Improving the process quality using statistical design of experiments: a case study

A technique known as Statistical design of experiments is a powerful technique for process characterization, optimization, and modeling. It has been widely accepted in manufacturing industry for improving product performance and reliability, process capability, and yield. This article illustrates the application of statistical design of experiments based on the Taguchi approach in a certain company that manufactures electromagnetic clutch coils. The objective of the study was to improve the quality of the existing process and thereby achieve heightened customer satisfaction for the product. An eight-trial experiment was conducted with the aim of reducing the number of rejects from the process. The expected savings per month was estimated to be over $11,500. The results of the study have provided a greater stimulus for the wider application of statistical design of experiments in other core processes within the company.