained in the experimental condition with over 10 micron granulation, peak metal temperature (PMT) of 232°C, high quality pigment, resin content of 55%, catalyst content of 4.1%, using medium quality plate and maximum content of additives. The effectiveness of the proposed method was determined by comparing the risk priority number (RPN) in FMEA before and after implementing Taguchi Method which showed a 19 point drop in the mean RPNs for all the identified problems. The results verified the impact of Taguchi’s method on reducing product failure risk and enhancing product quality.
Enshaeeieh, M., Madani, M., Abdoli, A., Nahavi, A., Asgari Karchagani, F. (2016), "Optimization of the production of microbial oil and xyllitol in fat-producing yeast", Journal of Applied Biology, 29(1), 5-21.[In Persian]
Rekabdar, F., Ghashelaghi, A., Hemati, M., Reyhani, A., Rajai, F. (2014), "Optimization of operating conditions in a membrane ultrafiltration system using the Taguchi method", Journal of Oil Research, 24(79), 108-119.[In Persian]
Kiyomarshypour, N., Shoja Razavi, R., Ghani, K. (2011), "Evaluation of the Optical Properties of the White Thermal Heat Controls of the Silicate Base of the Satellite Using the Taguchi Method", Scientific and Research Journal of Paint Science and Technology, 6(3), 207-197.[In Persian]
Aloini, D., Dulmin,R. and Mininno,V. (2012)," Risk assessment in erp projects", information systems 37,183–199.
Ambekar, S.B., Edlabadkar,A., Shrouty,V. (2013), " A Review: Implementation of Failure Mode and Effect Analysis", International Journal of Engineering and Innovative Technology (IJEIT), 2(8), 37-41.
Antony, J. (2006). "Taguchi or classical design of experiments: a perspective from a practitioner", Sensor review,26(3), 227–230.
Bharathi, D.Baskaran,R. (2014), "Improvement of painting process in steel structure using taguchi’s method of experimental design", international journal of mechanical and industrial technology, 2(1), 1-9.
Dagsuyu,C.,Göçmen,E., Narlı,M. and Kokangül,A. (2016), "Classical and fuzzy FMEA risk analysis in a sterilization unit" Computers & Industrial Engineering, 101 ,.286–294.
Dhawane,S.H., Kumar,T., Halder,G. (2016)," biodiesel synthesis from hevea brasiliensis oil employing carbon supported heterogeneous catalyst: optimization by taguchi method", renewable energy, 89, 506-514.
Ji,Y,.Tian.Y,.Ahnfelt.M,.Sui.L.,2014,"Design and optimization of a chromatographic purification process forStreptococcus pneumoniae serotype 23F capsular polysaccharide by aDesign of Experiments approach", Journal of Chromatography A, 1348 (2014) 137–149.
Kang,J. Sun,L.Sun,H.,Wu,C. (2017), "Risk assessment of floating offshore wind turbine based on correlation-FMEA", Ocean Engineering, 129, 382–388.
Konda,R., Rajurkar,K.P.,Bishu, R.R., Guha, A., Parson, M. (1999), "Design of experiments to study and optimize process performance", International journal of quality & reliability management, 16(1), 56-71.
Kumru,M.,Kumru,P.Y. (2013),” Fuzzy fmea application to improve purchasing process in a public hospital”, Applied soft computing, 13, 721–733.
Mariajayaprakash,A,. Senthilvelan,T. (2016)," failure detection and optimization of sugar mill boiler using fmea and taguchi method", engineering failure analysis 30, 17–26.
Nooramin, A.S., Ahouei,V.R., Sayareh, J. (2012), A Systematic Framework for Implementing Six Sigma in the Landside of Marine Container Terminals, Journal of the Persian Gulf, 3(8), 55-66.
Ohlsson,K.Bergman,T.,Sundell,P.E.,Deltin,T.,Tran,I.,Svensson,M.Johansson,M. (2012), "Novel coil coating systems using fatty acid based reactive diluents", Progress in Organic Coatings, 73(4), 291– 293.
Phadke,M.s. (1989), "Quality Engineering Using Robust Design", .Englewood Cliffs:PTR Prentice-Hall, Inc.
Shahin.A,Karbasian.M,Ahmadi.M,1386," Quality Improvement of Plast Sheet By Robust Design",( M.Sc., Islamic Azad University, Najafabad Branch)
Shyam Kumar Karna,S.K.,Sahai,R. (2012)", An Overview on Taguchi Method", International Journal of Engineering and Mathematical Sciences, 1, 11-18.
