Modelling process robustness: a case study of centrifugal casting

A robust process minimises the effect of the noise factors on the performance of a product or process. The variation of the performance of a robust process can be measured through modelling and analysis of process robustness. In this paper, a comprehensive methodology for modelling and analysis of process robustness is developed considering a number of relevant tools and techniques such as multivariate regression, control charting and simulation within the broad framework of Taguchi method. The methodology as developed considers, in specific terms, process modelling using historical data pertaining to responses, inputs variables and parameters as well as simulated noise variables data, identification of the model responses at each experimental setting of the controllable variables, estimation of multivariate process capability indices and control of their variability using control charting for determining optimal settings of the process variables using design of experiment-based Taguchi Method. The methodology is applied to a centrifugal casting process that produces worm-wheels for steam power plants in view of its critical importance of maintaining consistent performance in various under controllable situations (input conditions). The results show that the process settings as determined ensure minimum in-control variability with maximum performance of the centrifugal casting process, indicating improved level of robustness.