Su,C.T. Lin,H.C.Teng,P.W. and Yang,T. (2014), "Improving the reliability of electronic paper display using fmea and taguchi methods: a case study", microelectronics reliability, 9(54), 6-7.
_||_Enshaeeieh, M., Madani, M., Abdoli, A., Nahavi, A., Asgari Karchagani, F. (2016), "Optimization of the production of microbial oil and xyllitol in fat-producing yeast", Journal of Applied Biology, 29(1), 5-21.[In Persian]
Rekabdar, F., Ghashelaghi, A., Hemati, M., Reyhani, A., Rajai, F. (2014), "Optimization of operating conditions in a membrane ultrafiltration system using the Taguchi method", Journal of Oil Research, 24(79), 108-119.[In Persian]
Kiyomarshypour, N., Shoja Razavi, R., Ghani, K. (2011), "Evaluation of the Optical Properties of the White Thermal Heat Controls of the Silicate Base of the Satellite Using the Taguchi Method", Scientific and Research Journal of Paint Science and Technology, 6(3), 207-197.[In Persian]
Aloini, D., Dulmin,R. and Mininno,V. (2012)," Risk assessment in erp projects", information systems 37,183–199.
Ambekar, S.B., Edlabadkar,A., Shrouty,V. (2013), " A Review: Implementation of Failure Mode and Effect Analysis", International Journal of Engineering and Innovative Technology (IJEIT), 2(8), 37-41.
Antony, J. (2006). "Taguchi or classical design of experiments: a perspective from a practitioner", Sensor review,26(3), 227–230.
Bharathi, D.Baskaran,R. (2014), "Improvement of painting process in steel structure using taguchi’s method of experimental design", international journal of mechanical and industrial technology, 2(1), 1-9.
Dagsuyu,C.,Göçmen,E., Narlı,M. and Kokangül,A. (2016), "Classical and fuzzy FMEA risk analysis in a sterilization unit" Computers & Industrial Engineering, 101 ,.286–294.
Dhawane,S.H., Kumar,T., Halder,G. (2016)," biodiesel synthesis from hevea brasiliensis oil employing carbon supported heterogeneous catalyst: optimization by taguchi method", renewable energy, 89, 506-514.
Ji,Y,.Tian.Y,.Ahnfelt.M,.Sui.L.,2014,"Design and optimization of a chromatographic purification process forStreptococcus pneumoniae serotype 23F capsular polysaccharide by aDesign of Experiments approach", Journal of Chromatography A, 1348 (2014) 137–149.
Kang,J. Sun,L.Sun,H.,Wu,C. (2017), "Risk assessment of floating offshore wind turbine based on correlation-FMEA", Ocean Engineering, 129, 382–388.
Konda,R., Rajurkar,K.P.,Bishu, R.R., Guha, A., Parson, M. (1999), "Design of experiments to study and optimize process performance", International journal of quality & reliability management, 16(1), 56-71.
Kumru,M.,Kumru,P.Y. (2013),” Fuzzy fmea application to improve purchasing process in a public hospital”, Applied soft computing, 13, 721–733.
Mariajayaprakash,A,. Senthilvelan,T. (2016)," failure detection and optimization of sugar mill boiler using fmea and taguchi method", engineering failure analysis 30, 17–26.
Nooramin, A.S., Ahouei,V.R., Sayareh, J. (2012), A Systematic Framework for Implementing Six Sigma in the Landside of Marine Container Terminals, Journal of the Persian Gulf, 3(8), 55-66.
Ohlsson,K.Bergman,T.,Sundell,P.E.,Deltin,T.,Tran,I.,Svensson,M.Johansson,M. (2012), "Novel coil coating systems using fatty acid based reactive diluents", Progress in Organic Coatings, 73(4), 291– 293.
Phadke,M.s. (1989), "Quality Engineering Using Robust Design", .Englewood Cliffs:PTR Prentice-Hall, Inc.
Shahin.A,Karbasian.M,Ahmadi.M,1386," Quality Improvement of Plast Sheet By Robust Design",( M.Sc., Islamic Azad University, Najafabad Branch)
Shyam Kumar Karna,S.K.,Sahai,R. (2012)", An Overview on Taguchi Method", International Journal of Engineering and Mathematical Sciences, 1, 11-18.
Su,C.T. Lin,H.C.Teng,P.W. and Yang,T. (2014), "Improving the reliability of electronic paper display using fmea and taguchi methods: a case study", microelectronics reliability, 9(54), 6-7.